Aftertreatment Coolant Valve Removal and Replacement Page 1 of 13

JCB Loadall Help Files (9819-0300)

Aftertreatment Coolant Valve Removal and

Replacement

Home Page > Support Files > Aftertreatment Coolant Valve Removal and Replacement

Introduction
General Safety
Aftertreatment Coolant Valve Removal
Aftertreatment Head Unit Replacement

Introduction
If the aftertreatment coolant valve requires removing and replacing, the following procedure should be
completed for all machine models except 506-36, 507-42, 509-42, 510-56, 512-56 & 514-56.

General Safety
Before beginning the coolant valve removal and replacement process, this procedure should be read from start
to finish and fully understood.
Ensure compliance with all relevant site safety procedures.
Park the machine on a flat surface and isolate if possible. All hydraulic safety devices such as Jury struts
should be fitted to the lift ram when working under the boom.
All operators should be sufficiently trained in the operation of the machine in order to carry out any work
required.
Wear protective clothing and personal safety equipment (PPE) issued or called for by the job conditions, local
regulations or as specified by your employer.
Do not wear loose clothing or jewellery that could get caught on controls or moving parts.

Aftertreatment Coolant Valve Removal

1. Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start
the service work.
2. Ensure that the machine has been isolated, the ignition key has been removed and that the 'DO NOT
OPERATE' cover has been placed on the steering wheel.
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3. Ensure that the absorption mats are placed below the machine in order to capture any fluid lost during the
removal of the coolant valve.

4. Open the cab door and remove the kick strip using a #2 Posi drive screw driver to remove the 4 screws.
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5. Remove the rubber floor mat.

Note: Take care when removing the rubber floor mat to prevent damage to the pedal switch.

6. Remove the access panel from the cab floor plate using a 5mm hex key to remove the 6 bolts.
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7. Remove the 4 cab step bolts and remove the cab steps.

8. Remove the nut on the battery and remove the terminal cover.
9. Remove the battery location strap by removing the nut and pin.

10. Slide the battery tray out.

11. Remove the battery terminal link cables using 11mm and 13mm sockets.
Note: when removing a battery, always disconnect the earth (black) cable first; when installing a battery,
always connect the live (red) cable first.

12. Remove the batteries one at a time using the integrated handle.
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13. Remove the 5 fuel tank rear cover plate bolts and remove the cover plate.

14. Pump the fuel out of the machine into a suitable container.
15. Partially loosen the 2 24mm nuts on the underside of the fuel tank.
16. Remove the 2 fuel pipes and wiring harness from the fuel sender unit.

17. Remove the jubilee clip from the fuel filler neck.
18. Remove the 3 DEF lines from hose retention guides.
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19. Place a scissor jack underneath the fuel tank and allow it to take the weight of the tank.
20. Fully remove the 2 24mm nuts on the underside of the fuel tank.
21. Partially lower the tank using the scissor jack until the tank return hose is visible.

22. Remove the tank return hose, tank cap retention chain and spring.
23. Fully remove the fuel tank from the machine and move into a safe storage area away from any naked
flames, sparks or sources of ignition.
24. Vent the machine’s coolant system by slowly releasing the cap on the expansion bottle underneath the
bonnet.
25. Apply a hose clamp to each hose flowing in and out of the coolant valve no more than 6 inches from the
end of the hoses.
26. Remove these hoses from the valve, as well as the harness by twisting anti-clockwise.
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27. Remove the 13mm bolt that attaches the coolant valve mounting bracket and remove the coolant valve.

Reference Data

Tools

#2 Pozi Drive Screw Driver

5mm Hex Key

11mm Socket

13mm Socket

Scissor Jack

Aftertreatment Coolant Valve Replacement

1. Swap the mounting bracket onto the new coolant valve. Check that the arrow on the valve is pointing in
the same direction as that on the bracket, and the direction of the harness connection is opposite to the
arrow direction.
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2. Installation is the reversal of the removal procedure.

3. In addition, remove the fuse box cover and check that the powertrain bus is connected.
4. Connect a DLA to the diagnostic port and initialise ServiceMaster 4.

5. Select “Construction/Agricultural/Waste” and “Telescopic Handlers - Tier 4”.

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6. Key on the machine to position 1 and select “Engine Diagnostics”. Connect to the machine using the
green connect button on screen.
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7. Check for fault codes, ensure none are active and erase all codes.

8. Select “Aftertreatment System” and identify the image of the coolant valve. Start the machine’s engine and
run for 60 seconds until the red marker by the coolant valve image turns green. If this does not happen,
key off and try again.
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9. Continue to run the machine and allow it to reach temperature so that DEF is dosed into the exhaust.
Check that no faults have appeared. Key off the machine and close “Engine Diagnostics”.
10. Switch from the powertrain bus to the vehicle bus.
11. Key on the machine and open “Datalogger” on ServiceMaster 4. Connect to the machine and press F11 to
read faults. Once downloaded, faults can be saved or printed for future reference.
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12. Clear the “Datalogger” of all faults by using the “Reset” tab.
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13. Disconnect the machine from ServiceMaster 4 and close the software.
14. Disconnect the DLA from the diagnostic port and refit the fuse box cover.

Reference Data

Tools

#2 Pozi Drive Screw Driver

5mm Hex Key

11mm Socket

13mm Socket

Scissor Jack

Additional information on the aftertreatment system can be found in the Engine help files.
This topic last edited on 11/22/2021