Information injection-pump assembly
ZEXEL
101602-2340
1016022340
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Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
Note: Only perform these troubleshooting steps when the DEF tank is fully thawed and there is no remaining ice crystals/slush in the tank.Note: If any of the troubleshooting indicates the replacement of the DEF manifold, do not replace the DEF manifold. Repair the DEF manifold using the DEF manifold sensor kit.
Use the electronic service tool to download a full Product Status Report (PSR) (including all histograms and histories) before performing any troubleshooting.
Review the PSR to determine which code/events recorded have led to the activation SCR inducement codes:Note: Check the "Aftertreatment Abnormal Shutdown History" for Hot/Cold Shutdown events which may have occurred prior to the current inducement situation and may be an indication the system was incorrectly shut down previously.
A Cold Shutdown is recorded when the ambient temp is below −5° C (23° F) and the system has not completed the cooldown and system purge during the previous key-cycle.
Only investigate a logged 1235-9 (5856-9) code if the code has occurred less than 5 hours prior to the current diagnostic clock value. If the code is not persistent, the code is likely to be generated by either old engine software or a power supply dropping below the min supply voltage. If the code is showing a persistent triggering when on the latest engine software, this condition would indicate a hardware/connection issue.
DEF level codes (1761-xx/E954) are not to be considered a sign of DEF Manifold hardware failure (especially when in low ambient temperatures) unless the codes remain persistent after a tank fill. If there is another code present such as 1761-2/3130-2 (DEF level – Erratic) or 5392-31/E1370 (DEF Loss of Prime), this condition would indicate a system level issue, or the DEF tank has recently been fully drained down for an extended period and may require time for any DEF deposits to dissolve before level readings stabilize.
The order of troubleshooting codes should be SCR Inducement last, with DEF Tank Level codes second from last, always troubleshooting the DEF Volume Erratic (1761-2/3130-2) or DEF – Loss of Prime (5392-31/E1370) codes first.
Prior to beginning any troubleshooting of the codes reviewed in Step 2 and based on analysis, check that the coolant diverter valve is functioning correctly. Not allowing a small coolant flow to heat DEF tank fluid unintentionally above ambient temperature without triggering any codes, refer to Troubleshooting, DEF Tank Temperature Is High.
Ensure that the coolant flow direction is aligned with the flow direction arrow valve on the valve body. Refer to Step 3civ.
Record the ambient air temperature and DEF tank fluid temperature prior to starting the engine. Use these temperature readings as the reference for determining a temperature increase after warming the engine at idle. Refer to Step6.Note: As DEF is used as the
Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
Note: Only perform these troubleshooting steps when the DEF tank is fully thawed and there is no remaining ice crystals/slush in the tank.Note: If any of the troubleshooting indicates the replacement of the DEF manifold, do not replace the DEF manifold. Repair the DEF manifold using the DEF manifold sensor kit.
Use the electronic service tool to download a full Product Status Report (PSR) (including all histograms and histories) before performing any troubleshooting.
Review the PSR to determine which code/events recorded have led to the activation SCR inducement codes:Note: Check the "Aftertreatment Abnormal Shutdown History" for Hot/Cold Shutdown events which may have occurred prior to the current inducement situation and may be an indication the system was incorrectly shut down previously.
A Cold Shutdown is recorded when the ambient temp is below −5° C (23° F) and the system has not completed the cooldown and system purge during the previous key-cycle.
Only investigate a logged 1235-9 (5856-9) code if the code has occurred less than 5 hours prior to the current diagnostic clock value. If the code is not persistent, the code is likely to be generated by either old engine software or a power supply dropping below the min supply voltage. If the code is showing a persistent triggering when on the latest engine software, this condition would indicate a hardware/connection issue.
DEF level codes (1761-xx/E954) are not to be considered a sign of DEF Manifold hardware failure (especially when in low ambient temperatures) unless the codes remain persistent after a tank fill. If there is another code present such as 1761-2/3130-2 (DEF level – Erratic) or 5392-31/E1370 (DEF Loss of Prime), this condition would indicate a system level issue, or the DEF tank has recently been fully drained down for an extended period and may require time for any DEF deposits to dissolve before level readings stabilize.
The order of troubleshooting codes should be SCR Inducement last, with DEF Tank Level codes second from last, always troubleshooting the DEF Volume Erratic (1761-2/3130-2) or DEF – Loss of Prime (5392-31/E1370) codes first.
Prior to beginning any troubleshooting of the codes reviewed in Step 2 and based on analysis, check that the coolant diverter valve is functioning correctly. Not allowing a small coolant flow to heat DEF tank fluid unintentionally above ambient temperature without triggering any codes, refer to Troubleshooting, DEF Tank Temperature Is High.
Ensure that the coolant flow direction is aligned with the flow direction arrow valve on the valve body. Refer to Step 3civ.
Record the ambient air temperature and DEF tank fluid temperature prior to starting the engine. Use these temperature readings as the reference for determining a temperature increase after warming the engine at idle. Refer to Step6.Note: As DEF is used as the