101603-7495 ZEXEL 9 400 615 187 BOSCH INJECTION-PUMP ASSEMBLY 9400615187 1016037495 1156026734

Introduction
The Environmental Protection Agency (EPA) has mandated that a DEF quality sensor must be installed on certain engines built after 2016. This new DEF quality sensor is integrated into the DEF header inside the DEF tank. The new style DEF header utilizes CAN C communication, so the wiring to the DEF header has been slightly modified on product going forward. However, the Dosing Control Unit (DCU) remains compatible to both setups with the latest engine software. ( 507-7605 Engine Software (24V DCU) or 507-7546 Engine Software (12V DCU)). As part of the DEF quality sensor implementation, a new configuration parameter setting is used on the engine Electronic Control Module (ECM) in Cat ET to identify whether a DEF quality sensor is"installed" or "not installed". Below are some different diagnostic codes for incompatible hardware and configuration setting as well as different service scenarios that may be encountered with this change and how to resolve any issues in these particular service scenarios. In addition to this Special Instruction, there is a video detailing these changes posted on Cat Channel 1.Diagnostic Codes When Parts/Settings Are Not Compatible
DEF quality header not installed but configuration set to "installed".
Table 1
J1939 Code and Description CDL Code and Description
1235-9
J1939 Network #3 : Abnormal Update Rate 5856-9
J1939 Network #3 : Abnormal Update Rate DEF quality header installed but configuration set to not installed.
Table 2
J1939 Code and Description CDL Code and Description
1761-3
Aftertreatment 1 Diesel Exhaust Fluid Tank Level : Voltage Above Normal 3130-3
Aftertreatment #1 SCR Catalyst Reagent Tank #1 Level Sensor : Voltage Above Normal
3031-3
Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature : Voltage Above Normal 3134-3
Aftertreatment #1 SCR Catalyst Reagent Tank #1 Temperature Sensor : Voltage Above Normal DEF Quality Sensor Service Scenarios
Replacement Industrial Engine (2016 and earlier builds)
Replace with new engine (old engine no longer serviceable). Update to DEF quality sensor by installing a new DEF header, wiring harness, and DCU software and changing DEF quality sensor configuration status to "installed" in Cat ET.Replacement Machine Engine (2016 and Earlier Builds)
Replace with older service replacement Engine Arrangement Complete (EAC) engine (no other changes needed, confirm that DEF quality sensor configuration is set to "not installed" in CAT ET).
If dealer orders new EAC, update to DEF quality sensor is required (below scenario).Replacement Engine (2017and Future Builds)
Replace with latest EAC engine.Install DEF Quality Sensor on 2016 or Earlier Builds
Requires DCU software update, Pump, Electronic, and Tank Unit (PETU) wiring harness update, change DEF quality sensor configuration status to"installed".Replace DCU
No effect - new DCU hardware and software is compatible to both DEF headers.Replace Engine ECM
No effect when using ECM replacement file.
If engine ECM is replaced without the ECM replacement file, the DEF quality sensor configuration setting will default to "not installed" and may need to be updated if machine utilizes DEF quality sensor (requires Factory Passwords to change).Replace Wiring Harness
No effect - both new and old harness part numbers are available. Order same part number that is removed.