A lot of what the issue is that DEF crystallizes.
Also, the def in line actually gets pumped back into the tank, so if you are turning your machine off, make sure you don't kill it before you hear the def pump stop pumping it back.
For a beginning of the season, as there will always be a little of bit of DEF crystallized in your tank, best mix it with a fresh batch of def to try make the solution again. If you are having especially troublesome issues, maybe even run the new def in through the lines, then let the pump get it back in a few times to make sure there aren't going to be crystals getting stuck in your screens.