TSB 603 Service Bulletin/Repair Instructions

Newmar Corporation

PO Box 30

Nappanee, IN 46550
TSB 603

June. 14, 2023
TECHNICAL SERVICE BULLETIN

AFFECTED MODELS
2023 :: Dutch Star, Supreme Aire, New Aire, Mountain Aire, London Aire, Essex

DESCRIPTION
This Solar issue only affects these models equipped with factory installed lithium batteries and

factory installed Solar option 3L010 before 2023 eco 1211 (2/20/2023).

ISSUE
It has been discovered in the field that the solar controller and remote do not interact well with

the lithium package and errors out.

UNITS AFFECTED
Please refer to the attached population list for affected units and VINs.

CORRECTIVE ACTION
On affected units follow the attached work instructions to remove and replace the Solar controller

and the solar remote panel.

PARTS NEEDED

Item Description
Quantity
Newmar Part #
MMPT solar controller
1 ea.
166694
MMPT Solar remote panel
1 ea.
166695
Adapter panel
1 ea.
108200X
Heat shrink 1/16”x4”
2 ea.
036783A
Fuse Maxi 30 amp
1 ea.
036196
Fuse holder Maxi
1 ea.
026943
Blue butt connector 6ga.
1 ea.
37298
Heat shrink ¼”x4”
2 ea.
036784A
Pin Molex minifit
8 ea.
036785
FLAT RATE CODE:
TSB 603
LABOR TIME.
2.0 hrs.
IMPORTANT: Please read this bulletin in its entirety prior to beginning any diagnosis or repairs.

NOTICE: Any technical information published in this bulletin is intended for use only by a qualified, Newmar-authorized service technician. Newmar is not responsible for the misuse of this information.
Instruc�ons to Remove a Xantrex C-60 Load/Charge Controller and C40 Remote Panel and Replace with a Xantrex MPPT Charge Controller

and Matching Solar Remote Panel

Removing the Xantrex C-60 Load/Charge Controller

1.

2.

3.

4.

5.

6.

7.
Unplug the unit and turn oﬀ the Batery Management System (BMS).

Cover the solar panels on the roof to prevent voltage from solar panels.

Remove the cover from the Load/Charge controller.

Remove the plas�c cover from the posi�ve buss bar.

Disconnect the red wire going to the solar controller from the buss bar.

Disconnect the batery ground and posi�ve from the solar controller.

Remove the fusible link from the compartment backer and set it oﬀ to the side (you will

need a piece of this wire later).

8. Disconnect the solar posi�ve and nega�ve wires, and tape them up to prevent arcing if

the solar panel is receiving light.

9. Remove the remote wire from the old controller.

10. Remove the old solar load charge controller from the compartment backer.
Installing the Xantrex MPPT Solar Charge Controller

•

•

•
•

•

•

•

•
Install the new MPPT controller on the compartment backer in approximately the same

loca�on.

Hook up the posi�ve and nega�ve solar wires to the new controller.

Take the new fuse holder (provided with TSB parts) and cut the wire in half. Then hook

up one end to the MPPT controller in the batery-posi�ve connec�on and the other to

the same terminal where the old red wire was removed. Make it longer by cu�ng oﬀ

the wire from the old fusible link (use the piece of wire with the ring terminal), and use a

large blue but connector to extend the wire to hook up to the buss bar.

Hook up the white 12-volt wire previously removed to the solar remote wire PV.

Install the fuse in the red fuse holder.

Reinstall the plas�c cover over the posi�ve buss bar.

Uncover the solar panels.

This completes the controller hook-up, except for the remote. Follow the steps below to

remove the old remote panel and connect the new remote panel.
Removing the Xantrex C-40 Remote Panel

•

•

•
•

•

•

•

•

•

•
•
Go to the remote panel loca�on (usually in the front overhead).

Remove the screws moun�ng the panel, pull the panel out, and disconnect the

communica�on wire.

Cut both ends oﬀ the old communica�on wire (remote panel and controller).
Strip back the insula�on approximately 1.5 inches (1.5”).

Separate the wires. Cut oﬀ the green and white wire, and leave the blue, yellow, red, and

black wires at each end.

Slip on a piece of the larger shrink tube.

Cut the small shrink tube into four equal pieces, then slip a piece of the small shrink

tube on each of the remaining wires.

Take the terminal ends (provided with TSB parts), and crimp one onto each end of the

remaining wires.

Using the crimping tool, crimp the terminal end with no wire in it (to make the terminal

smaller and ﬂater for a beter ﬁt into the terminal end).

Take the new harness and remove the connector from the ends of the wire. Then put

them on the old wiring, making sure the colors are in the correct loca�on (just like the

new harness) with terminal screws facing you and the terminal screws toward the

botom from le� to right (red, blue, yellow, black), and repeat at both ends.

Before plugging in, use heat to shrink the tubing over the small wires, and then slide the

larger tubing up and shrink with heat.
Installing the Xantrex MPPT Solar Remote Panel

•

•

•
Slide the new remote panel into the ﬁller panel (provided with TSB parts).

Plug the terminal ends into the remote and the controller. The controller should be

ac�ve.

Center the new remote over the exis�ng hole in the plas�c panel, making sure it covers

all old screw holes. While holding it in place, pre-drill one hole into the plas�c panel with

a 1/8” drill. Secure it with one screw, then drill the remaining holes, and install screws in

panel.
This concludes the replacement procedure. Complete the following steps provided by Xantrex

to properly program the se�ngs for the temperature and batery type.

Source:

Document Name: Xantrex Solar MPPT Remote Panel (710-0010) Owner’s Guide

Document Number: 975-1013-01-01 Rev 1

Document Date: Oct 2019
To change the temperature unit setting:

Power
1. Short press
to turn on the panel, if not already on.
Menu
2. Press

displayed.
repeatedly until the BAT1
device screen is
Up / Set
3. Press
repeatedly until the temperature, the
icon, and the
icon are displayed.

Up / Set
4. Press and hold

for 5 seconds until the temperature

value changes and flashes to degC (or degF).

Menu
5. Press
to browse the desired temperature unit (degC or

Up / Set
degF), then press
20
to confirm your selection.
975-1013-01-01 Rev A

Oct 2019
To change the battery type setting:

Power
1. Short press
to turn on the panel, if not already on.
Menu
2. Press
repeatedly until the BAT1
(or BAT2
) device screen is displayed.

Up / Set
3. Press
repeatedly until the current battery type, the

icon, and the
icon are displayed.
Up / Set
4. Press and hold

type flashes.
for 5 seconds until the current battery
Menu
5. Press

to browse the desired battery type (for more on

battery types, see your charge controller's owner's guide), then

Up / Set
press
975-1013-01-01 Rev A

Oct 2019
to confirm your selection.
21
Prod#

USA UNITS

270189

270190

270194

270195

270198

270202

270203

270205

270207

502008

502019

502026

502027

502028

502029

502030

502031

502032

502033

502034

502035

502036

502037

502038

502039

502042

502044

502045

502049

502054

502065

502113

610574

610584

610594

610675

610684

610685

610690

610696

610702

610704

610716

610719

610720
VIN Number
Year Brand Type Floor Chassis Date in
Date out
3ALHC5DV3NDNH4006

1FVHC5DV0NHNH4023

1FVHC5DV8PHNL7728

1FVHC5DV0PHNW3952

1FVHC5DV1PHNW3944

1FVHC5DV8NHNL7709

1FVHC5DV6PHNL7730

1FVHC5DV5NHNL7716

1FVHC5DVXPHNL7729

4VZVU1R19PC091255

4VZVU1R16PC091262

4VZVU1R10PC093735

4VZVU1R15PC093228

4VZVU1R11PC094179

4VZVU1R1XPC093533

4VZVU1R19PC093457

4VZVU1R13PC093700

4VZVU1R14PC093737

4VZVU1R10PC093881

4VZVU1R11PC094263

4VZVU1R10PC093900

4VZVU1R15PC093553

4VZVU1R16PC093643

4VZVU1R17PC093229

4VZVU1R12PC093428

4VZVU1R15PC093701

4VZVU1R17PC093554

4VZVU1R13PC093289

4VZVU1R1XPC093970

4VZVU1R1XPC093290

4VZVU1R10PC093640

4VZVU1R16PC093853

4VZAU1D98PC091260

4UZFCHFE7PCNW9001

4UZACHFE5PCNX0397

4VZAU1D1XPC093795

4UZFCHFE0PCUK2941

4UZFCHFEXPCUM0590

4UZFCHFE7PCUH0416

4UZFCHFE8PCUP6360

4VZAU1D15PC093297

4UZFCHFE2PCUJ6557

4UZFCHFE1PCUM0588

4VZAU1D19PC093707

4VZAU1D18PC093973
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3/3/2022

3/10/2022

9/27/2022

12/19/2022

12/16/2022

9/22/2022

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