NHTSA ID Number: 10240073
Manufacturer Communication Number: TSB 603
TSB/Document Date: 2023-08-02
Summary
Xantrex solar controller
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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TSB/Document ID: TSB 603
Replacement Service Bulletin Number:
MFR Communication Date: 2023-06-14
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM:SOFTWARE
MFR Component System:
MFR Component Subsystem:
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