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Old 11-27-2022, 06:37 AM   #1
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DEJAVUE - Headlight Diode Meltdown

Back on 6/28/20, I posted a question to this forum, for an answer to solve an overheated headlight diode to the point of melting issue.
Subsequent posts of 7/01, 7/02, 8/02, 10/31, 11/10 and the final resolve was made in Nappanee and posted on 11/25/2020.
Well here it is 2 years later and the same overheating headlight diode issue has recurred.
The Newmar resolve was to replace the "recalled" electrical harness.
Today, when I spoke with Newmar service they said I must take the RV to a authorized Newmar dealership to test the electrical system to determine if in fact it is the same issue.
Well, as typical for me, I planned on departing on Dec 29, 2022 for Naples Fl.
I called the three NJ RV dealerships I have used in the past.
Risko RV of Wall, NJ is out of business. Dylans RV said they only service RV's sold from their business.
But my hope is on Dec 09, 2022 for my appointment with Cuzan's Service of Absecon NJ.
In the meantime, has any other 2016 Ventana LE 4037 owner had this issue, or am I the only Newmar owner having this oddball issue? Which is my typical experience.
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Old 11-27-2022, 10:25 AM   #2
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I perused your past posts on the subject, but what I can't understand is why a diode is needed where it is? A 4A diode has no business even getting warm, it means it's overloaded. Is this diode performing some important function? Where is in in relation to battery power to the headlamps?


Do you have a wiring diagram of the headlamp circuit? I'd like to understand where this diode is at so I can guess at whether or not Freightliner messed up and hooked your lights up to multiple power sources. Typically a diode setup would drive relays instead of loads.


I found the diode's design schematics, which suggest it's set up for dual circuit power supply, with one side being independent and the other side split. I would only see it overloading in normal operation if for some reason the split side circuit failed and additional power was pulled through the independent diode. It's made with 3 separate 4A continuous rated diodes, one side has 2 diodes feeding both outputs and the other has 1 feeding 1 output. It's not a configuration that should have direct power going to or from the bulbs, though, unless there is one unit per bulb and one side of it is for the low-intensity DRL mode. An H13 is 55 watts low beam, 65 watts high beam. At 12vdc that's well outside the expected performance of these diodes.
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Old 11-27-2022, 10:25 AM   #3
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Well, I must say that I completely missed your original posting on the issue .

But I have had problems with the front cap wiring (Newmar installed) on my Freightliner chassis.
Is your coach on a Frieghtliner chassis?

EDIT: Found and read the 11/25/20 thread and your chassis is Freightliner.

Does your coach have the "Smart wheel"?
Do you still have the wiring schematics?
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Old 11-28-2022, 08:39 AM   #4
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TY Suburbazine and Skip426 for taking the time to address this issue.
Yes I do have a headlite schematic as well as ALL the numerous email correspondences which has all your questions answered. However, I am unable to copy and paste any of this information into this IRV2 format.
When I attempt to paste a copy a message asked for a URL associated address which I can't find.
Since I have limited electrical knowledge to be able to answer your queries correctly, I would rather post what information I have obtained from manufacturers as well as Nappanee Techs for a much quicker understanding.
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Old 11-28-2022, 06:16 PM   #5
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Dejavue

I finally was able to figure out how to attach photos.
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Old 11-28-2022, 06:41 PM   #6
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Pictures of the harness is useful but I need the actual circuit diagram to be helpful. The 2 relays should be your actual load carriers, pull them out and see if your diodes still get hot.

Also, your marked ground wire is definitely attached to a positive terminal.
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Old 11-30-2022, 07:07 AM   #7
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Dejavue

TY for correcting my mistaken ground wire ID.

OK, I believe I successfully attached the schematic.

Today I received new Diodes, 7.5A CB's and two relays.
I will first try your suggestion with the original hardware in place and monitor the outcome.

If overheating occurs, I will change all hardware within the harness and test.
The results will be posted for any additional help/suggestions.

I was able to make an appointment with a Freightliner Tech on Dec 08.
Cutting it close for my intended departure from NJ to Naples Fl on Dec 29.

When it rains, it pours on me.

I now just developed overextending of the passenger wiper arm and the blade stowing on the paint portion below the windshield glass. Had this same issue now as a third occurrence even with each occurrence having new arms installed at Nappanee.
I digress, no need to comment, I'm just frustrated.

TY again.
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Old 11-30-2022, 01:34 PM   #8
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Dejavue

Corrected photo.
Wrong identified ground wire of two photos.
Both have been corrected on my photos as # 5 Leg Hot Supply 12 V.
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Old 01-25-2023, 11:14 PM   #9
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update.
Have appt with mother ship for repairs. I hope!
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