Outback FX-Class, FXR-Class Service Manual

FX-Class and FXR-Class

Inverter/Charger

Service Instructions

Purpose and Scope

These instructions detail how to remove and replace the following parts of any FX-class or
FXR-class inverter/charger.



Control Printed-Circuit Board Assembly (PCBA)



AC Printed-Circuit Board Assembly (PCBA)



FET Printed-Circuit Board Assembly (PCBA)



Ribbon Cables

These instructions extend to all FX, FXR, VFX, VFXR, GTFX, GVFX, and GFX models, including all
mobile and international models.

Tools Required



#2 Phillips screwdriver



3/8” flat blade screwdriver



4mm hex wrench (included)



Strap wrench



Long-nose pliers



10mm socket with 12” extension & torque wrench



10mm wrench (standard and torque)



Power supply (9-volt batteries may be used)



Voltmeter or DVM

Disassembly

This procedure describes the removal of all circuit boards in an FX-class or FXR-class inverter. The
exact steps and order may vary with the repairs needed.

The order of removal depicted here is:

1. Control PCBA

2. AC PCBA

3. FET PCBA

If not all boards need to be replaced, the installer may proceed through the steps that are required
and ignore the subsequent disassembly. (Note that replacing the AC PCBA requires removal of the
Control PCBA regardless of any other steps.)

The installer should then proceed to the reassembly and testing steps, which begin on page 7.

900-0107-01-00 Rev A 1

FX-Class and FXR-Class

To disassemble the inverter:

1. Disconnect power; turn off all DC and AC sources to the inverter.

2. Remove the DC Cover or Turbo Fan. Remove the battery terminal covers. Using a #2 Phillips

screwdriver, remove the two screws attaching the AC Cover as shown in Figure 1. Remove the rubber
washers, rubber grommet, and AC Cover as shown in Figure 1.

Screw

Grommet

AC Plate

Screw

Washer

Figure 1 AC Cover & Access Plate

3. Remove the AC Plate. See Figure 1.

4. Disconnect all AC and DC wiring to the inverter. Using a meter, verify that no AC or DC voltage is present.

5. Using the strap wrench, remove the red and black ring nuts located on the battery terminals. See Figure 2.

NOTE: If the ring nuts are too tight, a hammer and flat screwdriver may be used to tap the ring nuts
counterclockwise. A small pipe wrench may be used. Cover the jaws of the wrench with tape to
minimize damage to the plastic nuts.

Ring Nuts

Figure 2 Ring Nuts

2 900-0107-01-00 Rev A

Part Replacement Instructions

6. Using a #2 Phillips screwdriver, remove the 6 screws located in the AC wiring compartment. See Figure 3.

Screws

Figure 3 AC Compartment Screws

7. Using the 4mm hex wrench, remove all 8 hex bolts that connect the top cover to the bottom chassis of

the inverter. The locations of these bolts are shown in Figure 4.

IMPORTANT:

After removing the hex bolts, read the next step carefully before removing the cover.

CAUTION: Equipment Damage

Inverter components will be damaged if the cover is removed too quickly. The cover
and fan are wired to the internal FET board with a PCB connector. See Figure 5.

8. Carefully lift the inverter cover, just far enough to locate the fan wire.

900-0107-01-00 Rev A 3

Figure 4 Top Cover Hex Bolts

FX-Class and FXR-Class

9. Disconnect the fan wire. The connector locations are different for FX-class and FXR-class inverters. The

locations are shown in Figure 5.

PCB Connector

(FX-class)

PCB Connector (FXR-class)

Figure 5 Fan Connector

10. Remove the top cover and set it aside.

11. Remove the O-rings that are seated on the battery terminals. Remove the gasket located on top of the

AC PCBA. See Figure 6.

NOTE: A larger O-ring travels the perimeter of the chassis and may come off during disassembly. If so,
reinstall the O-ring during reassembly.

Battery Terminal O-Rings

AC Compartment Gasket

Inverter O-Ring

12. Remove the two ribbon cables that join all three circuit boards. One cable connects the FET PCBA to the

Control PCBA. The other connects the AC PCBA to the Control PCBA.

To remove the ribbon cables, release the levers on each connector that holds the cable in place. The
locations of the cable connectors are shown in Figure 7 and Figure 8.

4 900-0107-01-00 Rev A

Figure 6 Gasket and O-Rings