Ryobi | RY907022FI | Owner Manual | RYOBI RY907022FI Owner Manual

RYOBI RY907022FI Owner Manual
RY907000FI
Electronic Fuel
Injection (EFI)
Diagnostics
Service Manual
FOR RY907000FI
RYOBI 7,000 WATT GENERATOR
LOCATE GENERATOR AT LEAST 20 FT.* AWAY TO REDUCE THE
RISK OF CARBON MONOXIDE GETTING INSIDE THE HOME
* Minimum distance as recommended by U.S. Department of Health and Human
Services Centers for Disease Control and Prevention (www.cdc.gov/co). Your specific
home and/or wind conditions may require additional distance.
Exhaust (CO)
Direct exhaust AWAY
from all windows, doors,
and vents.
KEEP AT LEAST
20 FT. AWAY
CO Detector
in Living Areas
Only use OUTSIDE and
FAR AWAY from windows,
doors, and vents.
PRODUCT SPECIFICATIONS
ENGINE
GENERATOR
Engine Type......................................................... 420cc, EFI
Rated Voltage....................................................120 V/240 V
Spark Plug .......................................... F6RTC or equivalent
Rated Amps.................................................... 58.3 A/29.1 A
Fuel Volume................................................................. 6 gal.
Rated Output*..........................................................7000 W
Engine Lubricant Volume........................................... 32 oz.
*Rated output determined by PGMA Standard G300
Starting Watts...........................................................8750 W
Rated Frequency.........................................................60 Hz
TABLE OF CONTENTS
Important Safety Instructions..................................................................................................................................................2
EFI Components......................................................................................................................................................................2
Fuel Recommendations..........................................................................................................................................................3
System Description.................................................................................................................................................................3
RY907000FI Wiring Diagrams.................................................................................................................................................4
Using the EFI Diagnostic Kit.............................................................................................................................................. 5-10
RY907000FI ECU PIN-OUT Reference.................................................................................................................................11
Diagnostic Troubleshooting Codes (DTCS) Matrix.......................................................................................................... 12-18
Parts and Service..................................................................................................................................................................19
IMPORTANT SAFETY INSTRUCTIONS
Use only recommended or equivalent replacement parts and accessories. Use of any other parts or failure to follow
­maintenance/service instructions may create a risk of shock or injury. Maintain the unit per maintenance instructions located in the generator’s Operator’s Manual. Inspect the unit before each use for loose fasteners, fuel leaks, etc. Replace
damaged parts.
EFI COMPONENTS
Typical electronic fuel injection (EFI) system and related components include:
 Fuel Pump Module — Electronic pump and regulator to generate fuel pressure
 Fuel Filter — Particle and debris filtration of fuel system
 High Pressure Line — Connection from pump to fuel injector
 Ignition Coil — Transformer for high voltage spark generation
 Engine Start Switch — Commands engine to start
 Engine Starter Relay — Control of the engine starter
 Cranshaft Position Sensor — Rotational trigger for monitoring engine position
 Engine Temperature Sensor — Temperature operating point measurement
 Oxygen Sensor — Exhaust mixture monitoring device
 Wire Harness Assembly — System connection for electrical components
 EJT27 Throttle Body Assembly — Integrated engine control electronics and throttle body assembly
• Dual Core Processor Electronic Control Unit (ECU)
• Fuel Injector
• Throttle Body/Intake Manifold
• Temperature and Pressure Sensors
• Malfunction Indicator Lamp (MIL)
Page 2
FUEL RECOMMENDATIONS
Refer to the generator’s Operator’s Manual.
SYSTEM DESCRIPTION
The RYOBI™ EFI system is designed for optimal engine performance with improved fuel efficiency and lower emissions than
a comparable carbureted machine. Fuel and spark functions are electronically controlled and engine operation continuously
monitored during operation to maintain an ideal air/fuel ratio and best power. Electronic control is achieved through the use
of a throttle body assembly, which combines electronics, sensors, and throttle body functionality into a single unit. The EFI
system components connect to the throttle body assembly through the wire harness or high pressure line.
Fuel is routed from the tank to the fuel pump module. A directional fuel filter is positioned between the tank and the pump
module to prevent damage or failure of the EFI components. The fuel pump module takes in fuel from the tank via gravity
feeding and generates approximately 39 psi of fuel pressure to the high pressure line. This high pressure line then terminates
at the fuel injector located on the throttle body assembly where it is electronically controlled.
Spark is generated by the inductive ignition coil. Charging and discharging is electronically controlled using energy from
the battery to produce the spark. The ignition timing is dynamic during the operation of the engine and will vary based on
operating conditions.
To allow electronic control of various functions, a crankshaft position sensor is used to monitor a pattern of teeth machined
into the engine flywheel. These teeth are detected by the crankshaft position sensor and processed such that control based
on angular engine events can be achieved. The pattern of teeth are all equally spaced with a single tooth removed to provide a reference point in the rotation.
Sensor data is essential to controlling the air/fuel mixture. Engine temperature is used for warm up and prevention of overheating. Precise control comes from the feedback of the oxygen sensor. This component provides rich or lean data used
for managing the fuel injector. An integrated heater is used for fast transition from open loop to closed loop operation.
The central component of the system is the throttle body assembly, which is composed of an electronic control unit (ECU),
fuel injector, temperature and pressure sensors, and mechanical throttle body. With connections to all other components
of the system, the throttle body assembly enables precise control of the engine through software algorithms running on
the ECU. Using a dual core micro-controller, these algorithms monitor the various sensors in the system and then control
the fuel pump module, oxygen sensor heater, fuel injector, and ignition coil.
Integral to the throttle body assembly are multiple temperature and pressure sensors. These devices provide data necessary for consistent engine operation regardless of temperature and altitude. External sensors include engine temperature,
crankshaft position, and oxygen sensors.
Operation of the engine begins with turning on the power switch. When turned on, a red MIL located on the throttle body
ECU will turn on and off indicating power is on and the light is functional. A constant on of the light indicates a fault code
is present and diagnostics are to be performed. With no active MIL, the engine can be started with the pull starter or the
electric start. For electric start, the push button commands the engine to start through control by the EFI system. With
electronic control of the starter relay, a controlled start is performed where the user is not required to hold the button during the cranking of the engine. A simple switch press creates a command to the EFI system that allows a consistent start
of the engine. Start cycle will time out after 5 seconds if engine start is not detected. Once the engine is rotating, the EFI
system will begin to control fuel and spark and result in the starting of the engine. A warming phase will occur once started.
This warming of the engine is transparent to the operation and requires no special considerations such as a choke or other
fuel enrichment controls found on a carbureted unit. After the warm up is completed, the EFI system will begin closed loop
control of the air/fuel mixture using the oxygen sensor feedback. Closed loop operation may be briefly canceled during
large engine transients such as when a large load is applied.
If any system faults are detected, the MIL will turn on indicating there is an issue with the system. These faults are stored
in the ECU and can be retrieved using the EFI Diagnostic Kit. Depending on the fault, the engine may continue to run but
have reduced performance and non-compliant emissions. Diagnostics and troubleshooting should be performed if the MIL
is on. A qualified technician can access stored fault codes using a cable that plugs into the unit harness and a Windowsbased computer. Contact RYOBI Customer Service for more detailed information.
Page 3
RY907000FI WIRING DIAGRAMS
ENGINE FUEL INJECTION WIRING DIAGRAM
CHASSIS WIRING HARNESS DIAGRAM
Page 4
USING THE EFI DIAGNOSTIC KIT
The RYOBI™ EFI Diagnostics Kit Includes:

EFI Diagnostics Service Manual (Part number 995000285)

USB Jump Drive with RYOBI™ EFI Software Program (Part number 903352003)

Cable Assembly (for connecting computer to RYOBI™ EFI Generator) (Part number 290435055)
 Install the RYOBI™ EFI Service Diagnostics Software on your Windows-based computer using the USB drive supplied in the RYOBI™
EFI Diagnostics Kit.
 Determine if your MIL (Malfunction Indicator Lamp) is illuminated on the generator’s front electrical panel.
NOT Illuminated
Illuminated
NOTE: If the MIL indicator is illuminated, further diagnostics of the unit are needed to determine the exact DTC (Diagnostic
Trouble Code(s).
Page 5
USING THE EFI DIAGNOSTIC KIT
For cases where the MIL indicator is illuminated:
 Locate the interface cable from the kit.
 Connect the interface cable’s 4-pin connector to the 4-pin connector located on the generator’s main wire harness. Plug the interface
cable’s USB plug into a USB port on your Windows-based computer.
TOP View of 4-Pin Diagnostics Harness Connector for Reference
Page 6
USING THE EFI DIAGNOSTIC KIT
 Open the RYOBI™ Diagnostics Software Program.
First open
With ECU powered off
 Place your generator’s engine switch in the ON or middle position.
First open
Switch in ON position
 If you receive this error message, the generator’s engine switch is not in the ON position. Turn the engine switch ON and press the
button to refresh.
With ECU powered off
Page 7
USING THE EFI DIAGNOSTIC KIT

With
sensorwith
unplugged
Connected
ECU powered on
After finding the device, the software will show the engine serial number and the fault code(s).
Active code.
Once the fault or faults are noted, turn to the DTC Troubleshooting Matrix on page 12 for additional a
­ ssistance in repairing the issue.
An Active Fault Code will be labeled Active. A Non-Active Fault will be labeled Stored.

Stored code (Non active)
After correcting the issue by either repairing or replacing components, the Fault will no longer be Active. It will change to Stored. You
With
sensor
can clear all DTCs
by pressing
this unplugged
button:
Active code.
Stored code (Non active)
Page 8
USING THE EFI DIAGNOSTIC KIT
 Once you place the generator’s engine switch in the OFF position, your generator’s identifying information will disappear.
 Unplug the interface cable and reinstall the dust cover to the 4-pin connector on the main wire harness. The generator is now ready
to be put back into service.
Page 9
USING THE EFI DIAGNOSTIC KIT
 Turn the generator’s engine switch to the OFF position. This will ensure that the unit’s battery is not drained inadvertently.
Switch in OFF position
Page 10
RY907000FI ECU PIN OUT REFERENCE
Page 11
DIAGNOSTIC TROUBLESHOOTING CODES (DTCS) MATRIX
Item
Fault
Code
1
P0031
Condition
O2 Sensor
Heater Control
Circuit Low
Cause
Actions
Indicates an issue with the oxygen sen- • Check the electrical connector is positively fixed to
the oxygen sensor.
sor heater control circuitry where the
ECU has detected low voltage. The • Inspect wiring to the oxygen sensor and sensor body
following conditions are examples of
for damage. Repair and replace as necessary.
what may occur causing this fault:
• Verify continuity between Oxygen Sensor ­Connector
• Wiring to the oxygen sensor has
Pin A and ECU Connector Pin F3.
become damaged and shorting to • Verify continuity between Oxygen Sensor ­Connector
the chassis.
Pin B and ECU Connector Pin C4.
• The connector for the oxygen sensor • Clear DTCs.
has been disconnected.
• Observe whether P0031 is still active.
• The oxygen sensor has electrically
• If still active, further inspection and diagnostics will be
failed and is no longer operational.
required before returning generator to service.
• If no longer active, return the generator to service.
2
P0032
O2 Sensor
Heater Control
Circuit High
Indicates an issue with the oxygen • Check that the electrical connector is positively fixed
to the oxygen sensor.
sensor circuitry where the ECU has
detected high voltage. The following • Inspect wiring to the oxygen sensor and sensor body
conditions are examples of what may
for damage. Repair and replace as ­necessary.
occur causing this fault:
• Using a multimeter, measure resistance across pins
• Wiring to the oxygen sensor has
A and B of the oxygen sensor. A resistance of 16-25
become damaged and shorting to a
ohms is typical for a sensor that has been allowed to
battery voltage source.
stabilize at room temperature. If the sensor is outside
this range, the heater has been damaged and the
• The oxygen sensor has electrically
sensor needs to be replaced.
failed and is no longer operational.
• Verify continuity between Oxygen Sensor ­Connector
Pin A and ECU Connector Pin F3.
• Verify continuity between Oxygen Sensor ­Connector
Pin B and ECU Connector Pin C4.
• Clear DTCs.
• Observe whether P0032 is still active.
• If still active, further inspection and diagnostics will be
required before returning generator to service.
• If no longer active, return the generator to service.
3
P0105
Intake Air
Indicates that the internal intake air pres- • Inspect the ECU for signs of physical tampering. Look
­Pressure Circuit
for pry marks between the throttle body metal and the
sure sensor has failed. When this DTC
plastic cover of the ECU. Look for broken locking tabs
is active, the ECU will intentionally
on the plastic cover of the ECU. Look for small holes
prevent its cylinder from running. This
in the plastic cover of the ECU, including checking in
can occur in the following conditions,
the connector cavity.
in order of decreasing likelihood:
•
Ensure
the ECUs have a stable power supply from a
• The ECU has been physical tampered
healthy charged battery (12v+).
with.
• The ECU has been tampered with • Use the manufacturer diagnostic software to reprogram
the ECU with the latest service p
­ ackage.
using a third party calibration tool.
•
Clear
DTCs.
• The intake air pressure sensor inside
of the ECU has failed.
• Observe whether P0105 is still active.
• If P0105 is still active, the ECU is permanently damaged and the ECU must be replaced. Follow the ECU
replacement procedure found later in this document.
• If P0105 is no longer active, the ECU has been recovered and is safe to use moving forward. In this case, it
is likely that the ECU was tampered with using a third
party calibration tool.
Page 12
DIAGNOSTIC TROUBLESHOOTING CODES (DTCS) MATRIX
Item
Fault
Code
4
P0110
Condition
Intake Air
­Temperature
Circuit
Cause
Actions
Indicates that the internal intake air • Inspect the ECU for signs of physical tampering. Look
for pry marks between the throttle body metal and the
temperature sensor has failed. The
plastic cover of the ECU. Look for broken locking tabs
engine will be allowed to run with
on the plastic cover of the ECU. Look for small holes
degraded performance in this situin the plastic cover of the ECU, including checking in
ation. This can occur in the following
the connector cavity.
conditions, in order of decreasing
likelihood:
• Ensure the ECUs have a stable power supply from a
healthy charged battery (12V+).
• The ECU has been physical tampered
with.
• Use the manufacturer diagnostic software to reprogram
the ECU with the latest service p
­ ackage.
• The ECU has been tampered with
using a third party calibration tool.
• Clear DTCs.
• The intake air temperature sensor • Observe whether P0110 is still active.
inside of the ECU has failed.
• If P0110 is still active, the ECU is permanently damaged and the ECU must be replaced. Follow the ECU
replacement procedure found later in this document.
• If P0110 is no longer active, the ECU has been recovered and is safe to use moving forward. In this case, it
is likely that the ECU was tampered with using a third
party calibration tool.
5
P0131
O2 Sensor
Circuit Low
Voltage
Indicates an issue with the oxygen • Check that the electrical connector is positively fixed
to the oxygen sensor.
sensor circuitry where the ECU has
detected low voltage. The following • Inspect wiring to the oxygen sensor and sensor body
conditions are examples of what may
for damage. Repair and replace as ­necessary.
occur causing this fault:
• Verify continuity between Oxygen Sensor ­Connector
• Wiring to the oxygen sensor has
Pin C and ECU Connector Pin C1.
become damaged and shorting to
• Verify continuity between Oxygen Sensor ­Connector
the chassis.
Pin D and ECU Connector Pin D1.
• The connector for the oxygen sensor
• Clear DTCs.
has been disconnected.
• Observe whether P0132 is still active.
• The oxygen sensor has electrically
failed and is no longer operational. • If still active, further inspection and diagnostics will be
required before returning generator to service.
• Significant air leak path near oxygen
•
Verify
condition of exhaust manifold, and look for
sensor tip.
cracks, leaking exhaust gaskets, loose sensor con• Oxygen Sensor has been contaminection to manifold.
nated through excessive oil consumption, or use of non-sensor safe • Replace Oxygen Sensor if sensor tip appears to be
contaminated, and previous diagnostic items have
chemicals (starting fluids, cleaners,
been verified.
etc.).
• Observe whether P0131 is still active. If no longer
active, return the generator to service.
Page 13
DIAGNOSTIC TROUBLESHOOTING CODES (DTCS) MATRIX
Item
Fault
Code
6
P0132
Condition
O2 Sensor
Circuit High
Voltage
Cause
Actions
Indicates an issue with the oxygen • Check that the electrical connector is positively fixed
to the oxygen sensor.
sensor circuitry where the ECU has
detected high voltage. The following • Inspect wiring to the oxygen sensor and sensor body
conditions are examples of what may
for damage. Repair and replace as ­necessary.
occur causing this fault:
• Verify continuity between Oxygen Sensor ­Connector
• Wiring to the oxygen sensor has
Pin C and ECU Connector Pin C1.
become damaged and shorting to a
• Verify continuity between Oxygen Sensor ­Connector
battery voltage source.
Pin D and ECU Connector Pin D1.
• The oxygen sensor has electrically
• Clear DTCs.
failed and is no longer operational.
• Observe whether P0131 is still active.
• Long term excessively rich engine
• Verify condition of exhaust manifold, and look for
operation.
cracks, leaking exhaust gaskets, loose sensor con• Oxygen Sensor has been contaminection to manifold.
nated through excessive oil con•
Verify
fuel pressure is within manufacturer specification.
sumption, or use of non-sensor safe
chemicals (starting fluids, cleaners, • Remove fuel injector with ignition on / engine off to
etc.)
verify injector is not stuck open.
• Replace Oxygen Sensor if sensor tip appears to be
contaminated, and previous diagnostic items have
been verified.
• If still active, further inspection and diagnostics will be
required before returning generator to service.
• If no longer active, return the generator to s­ ervice.
• Observe whether P0132 is still active. If no longer
active, return the generator to service.
7
P0261
Fuel Injector
Circuit Low
Indicates an issue with the fuel injector • Check the electrical connector is positively fixed to
the fuel injector.
circuitry where the ECU has detected
low voltage. The following conditions • Inspect wiring to the fuel injector and the injector body
are examples of what may occur
for damage. Repair and replace as necessary.
causing this fault:
• Verify continuity between Fuel Injector Connector Pin
• Wiring to the fuel injector has become
1 and ECU Connector Pin D4.
damaged and shorting to the chassis.
• Verify continuity between Fuel Injector Connector Pin
• The electrical connector at the fuel
2 and ECU Connector Pin F3.
injector has become disconnected
• Using a multimeter, check the resistance of the fuel
or damaged.
injector. Nominal resistance is approximately 12 ohms.
• The fuel injector has electrically failed
If open circuit, replace the fuel injector.
and is no longer operational.
• Clear DTCs.
• System Voltage low (<10V)
• Observe whether P0261 is still active.
• If still active, further inspection and diagnostics will be
required before returning generator to service.
• If no longer active, return the generator to service.
Page 14
DIAGNOSTIC TROUBLESHOOTING CODES (DTCS) MATRIX
Item
Fault
Code
8
P0262
Condition
Fuel Injector
Circuit High
Cause
Actions
Indicates an issue with the fuel injector • Check the electrical connector is positively fixed to
the fuel injector.
circuitry where the ECU has detected
high voltage. The following condi- • Inspect wiring to the fuel injector and injector body for
tions are examples of what may occur
damage. Repair and replace as necessary.
causing this fault:
• Verify continuity between Fuel Injector Connector Pin
• Wiring to the fuel injector has become
1 and ECU Connector Pin D4.
damaged and shorting to a battery
• Verify continuity between Fuel Injector Connector Pin
voltage source.
2 and ECU Connector Pin F3.
• The fuel injector has electrically failed
• Using a multimeter, check the resistance of the fuel
and is no longer operational.
injector. Nominal resistance is approximately 12 ohms.
If shorted with resistance near zero ohms, replace the
fuel injector.
• Clear DTCs.
• Observe whether P0262 is still active.
• If still active, further inspection and diagnostics will be
required before returning generator to service.
• If no longer active, return the generator to service.
9
P0562
System Voltage
Low
Indicates battery voltage in the generator EFI system is less than recommended for proper operation.
This can occur due to the following
conditions:
• Check wiring harness and ground connections.
• Loose/corroded battery terminal connections.
• Verify charging system operation.
• Load test and if defective replace battery.
• The generator’s voltage regulator has
been damaged.
• The generator battery has been discharged or is faulty.
• The generator is failing to charge the
battery.
• Battery charge low (<10V)
10
P0563
System Voltage
High
Indicates battery voltage in the generator • Verify charging system operation.
is above a safe threshold. This can • Load test and if defective replace battery.
occur due to the following conditions:
• The generator’s voltage regulator has
been damaged.
• The generator battery has been overcharged or is faulty.
11
P0602
ECU
­Programming
Error
Indicates that the memory containing
the ECU program has become corrupted. When this DTC is active,
the ECU will intentionally prevent its
cylinder from running. This can occur
in the following conditions, in order
of decreasing likelihood:
• Ensure the ECU has a stable power supply from a
healthy charged battery.
• Use the manufacturer diagnostic software to reprogram
the ECU with the latest service package.
• Clear DTCs.
• Observe whether P0602 is still active.
• The ECU was tampered with using a • If P0602 is still active, the ECU program memory is
permanently damaged and the ECU must be replaced.
third party calibration tool.
•
If
P0602 is no longer active, the ECU has been recov• An unexpected error occurred while
ered and is safe for future use.
reprogramming the ECU, using the
manufacturer diagnostic software.
• An intermittent (nonpermanent) program memory failure occurred.
• The program memory has become
permanently damaged.
Page 15
DIAGNOSTIC TROUBLESHOOTING CODES (DTCS) MATRIX
Item
Fault
Code
12
P0605
Condition
Cause
Actions
ECU Read Only Indicates that the calibration memory
Memory Error
inside of the ECU is corrupt. When
this DTC is active, the ECU will intentionally prevent its cylinder from
running. This can occur in the following conditions, in order of decreasing
likelihood:
• Ensure the ECUs have a stable power supply from a
healthy charged battery.
• Use the manufacturer diagnostic software to reprogram
the ECU with the latest service package.
• Clear DTCs.
• Observe whether P0605 is still active.
• The ECU was tampered with using a • If P0605 is still active, the ECU calibration memory is
permanently damaged and the ECU must be replaced.
third party calibration tool.
Follow the ECU replacement procedure found later in
• An unexpected error occurred while
this document.
reprogramming the ECU, using the
• If P0605 is no longer active, the ECU has been recovmanufacturer diagnostic software.
ered and is safe to use moving forward.
• An intermittent (nonpermanent) calibration memory failure occurred.
• The calibration memory has become
permanently damaged.
13
P0606
ECU Processor
Indicates that a noncritical device inside • Inspect the ECU for signs of physical tampering. Look
for pry marks between the throttle body metal and the
of the ECU has failed. This can occur
plastic cover of the ECU. Look for broken locking tabs
in the following conditions, in order
on the plastic cover of the ECU. Look for small holes
of decreasing likelihood:
in the plastic cover of the ECU, including checking in
• The ECU has been physically tamthe connector cavity. Regardless of whether tampering
pered with.
is present or not, proceed with the following steps to
• The ECU has been tampered with
attempt to repair the problem.
using a third party calibration tool.
• Ensure the ECUs have a stable power supply from a
• The noncritical device inside of the
healthy charged battery.
ECU has failed.
• Use the manufacturer diagnostic software to reprogram
the ECU with the latest service package.
• Clear DTCs.
• Observe whether P0606 is still active.
• If P0606 is still active, the ECU is permanently damaged and the ECU should be replaced. Follow the ECU
replacement procedure found later in this document.
• If P0606 is no longer active, the ECU has been recovered and is safe to use moving forward. In this
case, it is likely that the ECU was tampered with
using a third party calibration tool.
14
P0607
ECU
­Performance
Indicates that a critical device inside of • Inspect the ECU for signs of physical tampering. Look
for pry marks between the throttle body metal and the
the ECU has failed. When this DTC
plastic cover of the ECU. Look for broken locking tabs
is active, the ECU will intentionally
on the plastic cover of the ECU. Look for small holes
prevent its cylinder from running. This
in the plastic cover of the ECU, including checking in
can occur in the following conditions,
the connector cavity. Regardless of whether tampering
in order of decreasing likelihood:
is present or not, proceed with the following steps to
• The ECU has been physically tamattempt to repair the problem:
pered with.
• Ensure the ECUs have a stable power supply from a
• The ECU has been tampered with
healthy charged battery.
using a third party calibration tool.
• Use the manufacturer diagnostic software to reprogram
• The critical device inside of the ECU
the ECU with the latest service package.
has failed.
• Clear DTCs.
• Observe whether P0607 is still active.
• If P0607 is still active, the ECU is permanently damaged and the ECU must be replaced.
• If P0607 is no longer active, the ECU has been recovered and is safe to use moving forward.
Page 16
DIAGNOSTIC TROUBLESHOOTING CODES (DTCS) MATRIX
Item
Fault
Code
15
P0628
Condition
Fuel Pump
Control Circuit
Low
Cause
Actions
Indicates an issue with the fuel pump • Check the electrical connector is positively fixed to
circuitry where the ECU has detected
the fuel pump.
low voltage. The following conditions • Inspect wiring to the fuel pump and pump body for
are examples of what may occur causdamage. Repair and replace as necessary.
ing this fault:
• Verify continuity between Fuel Pump Connector Pin 1
• Wiring to the fuel pump has become
and ECU Connector Pin H4.
damaged and shorting to the chassis,
•
Verify
continuity between Fuel Pump Connector Pin 2
or creating an open circuit condition.
and ECU Connector Pin F4 .
• The electrical connector at the fuel
pump has become disconnected or • Using a multimeter, check the resistance of the fuel
pump. Nominal resistance is approximately 12 ohms.
damaged.
If open circuit, replace the fuel pump.
• The fuel pump has electrically failed
• Clear DTCs using dealer tool.
and is no longer operational.
• Observe whether P0628 is still active.
• If still active, further inspection and diagnostics will be
required before returning generator to service.
• If no longer active, return the generator to service.
16
P0629
Fuel Pump
Control Circuit
High
Indicates an issue with the fuel pump • Check the electrical connector is positively fixed to
the fuel pump.
circuitry where the ECU has detected
high voltage. The following condi- • Inspect wiring to the fuel pump and the pump body
tions are examples of what may occur
for damage. Repair and replace as necessary.
causing this fault:
• Verify continuity between Fuel Pump Connector Pin 1
• Wiring to the fuel pump has become
and ECU Connector Pin H4.
damaged and shorting to a battery
• Verify continuity between Fuel Pump Connector Pin 2
voltage source.
and ECU Connector Pin F4.
• The fuel pump has electrically failed
• Using a multimeter, check the resistance of the fuel
and is no longer operational.
pump. Nominal resistance is approximately 12 ohms.
If shorted with resistance approximately zero ohms,
replace the fuel pump.
• Clear DTCs using Dealer tool.
• Observe whether P0629 is still active.
• If still active, further inspection and diagnostics will be
required before returning generator to service.
• If no longer active, return the generator to service.
17
P062F
ECU EEPROM
Error
Indicates that the electrically erasable
programmable read only memory
(EEPROM) inside of the ECU
has failed. This memory stores
parameters such as the fuel trim
parameters, so the information can
be retained while the ECU is in PD
mode. This DTC is considered noncritical, so the engine will be allowed
to run with degraded performance.
This can occur in the following
conditions, in order of decreasing
likelihood:
• An intermittent (nonpermanent) EEPROM failure occurred.
• The EEPROM has become permanently damaged.
Page 17
• Ensure the ECUs have a stable power supply from a
healthy charged battery.
• Use the manufacturer diagnostic software to reprogram
the ECU with the latest service package.
• Clear DTCs.
• Observe whether P062F is still active.
• If P062F is still active, the ECU EEPROM is permanently
damaged and the ECU should be replaced. Follow
the ECU replacement procedure found later in this
document.
• If P062F is no longer active, the ECU has been
recovered and is safe to use moving forward.
DIAGNOSTIC TROUBLESHOOTING CODES (DTCS) MATRIX
Item
Fault
Code
18
P0650
Condition
Cause
Actions
Malfunction
­Indicator Lamp
Control Circuit
Indicates a problem with the MIL circuit
on the ECU. Under these conditions,
the MIL will not illuminate due to a
damaged connection to the lamp. To
identify this issue, inspect the ECU
for the MIL bulb check sequence by
keying on and looking for the bulb
to illuminate for 2.5 seconds. ECUs
must be functional, as well as a
charged battery to verify operation.
• Ensure the ECUs have a stable power supply from a
healthy charged battery.
• Use the manufacturer diagnostic software to reprogram
the ECU with the latest service package.
• Clear DTCs.
• Observe whether P0650 is still active.
• If P0650 is still active, the ECU is permanently damaged and the ECU should be replaced. Follow the ECU
replacement procedure found later in this document.
• If P0650 is no longer active, the ECU has been recovered and is safe to use moving forward.
19
P2226
Barometric
Indicates that the internal barometric • Inspect the ECU for signs of physical tampering. Look
Pressure Circuit
for pry marks between the throttle body metal and the
air pressure sensor has failed. The
plastic cover of the ECU. Look for broken locking tabs
engine will be allowed to run with
on the plastic cover of the ECU. Look for small holes
degraded performance in this situin the plastic cover of the ECU, including checking in
ation. This can occur in the following
the connector cavity. If tampering is present, no warconditions, in order of decreasing
ranty should be honored for the ECU. Regardless of
likelihood:
whether tampering is present or not, proceed with the
• The ECU has been physical tampered
following steps to attempt to repair the problem.
with.
• Ensure the ECUs have a stable power supply from a
• The ECU has been tampered with
healthy charged battery.
using a third party calibration tool.
• Use the manufacturers diagnostic software to repro• The barometric pressure sensor
gram the ECU with the latest service package.
inside of the ECU has failed.
• Clear DTCs.
• Observe whether P2226 is still active.
• If P2226 is still active, the ECU is permanently
damaged and the ECU must be replaced. Follow
the ECU replacement procedure found later in this
document.
• If P2226 is no longer active, the ECU has been recovered and is safe to use moving forward. In this
case, it is likely that the ECU was tampered with
using a third party calibration tool.
20
P2300
Ignition Coil
Primary Control
Circuit Low
Indicates a issue with the ignition coil • Check the electrical connector is positively fixed to
the ignition coil.
circuitry where the ECU has detected
low voltage. The following conditions • Inspect wiring to the ignition coil and the coil body for
are examples of what may occur
damage. Repair and replace as necessary
causing this fault:
• Verify continuity between Ignition Coil Connector Pin
• Wiring to the ignition coil has become
A and ECU Connector Pin G2.
damaged and shorting to the chassis.
• Verify continuity between Ignition Coil Connector Pin
• The electrical connector at the igniC and ECU Connector Pin H1.
tion coil has become disconnected or
• Using a multimeter, check the resistance of the coil.
damaged.
Nominal resistance is approximately 1/2 ohm. If open
• The ignition coil has electrically failed
circuit, replace the ignition coil.
and is no longer operational.
• Clear DTCs.
• Observe whether P2300 is still active.
• If still active, further inspection and diagnostics will be
required before returning generator to service.
• If no longer active, return the generator to service.
Page 18
PARTS AND SERVICE
Prior to requesting service or purchasing replacement parts, please obtain your item, manufacturing,
and serial numbers from the product data plate.
ITEM NO._________________________________________
MANUFACTURING NO.____________________________
SERIAL NO._______________________________________
HOW TO OBTAIN REPLACEMENT PARTS: A replacement parts list is available online at www.ryobitools.com. Replacement parts can be purchased online or by calling 1-800-860-4050. Replacement
parts can also be obtained at one of our service centers.
HOW TO LOCATE A SERVICE CENTER: Service centers can be located online at www.ryobitools.
com or by calling 1-800-860-4050.
HOW TO OBTAIN CUSTOMER OR TECHNICAL SUPPORT: To obtain customer or technical support
please contact us at 1-800-860-4050.
DANGER:
Carbon Monoxide. Using a generator indoors CAN KILL YOU IN MINUTES.
Generator exhaust contains high levels of carbon monoxide (CO), a poisonous gas you cannot see or smell. If you can
smell the generator exhaust, you are breathing CO. But even if you cannot smell the exhaust, you could be breathing CO.
 Never use a generator inside homes, garages, crawlspaces, or other partly enclosed areas. Deadly levels of carbon
monoxide can build up in these areas. Using a fan or opening windows and doors does NOT supply enough fresh
air.
 ONLY use a generator outdoors and far away from open windows, doors, and vents. These openings can pull in
generator exhaust.
Even when you use a generator correctly, CO may leak into the home. ALWAYS use a battery-powered or battery-backup
CO alarm in the home.
If you start to feel sick, dizzy, or weak after the generator has been running, move to fresh air RIGHT AWAY. See a doctor.
You could have carbon monoxide poisoning.
Page 19
RY907000FI
Electronic Fuel Injection (EFI)
Diagnostics Service Manual
FOR RY907000FI
RYOBI 7,000 WATT GENERATOR
TECHTRONIC INDUSTRIES POWER EQUIPMENT
1428 Pearman Dairy Road, Anderson, SC 29625 USA
1-800-860-4050 • www.ryobitools.com
995000285
10-17-17 (REV:01)
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