The Ford CSG-649 is a 300 L 6-cylinder natural aspiration engine rated at 2600 rpm, producing up to 80 kW. It powers generator sets from Kohler, including the 30 RZ and 30RFZ. It holds 6 L (1.6 gal) of oil and 15 L (4.0 gal) of coolant.
Also known as: Ford CSG-649
Part of the Ford CSG649 engine family — 4 variants share parts & fitment.
| Oil capacity | 6.0 L |
|---|---|
| Coolant capacity | 15.0 L |
| Displacement | 300.0 L |
| Cylinders | 6 |
| Aspiration | Natural Aspiration |
| Rated speed | 2600 rpm |
| Gross power | 80 kW |
| Code | Meaning | Remedy |
|---|---|---|
| FAULT 1 or FAULT 2 | Engine shuts down immediately, engine runs for several seconds and then shuts down, or engine continues to run. | |
| LOW FUEL | Engine continues to run or is in standby mode. | Indicates fuel supply pressure is marginally low (5 inches [127 mm] WC or less). Check for partially closed shutoff valve, empty propane supply tank. For natural gas fueled sets, check with the gas utility. |
| 32 | High Coolant Temperature | |
| 32A | Emergency Stop | Reset the emergency stop switch. |
| 40 | Pre High Coolant Temp. | |
| 41 | Pre Low Oil Pressure | Check and adjust oil level or replace oil pump. |
| 62 | Low Battery Volts | |
| 63 | Low Fuel | Refuel the generator set. |
| 48 | Emergency Stop | |
| PUMP | Emergency Pump | |
| 4 | Platform in contact with live power lines and operator incapacitated | Contact authorized personnel to disconnect power supply from unit. Have someone summon first aid or rescue squad. If operator is unconscious, check if he is in a pinned position, or would be endangered if platform is moved. AFTER POWER IS CUT, use the emergency lowering procedure to bring platform with operator to a safe location to render first aid. |
| Symptom | Cause | Remedy |
|---|---|---|
| Engine will not crank. | Possible fault with control or starting system. | A. Correct fault and reset common fault circuit breaker. b. Poor battery cable connections. Clean the battery cable terminals and tighten all connections. c. Discharged or defective battery. Recharge or replace the battery. d. Replace the control circuit fuse (located inside the control panel) if it has blown. |
| The engine cranks, but does not start. | Possible fuel system problem. | A. Check for empty fuel tank, fuel leaks, or plugged fuel lines and correct as required. b. Check for dirty or plugged air filter and replace if necessary (see Maintenance section). c. Reset the tripped common fault circuit breaker and restart after correcting the problem. Contact an authorized service center for service if none of the above. |
| The engine shuts down due to high engine temperature or low coolant level. | 1. Indicates engine has overheated (engine temperature has risen above 230° F/110° C). Allow engine to cool down completely before proceeding with the following checks: a. Check coolant level and replenish if low. Look for possible coolant leakage points and repair if necessary. b. Check for obstructions to cooling airflow and correct as necessary. c. Check for a slipping fan belt and tighten if loose. d. Reset the tripped common fault circuit breaker. Contact an authorized service center for service if none of the above. | |
| Engine shuts down due to over-speed. | 5. Indicates engine has exceeded normal operating speed. Contact an authorized service center for service. | |
| Engine shuts down due to low oil pressure. | 4. Indicates e | |
| PRE HI ENGINE TEMP lamp lights. Engine continues to operate. | Indicates engine has begun to overheat and engine temperature has risen to approximately 220°F (104°C). | A. Reduce load if possible by turning off non-critical loads. b. Check air inlets and outlets and remove any obstructions to airflow. If engine can be stopped, follow procedure in step 3. |
| PRE LO OIL PRES lamp lights. Engine continues to operate. | Indicates engine has overheated (engine temperature has risen above 230°F/110°C) or coolant level is low (sets with coolant level sensor). | A. Check coolant level and replenish if low. Look for possible coolant leakage points and repair if necessary. b. Check for obstructions to cooling airflow and correct as necessary. c. Check for a slipping fan belt and tighten if loose. d. Reset control and restart after locating and correcting problem. Contact an authorized service center for service if none of the above. |
| LO OIL PRES lamp lights. Engine shuts down. | NOTE: See also step 6. | |
| LO OIL PRES lamp lights. Indicates engine oil pressure has dropped to 14 psi (97 kPa). | Check oil level, lines and filters. If oil system is OK but oil level is low, replenish. Reset control and restart. Contact an authorized service center if oil pressure is not in the range of 40 to 65 psi (276 to 449 kPa). | |
| OVERCRANK lamp lights and engine stops cranking. | A. Open any closed fuel shutoff valve. b. Check for dirty or plugged air filter and replace if necessary (see Maintenance section). c. Gaseous fuel delivery to the set is inadequate. Contact an authorized service center for service. d. Reset the control and restart after correcting the problem. Contact an authorized service center for service if none of the above. | |
| OVERSPEED lamp lights and the engine shuts down. | Indicates engine has exceeded normal operating speed. Contact an authorized service center for service. | |
| SWITCH OFF lamp flashes. | Indicates Run/Stop/Remote switch is in the Stop position which will prevent automatic starting if an automatic transfer switch is used. Move the Run/Stop/Remote switch to the Remote position for automatic starting. | |
| LO ENG TEMP lamp lights. Set is in standby mode but is not operating. | Lamp lights when engine coolant temperature is 70° F (21° C) or lower. Since the lamp goes out after the engine warms up, there should be no cause for alarm even during initial generator set operation. | |
| Fault lamp lights but no fault exists. Engine gauges show oil pressure, engine temperature, and frequency (speed) are within normal limits. | The monitor board or a sensor may be at fault. Contact an authorized service center for service. | |
| Engine starts from generator control panel but will not start automatically or from a remote panel. | Note: The Run/Stop/Remote switch must be in the Remote position for automatic or remote starting. | Remote circuit breaker is tripped. Reset breaker and restart. Contact an authorized service center if breaker trips after resetting. |
| No AC output voltage. | Field breaker is tripped. Reset breaker. Contact an authorized service center if voltage buildup causes breaker to trip. | |
| Green RUN lamp does not light following engine startup. | Indicates possible Start/Disconnect relay failure. Contact an authorized service center for assistance. | |
| RUN or fault lamp(s) does not light when Lamp Test switch is engaged. | Contact an authorized service center for assistance. | |
| Green RUN lamp lights following engine Startup. | Indicates all engine systems are normal. No corrective action required. | |
| HI ENG TEMP lamp lights. Engine shuts down. | A. Check coolant level and replenish if low. Look for possible coolant leakage points and repair if necessary. b. Check for obstructions to cooling airflow and correct as necessary. c. Check for a slipping fan belt and tighten if loose. d. Reset control and restart after locating and correcting problem. Contact an authorized service center if none of the above. | |
| PRELOOILPRES lamp lights. Engine continues to operate. | A. Wait until next shutdown period and then follow step 5 procedure. b. If engine can be stopped, follow procedures in step 5. | |
| OVERGRANK lamp lights and engine stops cranking. | A. Check for empty fuel tank, fuel leaks, or plugged fuel lines and correct as required. b. Check for dirty fuel filter and replace if necessary (see MAINTENANCE section). c. Check for dirty or plugged air filter and replace if necessary (see MAINTENANCE section). d. Check ignition system (see MAINTENANCE). e. Reset the control and restart after correcting the problem. Contact an authorized service center for service if none of the above. | |
| Engine runs and then shuts down, OVERSPEED lamp lights. | Contact an authorized service center for service. | |
| LO FUEL lamp lights. Engine continues to run. | Check fuel supply and replenish as required. | |
| LO FUEL lamp lights. Engine shuts down and LO OIL PRES lamp lights. | A. Check fuel level and replenish as required. b. Contact an authorized service center for service. | |
| The FAULT 1 or FAULT 2 fault lamp lights. | Engine shuts down immediately, engine runs for several seconds and then shuts down, or engine continues to run. a. The standard undesignated fault functions are programmed to shut down the set when a fault is sensed. Fault 1 is time delayed while Fault 2 is immediate. The nature of the fault is an optional selection that is determined when the set installation is designed. The undesignated fault functions may also be programmed for non-shutdown or non-time delay. b. Contact an authorized service center for service. | |
| Fault lamp turns on during operation | Follow the procedures listed below to locate and correct the problem. For any symptom not listed, contact an authorized service center for assistance. | |
| Line Circuit Breaker trips | Locate the source of the overload and correct as necessary. Manually reset the breaker to reconnect the load to the generator. |
Fault codes and symptom→remedy steps extracted from this engine’s service/owner documentation; verify against the official manual before servicing.
Compiled from service & troubleshooting documentation across every generator set that uses the Ford CSG-649.
| Item | Spec | Capacity | Part # | Interval | |
|---|---|---|---|---|---|
| Battery | BCI Group 31 - 950 CCA (after 6-15-88) | — | |||
| Coolant | 50% ethylene glycol and 50% clean, softened water | 28.8 L | — | ||
| Hydraulic filter | 100 Mesh (141 Micron), 200 sq. in., reusable wire filter element, Marvel #881 | 0-501-01010 | 250 hr | buy | |
| Oil | EO - per manufacturer recommendation | — |
Pooled from every document that names this exact engine — confirm the interval and part number against your unit's serial number.
Step-by-step procedures compiled from the Ford service manual for this engine.
| Item | Action | Hours | Months | Notes |
|---|---|---|---|---|
| return line filter | Change | 50 hr | First service — Service after first 50 hours of operation | |
| hydraulic oil | Change | 500 hr | Drain and replace every 500 hours and/or each year; service suction strainer at this time |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
| Type | Item | Value | Unit | Condition |
|---|---|---|---|---|
| Clearance | Backlash between rotation gear pinion and bull gear teeth | .010 | inch | |
| Other | Chrysler HB225 horsepower | 97 | horsepower | at 2600 RPM |
| Other | Cummins 4B3.9 horsepower | 76 | horsepower | at 2500 RPM |
| Other | Ford CSG-649 horsepower | 112 | horsepower | at 2500 RPM |
| Other | Ford CSG-649 torque | 246 | pounds ft. | at 2000 RPM |
| Other | John Deere 4239D horsepower | 80 | horsepower | at 2500 RPM |
| Other | PR-1 transmission total fluid capacity | 11 | quarts | |
| Other | Perkins 4.236 horsepower | 80 | horsepower | at 2500 RPM |
| Other | Pressure change per .010 inch work port relief shim | 100 to 125 | PSI | swing circuit relief adjustment |
| Pressure | Boom and Outrigger Circuit relief pressure | 2600 | PSI | at full flow, pump at 2000 RPM |
| Pressure | Boom structural protection pressure switch | 3100 | PSI | boom raise cylinder |
| Pressure | Chrysler HB225 engine oil pressure | 50 | PSI | at 800 RPM |
| Pressure | Cummins 4B3.9 engine oil pressure | 30-60 | PSI | |
| Pressure | Ford CSG-649 engine oil pressure | 35-60 | PSI | at 2000 RPM (HOT) |
| Pressure | John Deere 4239D engine oil pressure | 50 | PSI | at 2000 RPM |
| Pressure | Overload Alert unloader valve opening pressure | 2650 | PSI | boom topping cylinder base pressure |
| Pressure | Perkins 4.236 engine oil pressure | 57 | PSI | at 2600 RPM |
| Pressure | Steering system pressure | 1500 | PSI | factory setting |
| Pressure | Swing circuit work port relief valves | 1500 | PSI | |
| Pressure | Tire pressure | 90 | PSI | |
| Pressure | Winch and Extension Circuit relief pressure | 2500 | PSI | at full flow, pump at 2000 RPM |
| Speed | Cummins 4B3.9 governed speed | 2500 | RPM | |
| Speed | Ford CSG-649 governed speed | 2600 | RPM | |
| Speed | John Deere 4239D governed speed | 2500 | RPM | |
| Speed | Perkins 4.236 governed speed | 2500 | RPM | |
| Torque | Bull gear mounting bolts (3/4 dia.) | 280 | ft-lbs |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
| Fluid | Grade | Standard | Ambient | Capacity | Notes |
|---|---|---|---|---|---|
| Gear oil | MPL - Multipurpose Gear Lubricant SAE 90 | 4 speed transmission, drive axle, planetary hub | |||
| Gear oil | MPL* - Multipurpose Gear Lubricant SAE 140 | Winch | |||
| Gear oil | Universal Gear Lubricant 80W-90 (MIL2105C) | MIL2105C | 20.0 pints | Clark Model 12S0736 front drive/steer axle; differential 8 pints each hub | |
| Grease | MPG - Multipurpose Grease | Drive shaft, PTO shaft, steering cylinder ends, tie rod ends, boom hinge pin, topping cylinder, tip sheaves, axle pivot point, shift linkage, king pins, etc. | |||
| Hydraulic oil | Mobil AW-46 / Mobil DTE-25 / Conoco Super 46 / Texaco HD46 | Must contain rust and oxidation inhibitor, anti-foam and antiwear agents; must pass Vickers Vane Pump Test | Ambient temp range -15 to 110 deg F; factory fill; pour point -15 deg F max; viscosity index 95 to 100; visc SSU @100F 230 max; SSU @210F 47 min | ||
| Hydraulic oil | Mobil AW-68 / Mobil DTE-26 / Conoco Super 68 / Texaco HD68 | Must contain rust and oxidation inhibitor, anti-foam and antiwear agents; must pass Vickers Vane Pump Test | Ambient temp range 50 to 130 deg F; pour point 0 deg F max; viscosity index 95 to 100; visc SSU @100F 340 max; SSU @210F 53 min | ||
| Hydraulic oil | Mobil DTE-13 / Mobil Univ-ATF / Texamatic Type F | Must contain rust and oxidation inhibitor, anti-foam and antiwear agents; must pass Vickers Vane Pump Test | Ambient temp range -40 to 75 deg F; pour point -40 deg F max; viscosity index 140 min; visc SSU @100F 200 max; SSU @210F 44 min | ||
| Other | Open Gear Grease | Rotation gear teeth; example Mobilkote 5 | |||
| Other | Type C-3 Fluid (C-2/C-3) | 11.0 quarts | PR-1 Powershift transmission; change every 500 hours; examples Amoco C3, Chevron Torque Fluid 5, Exxon Torque Fluid 47, Gulf HT Fluid C-3, Mobil Power Fluid C-3 | ||
| Other | Wheel Bearing Grease | Wheel bearings; clean and repack |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
⚠ Do not check for hydraulic leaks with hands
Tools: 3000 PSI pressure gauge
⚠ Never use a rope clip on live side of the load hoist rope
⚠ Never lift more load with a given number of parts of line than recommended on the Crane Capacity Chart
⚠ Serious damage to the pump will result if it is run with the shut-off valves closed or with insufficient oil level in the reservoir
⚠ Be sure the shut-off valve is opened fully before putting the pump back in operation
⚠ Shifting from forward to reverse while in motion or above 1000 RPM can severely damage transmission and drive train
⚠ Never hold a control lever in the open position after the function has reached the end of its travel
⚠ Remove boom extension from base boom when using work platform or personnel buckets
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
| Part # | Description | Category |
|---|---|---|
| 254471 | Element, air cleaner | Air filter |
| A281 | Cinghia trapezoidale | Bearing |
| 550-00080 | BMC No. 0-550-00080 (Standard 4-spool) | Boom and outrigger control valve |
| 550-00081 | BMC No. 0-550-00081 (Optional 5-spool - Req'd w/opt. Front Winch) | Boom and outrigger control valve |
| 540-80025 | BMC No. 3-540-80025 | Boom elevating cylinder |
| 552-00041 | BMC No. 0-552-00041 | Boom elevation cylinder holding valve |
| 540-40043 | BMC No. 3-540-40043; Tip Section - 3-540-40044 | Boom extension cylinder |
| 540-40047 | BMC No. 3-540-40047; Tip Section - 3-540-40038 | Boom extension cylinder |
| 02-09 | Breaker Plate and Sub-Plate | Breaker plate |
| COVER.6616 | Oil pump cover | Cover |
| A21654 | Oil pump cover attaching screw | Cover attaching screw |
| 276206 | Hose, molded | Hose |
| X-577-41 | Hose | Hose |
| X-797-2 | Hose, flex | Hose |
| 82867-8 | Hydraulic valve lifter assembly | Hydraulic valve lifter |
| SCREW-20324-S | Oil pump screw | Oil pump screw |
| 0-861-16012 | BMC No. 0-861-16012 | Service part / kit |
| 2-651-00060 | WARNING NEVER USE A ROPE CLIP ON LIVE SIDE OF THE LOAD HOIST ROPE. THIS WILL SERIOUSLY WEAKEN THE ROPE. DEATH OR SERIOUS INJURY CAN RESULT FROM THE USE OF A ROPE CLIP ON THE HOIST ROPE. | Service part / kit |
| 276370 | Engine Block Heater Service Kit Tank Type 30RZ 120V | Service part / kit |
| 276371 | Engine Block Heater Service Kit Tank Type 30RZ 240V | Service part / kit |
| 285127 | Silencer Industrial I-N (Table 1) | Service part / kit |
| 285775 | Silencer Residential R-M (Table 1) | Service part / kit |
| 286788 | Silencer Critical C-BM (Table 1) | Service part / kit |
| 290483 | Silencer Residential R-BM (Table 1) | Service part / kit |
| 290484 | Silencer Residential R-N (Table 1) | Service part / kit |
| 290495 | Silencer Critical C-M (Table 1) | Service part / kit |
| 290496 | Silencer Critical C-N (Table 1) | Service part / kit |
| 326222 | Block Heater | Service part / kit |
| 326224 | Block Heater | Service part / kit |
| 326230 | Installed Block Heater Kit (120V) | Service part / kit |
| 326231 | Installed Block Heater Kit (240V) | Service part / kit |
| 343160 | Switch, high water temperature | Service part / kit |
| 345207 | Switch, vacuum | Service part / kit |
| 649528 | FULCRUM SEAT | Service part / kit |
| 6A529 | ROCKER ARM STUD NUT | Service part / kit |
| 9-340-00030 | Shim - .040" - Gresen #0458-001 | Service part / kit |
| 9-340-00031 | Shim - .020" - Gresen #0459-001 | Service part / kit |
| 9-340-00032 | Shim - .010" - Gresen #0462-001 | Service part / kit |
| 9-340-00070 | Work Port Relief Valve-Gresen #7460-002-PS-1500-C | Service part / kit |
| A-258495 | LP Gas Mixer | Service part / kit |
| A20459A | FIG. 44 Removing Fiber Camshaft Gear | Service part / kit |
| A2820-A | Installation | Service part / kit |
| A28300-A | Installation kal-f65L-6306-A | Service part / kit |
| A2834-A | BASIC ENGINE REMOVAL AND INSTALLATION (Continued) | Service part / kit |
| A2857-A | SPRING PAD | Service part / kit |
| A3007-A | Removal | Service part / kit |
| A3109-A | CYLINDER HEAD LIFTING EYE | Service part / kit |
| l-07 | Basic Engine Runout Gouge | Service part / kit |
| 552-00013 | BMC No. 0-552-00013 | Outrigger cylinder holding valve |
| 540-10034 | BMC No. 3-540-10034 | Outrigger cylinders |
| 520-00021 | BMC No. 0-520-00021 | Pump |
| A1327-8 | OIL PUMP | Pump |
| 3-333-10040 | BMC No. 3-333-10040 (Cummins) | Pump drive |
| 3-333-10070 | BMC No. 3-333-10070 (Cummins) | Pump drive |
| 501-01018 | BMC No. 0-501-01018 | Return line filter |
| A2825 | CRANKSHAFT FRONT OIL SEAL | Seal |
| A28429 | Crankshaft Rear Oil Seal | Seal |
| 240976 | Switch, high temperature 268298 Sender, temperature | Sensor |
| 255264 | Switch, low water temperature | Sensor |
| 271425 | Switch, anticipatory low oil pressure | Sensor |
| 258276 | Spark Plugs | Spark plug |
| 501-01010 | BMC No. 0-501-01010 | Suction strainer |
| WASHER-34805-S | Water washer | Water washer |
| 550-00075 | BMC No. 0-550-00075 | Winch and extension control valve |
Parts cataloged across all variants of this engine family — verify the exact part fits your specific variant and serial number before ordering.
The Ford CSG-649 engine has an oil capacity of 6.0 liters.
The Ford CSG-649 has a displacement of 300.0 liters with 6 cylinders.
The Ford CSG-649 powers 2 generator set(s), including Kohler 30 RZ, Kohler 30RFZ.
A commonly reported issue on generators using the Ford CSG-649 is: The engine shuts down due to high engine temperature or low coolant level.. Fix: 1. Indicates engine has overheated (engine temperature has risen above 230° F/110° C). Allow engine to cool down completely before proceeding with the following checks: a. Check coolant level and replenish if low. Look for possible coolant leakage points and repair if necessary. b. Check for obstructions to cooling airflow and correct as necessary. c. Check for a slipping fan belt and tighten if loose. d. Reset the tripped common fault circuit breaker. Contact an authorized service center for service if none of the above..