The Ford CSG-649 is a 4.95 L 6-cylinder natural aspiration engine rated at 1800 rpm, producing up to 61 kW. It powers generator sets from Kohler, including the 30 RZ and 30RFZ. It holds 6.6 L (1.7 gal) of oil and 28.8 L (7.6 gal) of coolant.
Also known as: Ford CSG-649
Part of the Ford CSG-649 engine family — 3 variants share parts & fitment.
| Oil capacity | 6.6 L |
|---|---|
| Coolant capacity | 28.8 L |
| Displacement | 4.951 L |
| Cylinders | 6 |
| Aspiration | Natural Aspiration |
| Rated speed | 1800 rpm |
| Gross power | 61 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. |
| 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.
| Item | Spec | Capacity | Part # | Interval | |
|---|---|---|---|---|---|
| Air filter | — | ||||
| Fuel filter | — | ||||
| Oil filter | — | ||||
| Battery | — | ||||
| Belt | BELT | D78P-4201-F | Amazon eBay | ||
| Coolant | 50% ethylene glycol and 50% clean, softened water | 28.8 L | — | ||
| Coolant filter | — | ||||
| Oil | — | ||||
| Spark plug | — |
Pooled from every document that names this exact engine — confirm the interval and part number against your unit's serial number.
| Part # | Description | Category |
|---|---|---|
| 254471 | Element, air cleaner | air_filter |
| J1088.16 | ARMATURE AND FIELD GROUNDED CIRCUIT TEST | armature_and_field_grounded_circuit_test |
| J1087-1G | ARMATURE OPEN CIRCUIT TEST | armature_open_circuit_test |
| A281 | Cinghia trapezoidale | bearing |
| D78P-4201-F | BELT | belt |
| B9A-14294-J | Blade Terminal | blade_terminal |
| 02-09 | Breaker Plate and Sub-Plate | breaker_plate |
| COVER.6616 | Oil pump cover | cover |
| A21654 | Oil pump cover attaching screw | cover_attaching_screw |
| A9077-1A | CRANKSHAFT VIBRATION DAMPER | crankshaft_vibration_damper |
| A9621-18 | D78P-4201-G | dial_indicator |
| J3567-2A | DISASSEMBLY AND ASSEMBLY | disassembly_and_assembly |
| 41086-1D | DISASSEMBLY AND ASSEMBLY (Continued) | disassembly_and_assembly_continued |
| J3566-1A | DISCONNECT HOLDING COIL GROUND LEAD (FINE WIRE INSIDE FRAME) | disconnect_holding_coil_ground_lead |
| J2574-1B | GASOLINE ENGINE | engine |
| 82630-18 | FABRICATED ADAPTER FITTING | fabricated_adapter_fitting |
| AB76S-1C | Feeler Gauge | feeler_gauge |
| A2274-1B | Coolant | fluid |
| 82322.1D | GASKET | gasket |
| A218 | Cylinder head gasket | gasket |
| A2K32-1E | Cylinder head gasket | gasket |
| A2232-1E | FEELER GAUGE | gauge |
| B4082-20 | Blue Grommet-Duraspark 11 | grommet |
| A3196-1D | STUD | hardware |
| 276206 | Hose, molded | hose |
| X-577-41 | Hose | hose |
| X-797-2 | Hose, flex | hose |
| 82867-8 | Hydraulic valve lifter assembly | hydraulic_valve_lifter |
| 12A199 | Duraspark Il Ignition Module | ignition_module |
| A3245-1C | INSTALLATION OF CYLINDER HEAD | installation_guide |
| A4B70-14 | INSTALLATION OF CYLINDER HEAD | installation_guide |
| AN87-16 | LOCATION FOR 5/16" - 18 LIFTING EYE | location_marking |
| 41372-2C | MILLED GEARS | milled_gears |
| A2905-4 | Oil Pan | oil_pan |
| SCREW-20324-S | Oil pump screw | oil_pump_screw |
| 276370 | Engine Block Heater Service Kit Tank Type 30RZ 120V | other_service |
| 276371 | Engine Block Heater Service Kit Tank Type 30RZ 240V | other_service |
| 2811-18 | OIL RING SPACER | other_service |
| 285127 | Silencer Industrial I-N (Table 1) | other_service |
| 285775 | Silencer Residential R-M (Table 1) | other_service |
| 286788 | Silencer Critical C-BM (Table 1) | other_service |
| 290483 | Silencer Residential R-BM (Table 1) | other_service |
| 290484 | Silencer Residential R-N (Table 1) | other_service |
| 290495 | Silencer Critical C-M (Table 1) | other_service |
| 290496 | Silencer Critical C-N (Table 1) | other_service |
| 326222 | Block Heater | other_service |
| 326224 | Block Heater | other_service |
| 326230 | Installed Block Heater Kit (120V) | other_service |
| 326231 | Installed Block Heater Kit (240V) | other_service |
| 343160 | Switch, high water temperature | other_service |
| 345207 | Switch, vacuum | other_service |
| 3791535 | BOLT-377850-S | other_service |
| 42227-2E | STATOR WINDINGS | other_service |
| 42228-2D | ELECTRONIC VOLTAGE REGULATOR | other_service |
| 649528 | FULCRUM SEAT | other_service |
| 6565-AB | CUP SHAPED ADAPTER TOOL | other_service |
| 6A529 | ROCKER ARM STUD NUT | other_service |
| A-258495 | LP Gas Mixer | other_service |
| A20459A | FIG. 44 Removing Fiber Camshaft Gear | other_service |
| A2176-20 | Identification Decal | other_service |
| A2820-A | Installation | other_service |
| A28300-A | Installation kal-f65L-6306-A | other_service |
| A2834-A | BASIC ENGINE REMOVAL AND INSTALLATION (Continued) | other_service |
| A2843-26 | BASIC ENGINE REMOVAL AND INSTALLATION (Continued) | other_service |
| A2857-A | Valve spring retainer lock | other_service |
| A2868-A | INSTALLING AND MEASURING PLASTIGAGE | other_service |
| A3007-A | Removal | other_service |
| A3010- | CLEANING AND INSPECTION | other_service |
| A3109-A | CYLINDER HEAD LIFTING EYE | other_service |
| B4187-14 | Diaphragm Assembly | other_service |
| B5A-19554-A | oil resistant sealer | other_service |
| BSA-14294-PAK | KIT NO. BSA-14294-PAK | other_service |
| D78P-4201-G | DIAL INDICATOR | other_service |
| D81P-6002-E | VALVE SEAT RUNOUT GAUGE | other_service |
| DOAZ-19584-A | Ford Polyethylene Grease | other_service |
| NUT..383256-S36 | WASHER —380097-S36 | other_service |
| S2572-10 | other_service | |
| SCREW-20324S | Screw | other_service |
| SCREW-20346-S | Screw | other_service |
| WASHER.34806-5 | Washer | other_service |
| l-07 | Basic Engine Runout Gouge | other_service |
| A2901-1C | AVS B= VERTICAL TAPER C VS D == HORIZONTAL TAPER A VSC AND B VS D = OUT OF ROUND CHECK FOR OUT-OF-ROUND AT EACH END OF JOURNAL | out_of_round_checker |
| A1327-8 | OIL PUMP | pump |
| A9623-1A | PUSH ROD + P | push_rod |
| 41085-1D | REMOVAL AND INSTALLATION | removal_and_installation |
| A9402-1A4 | RING GROOVE CLEANER (TOOL - D81L-6002-D) | ring_groove_cleaner |
| A2825 | CRANKSHAFT FRONT OIL SEAL | seal |
| A28429 | Crankshaft Rear Oil Seal | seal |
| A2897-1C | Seat Width Scale | seat_width_scale |
| 240976 | Switch, high temperature 268298 Sender, temperature | sensor |
| 255264 | Switch, low water temperature | sensor |
| 271425 | Switch, anticipatory | sensor |
| 258276 | Spark Plugs | spark_plug |
| B4084.24 | Spark Plugs | spark_plug |
| T74P-6666-A | Spark Plug Wire Remover | spark_plug |
| 41092-1E | STARTER DRIVE REPLACEMENT | starter_drive_replacement |
| J1083-1N | STARTER RELAY | starter_relay |
| A2895-1B | STRAIGHT EDGE | straight_edge |
| A9401-10 | Straight Edge | straight_edge |
| A29B-1A | TAPPET BLEED DOWN WRENCH | tool |
| A5765-18 | front cover seal remover tool | tool |
| T70P-68070-A | front cover seal installer tool | tool |
| T70P-68070-B | front cover seal removing tool | tool |
| A3453-1E | Valve Face Angle | valve_face_angle |
| A2857-0 | Valve lifter | valve_lifter |
| A9625-1A | VALVE SPRING PRESSURE TESTER - 4 | valve_spring_pressure_tester |
| J1086-2M | VOLTMETER CARBON PILE RHEOSTAT | voltmeter_carbon_pile_rheostat |
| WASHER-34805-S | Water washer | water_washer |
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 6.6 liters.
The Ford CSG-649 has a displacement of 4.951 liters with 6 cylinders.
The Ford CSG-649 powers 2 generator set(s), including Kohler 30 RZ, Kohler 30RFZ.