Specifications
| Standby power | 35 kW |
|---|---|
| Standby kVA | 44 |
Filters & service parts
model family| Item | Spec | Capacity | Part # | Interval | |
|---|---|---|---|---|---|
| Air filter | — | 100 hr | find | ||
| Fuel filter | — | 960 hr | find | ||
| Oil filter | — | 600 hr | find | ||
| Belt | T63L-8620-A | eBay $72.99 PartsGeek | |||
| Coolant | 28.8 | — | 1000 hr | ||
| Coolant filter | — | find | |||
| Oil | — | 600 hr |
Compiled from this model's family documentation — may include parts for closely-related variants. Confirm the exact part for your serial number.
Common questions
What is the power rating of the Ford csg-649?
The Ford csg-649 is rated 35 kW standby (44.0 kVA).
Troubleshooting
80Fault codes
| Code | Meaning | Cause | 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. | |
| All hydraulic functions inoperable | All hydraulic functions inoperable | Check error code at ground control. Hydraulic enable valve. Pump stroker valve. Low fluid in reservoir. Hydraulic pump defective. | Faulty Deadman button or foot switch. Wafer in hydraulic fluid. Improper oil viscosity. Hydraulic fittings loose or ports open. |
Symptoms & remedies
| Symptom | Cause | Remedy |
|---|---|---|
| Excessive heat | . Excessive water in the hydraulic fluid. . Improper oil viscosity. . Improper lubrication and hydraulic fluid. | . Drain and flush hydraulic system. See Section 2, System Flushing Procedure. . Replace hydraulic fluid with the correct fluid. See Section 2, Fluid Recommendations. . Drain and flush hydraulic system. See Section 2, System Flushing Procedure. . Rebuild pump as required. See Illustrated Parts Catalog or Component Repair Manual. |
| Water in hydraulic fluid | . Damp climate. . Hydraulic fitting or port open to contaminants. . Reservoir pressurization inoperative. | . Drain and flush hydraulic system. See Section 2, System Flushing Procedure. . Drain and flush hydraulic system. See Section 2, System Flushing Procedure. Replace worn pump components. See Illustrated Parts Catalog. . Check pressure. See Specifications. |
| No steer function. | . Steer toggle switch is bad. . Steer/axle valve. . Pilotoperated check valve. . Faulty steer cylinder. | . Check voltage available to the toggle switch. See Section 3, Electrical System. . Steer/axle valve is not fully engaged. See Section 2, Steer System. . Pilot operated check valve is dirty. Remove, clean and/or replace. See Section 2, Steer System. . Possibly plugged steer ports or damaged cylinder seals. Inspect, repair or replace steer cylinder. See Section 2,Steer System. |
| No axle extend/ retract function. | . Steer toggle switch is bad. . Steer/axle valve. . Pilotoperated check valve. . Faulty cylinders. | . Check voltage available to the toggle switch. See Section 3, Electrical System. . Steer/axle valve is not fully engaged. See Section 2, Axle Extend System. . Pilot operated check valve is dirty. Remove, clean and/or replace. See Section 2, Axle Extend System. . Possibly plugged lines, cylinder ports or damaged cylinder packings. Inspect, repair or replace cylinder. See Section 2, Axle Extend system. |
| No drive function. | . Platform drive speed control relay, drive potentiometer is bad. . Loose wires on control card. . Driver board card out of adjustment or faulty card. | . Ensure platform drive speed control relay is working properly. If boom is extended, confirm potentiometer is functioning. Repair or replace both components. See Section 3, Electrical System. . Tighten wires on control card and ensure proper location. See Section 3, Electrical System. . Adjust card according fo specifications. Replace faulty card. See Section 3, Electrical System. |
| No lift function. | . Loose wires on Y-axis driver board. . Driver board out of adjustment or faulty board. . Axle limit switches are not fully engaged. . Platform boom and swing speed control relay (CRS) and boom potentiometer not functioning properly. . Liff spool valve stack. . Holding valves not operating properly. | . Tighten Y-axis wires on driver board. See Section 3, Electrical System. . Adjustdriver board to specifications or replace faulty board. See Section 3, Electrical System. . Identify which one or more of the switches is nof engaged. Repair or replace switch. See Section 3, Electrical System. . Ensure platform boom and swing speed control relay is operating properly. Adjust boom potentiometer or replace faulty parts. See Section 3, Electrical Sys-fem. . Manually engage lift spool and check for operation. See Section 2, Boom Lift system. . Remove, clean, inspect, replace and test unit operation. See Section 2, Boom Lift System. |
| No extend or retract function/ boom only extends 3 meters. | . Loose wires on control card. . Driver board out of adjustment or a faulty card. . Faulty micro switch in control handle. . Axle switches not fully engaged. . Spool valve stuck, . Pressure reducing valve. | . Tighten wires and ensure proper location. See Section 3, Electrical System. . Adjustorreplace cards. See Section 3, Electrical Sys-fem. . Test and replace if faulty. See Section 3, Electrical system. . Identify which one or more of the switches is not engaged. Repair or replace switch. See Section 3, Electrical System. . Manually engage spool and check for proper operation. Replace if faulty. See Section 2, Telescope system. . Possibly leaking to tank. Inspect, clean and retest. Replace if faulty. See Section 2, Telescope System. |
| Pitting and etching of pump pistons | Cavitation, a gaseous condition within the fluid stream where the pressure is reduced to the vapor pressure of the fluid. The higher the system pressure the more violent the reaction will be. | . Low reservoir fluid level. . Air leaks in suction line. ._ Improper hydraulic fluid. . Vaporization of water. . Hydraulic fluid system has not been warmed before using full system pressure. . Pump speed too high. . Add hydraulic fluid. See Section 2, Fluid Recommendation. . Repair any suction hose leaks. . Have fluid analyzed regularly and drain and flush hydraulic system, then fill with recommended hydraulic fluid. |
| Heads of pump pistons worn to shape of cam and excessive heat build up | Poor lubrication, parts break through lubricant causing metal fo metal contact. | . Hydraulic fluid viscosity low. . Improper or poor grade hydraulic fluid or lubricant without proper anti wear additives. . Drain and flush hydraulic system, then fill with recommended hydraulic fluid. See Section 2, Fluid Recommendation and System Flushing Procedure. |
| Engine won't crank | Starter motor relay, starter motor interlock relay , low oil pressure/ high water temperature/ time delay relay, Power relay, ground/platform switch, ground toggle, platform ignition and start is bad or an engine failure. | A breakdown in any one of these components will cause the engine not to crank. Trace the available voltage for starter motor relay. Replace the component(s) that are bad. See Section 3, Electrical and Electrical Schematic. |
| Throttle actuator doesn't work | Throttle high speed relay or solenoid is bad. | A breakdown in any one of these components will cause the actuator not to function. Trace the available voltage to the throttle relay. Replace the component(s) that are bad. See Section 3, Electrical and Electrical Schematic. |
| Movement alarm will not sound | Movement alarm relay, power relay, horn or switch card on drive handle is bad. | A breakdown in any one of these components will cause the alarm not to function. Trace the available voltage to the horn. Replace the component(s) that are bad. See Section 3, Electrical and Electrical Schematic. |
| Axle cylinder drifts when trying to extend axles | Pilot operated check valve. | Remove, clean, repair or replace the pilot operated check valve. See Section 2, selector Valve Assembly. |
| Lift cylinder drifts down | . Holdingvalve cartridge dirty or faulty. . Cylinder seals are damaged. | . Clean, repair or replace the holding valve. See Section 4, Boom Lift Cylinder. . Replace cylinder seals. See Section 4, Boom Lift Cylinder. |
| Engine Runs Briefly and Shuts Down | Loss of Spark Frozen Fuel Regulator (Dry Fuel) Low Fuel Pressure Air Inlet Restriction Wiring Failure GCP Failure | |
| Engine Cranks But No Start | Faulty OEM Drivers Safety Shut-Off Seat Switch Coil Power Loss GCP Ground Loss GCP Power Loss Severe Vacuum Leak (Dry Fuel) Air Inlet Restriction Air Inlet Leak (Dry Fuel) Fuel Lock-Off Inoperative (Dry Fuel) Wiring Failure Low Fuel Pressure Ancillary Components Binding | |
| Engine Runs Poorly | High Fuel Pressure Low Fuel Pressure Contaminated Fuel Incorrect Fuel Select Table Selected Incorrect GCP Program Installed Actuator Air Blockage Map Sensor Leak Intake air leak Fuel Contaminated Noise Suppression Capacitor Failure Improper PCV Routing Valve Timing Low Cylinder Compression | |
| Engine Cranks Slowly | Excessive Engine Load (Hydraulic Pump Failing, Binding Ancillary Drive Components) Low Battery Voltage Incorrect Battery Specifications Incorrect Battery Cable Size Starter Relay Starter Failure (Excessive Drain) | |
| Engine Stalls/Quits | Faulty OEM Drivers Safety Shut-off Seat Switch Low Battery Voltage Low Fuel Pressure OEM Safety Shutdowns Bad MAP Sensor Air Restriction Coil Failure Fuel Mixer Binding (Dry Fuel) | |
| Runs Rough | Ground Loss Misrouted Spark Plug Wires Fuel System Failure Vacuum Leak Wiring Failure Low Fuel Pressure Spark Plugs Fouled Incorrect Valve Timing | |
| Misses | Fuel System Failure Misrouted Spark Plug Wires Spark Plug Gap Too High Spark Plugs Fouled Cracked Spark Plug Insulator Incorrect Valve Timing Compression Loss | |
| Hesitation/Stumble | Low Fuel Pressure Spark Plugs Fouled MAP Sensor Vacuum Signal Loss | |
| Surge | Low Fuel Pressure Map Sensor Failure Application or Ancillary System Momentarily Binding During Load or Unload | |
| Backfires | Faulty OEM Drivers Safety Shut-off Seat Switch Fouled Spark Plugs Spark Plug Wire Broke GCP Momentary Ground Loss Excess Lean Condition Fuel Lock-Off Leaking (Dry Fuel) Intake Manifold Leak Bad Intake Valve | |
| Lack of Power | Ancillary Components Binding Intake Air Restriction Crossed Spark Plug Wires Spark Plugs Fouled Fuel System Failure Low Fuel Pressure Low Cylinder Compression | |
| Spark Knock | Poor Quality or Contaminated Fuel Carbon Build-up Wrong Spark Plugs (Too High Heat Range) Fuel Delivery System PCV System Fuel Selection Timing Cylinder Hot Spots | |
| Oil System Concerns | Positive Crankcase Ventilation (PCV) System - High Oil Consumption Oil Viscosity External Leaks Improper Oil Dipstick Valve Seals Cylinder Wall Taper Excessive Worn Piston Rings | |
| Cooling System Concerns | Trapped Air Worn Drive Belt Worn Water Pump Stuck Thermostat Plugged Radiator (Internal & External) Dry Fuel System Running Rich | |
| Exhaust System Concerns - Black Smoke | Ignition System Fuel Delivery System Sticking Fuel Injector High Fuel Pressure PCV System Worn Piston Rings Worn Valve Guides | |
| Exhaust System Concerns - Blue Smoke | Ignition System Fuel Delivery System Sticking Fuel Injector High Fuel Pressure PCV System Worn Piston Rings Worn Valve Guides | |
| Fuel System Concerns | Leaky Lines Contaminated Fuel Excessive Alcohol in Fuel Incorrect Octane Rating | |
| Engine Noise | Low Oil Pressure Oil Filter Restriction | |
| 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. | |
| Hydraulic functions slow. | Low hydraulic pump pressure. | Check and adjust for correct pressure if necessary. |
| Function chatter. | Hydraulic fluid low. | Repair or replace pump. Check for pump suction air leak. |
| Hydraulic pump noise or squeal. | Low pressure. | Aeration of fluid in reservoir. |
| Engine won't crank. | Starter motor relay. Starter motor interlock relay. Oil pressure switch stuck in open position. Power relay. Ground/platform switch. Ground/platform ignition switch. Engine failure. Footswitch blocked or failure. | Trace the available voltage to starter motor relay. Replace the faulty component(s). Unblock footswitch or correct electrical problem. |
| Drive function only does not operate. | Check error code at ground control. Toggle switch (for ground) or joystick (for platform) electrical malfunction. Faulty drive valve coil or electrical connection. Drive valve spool is stuck. Drive brakes not releasing. Wheel drive motor component failure. | Correct electrical problem. Check switch (joystick) and wire continuity. Check electrical connection and coil for operation. Manually engage and check for proper operation. Replace if faulty. Test brake hydraulic pressure. Replace the motors. |
| Sweep function only does not operate. | Check error code at ground control. Steering directional control valve. Faulty steer coils or electrical connections. Faulty steer switch. Faulty cylinder packing. | Correct electrical problem. Check for disconnected, binding or damaged steering linkage; connect or replace steering linkage as necessary. The valve spools may be stuck. Remove valve and inspect, clean, repair or replace as needed. Check steer coils and electrical connections. Check steer switch. Replace packing. |
| Swing function only inoperative either direction. | Check error code at ground control. Spool valve stuck. Faulty valve coil or electrical connection. Mechanical malfunction. Counterbalance failure. | Manually engage swing spool and check for proper operation. Replace if faulty. Check coil or electrical connection for operation. Check for an obstruction between the pinion gear and swing bearing; remove the obstruction. Swing gearbox worm gear is broken; replace it. Swing motor shaft is broken or seized; replace the swing motor. |
| Extend or retract function from platform - none. | Check error code at ground control. Spool valve stuck. Mechanical failure. Pressure reducing valve possibly leaking to tank. Defective counterbalance valve. Faulty valve coil or electrical connections. | Correct electrical problem. |
| Boom track sagging. | Track pin holes stretched usually caused by a damaged beam support. | Check beam support and replace if necessary. Replace overhead guard and any other items damaged due to a damaged guard. Follow proper lubrication and cleaning procedures. |
| Boom track cross braces breaking. | Hoses wearing in the boom track. | Check hydraulic pressure and adjust if necessary. |
| Boom drifts down without footswitch actuated. | Mechanical failure. | Check that platform boom control lever returns to neutral position. Check counterbalance valve, and replace if necessary. Check for leaking lift cylinder, and repack as required. |
| Lift function only does not operate. | Mechanical failure. | Check error code at ground control. Manually engage lift hoist spool and check for operation. Check counterbalance valve for foreign material or internal damage; replace if damaged. Inspect, repair or replace cylinder. Check coil and electrical connections for operation. |
| Jib function - none. | Check error code at ground control. | Jib spool valve stuck. Holding valves not operating properly. Faulty cylinder. Faulty valve coil or electrical connections. Correct electrical problem. Manually engage jib spool and check for operation. Remove, clean, inspect, replace and test unit operation. Possibly plugged lines, cylinder ports or damaged cylinder packings. Inspect, repair or replace cylinder. Check coil and electrical connections for operation. |
| Platform does not level properly (platform drifting). | Damaged parts. | Defective counterbalance valve. Defective double pilot operated check valve. Defective master cylinder relief valve. Check for damaged parts such as bent pins or elongated pin holes; replace damaged parts. May need to replace slave cylinder. Check counterbalance valve for foreign material or internal damage; replace if damaged. Repair or replace as necessary. |
| Platform rotate function only does not operate. | Check error code at ground control. | Double pilot operated check valve (relief valve). Mechanical malfunction. Plugged valve orifice. Hydraulic line blockage. Faulty valve coil or electrical connections. Platform level toggle switch. Correct electrical problem. Install valve correctly. Check the valve cartridge and replace if necessary. If platform rotates only in one direction, check for physical constraints or foreign material restricting platform rotation; remove foreign material. Clean orifice. Check for blocked or partially blocked return hoses. Check coil and electrical connections for operation. Check electrical connections for operation or replace toggle switch. |
| Movement alarm will not sound. | Broken wire or connection in the alarm circuit. | Alarm is faulty. Trace electrical circuit to alarm. Replace the faulty component. |
| Tilt alarm sounds continuously. | Faulty fuse or broken connection after tilt sensor. | Replace fuse or correct electrical connection. |
| Tilt alarm does not sound when machine tilted. | Alarm is faulty. Tilt sensor or electrical connection faulty. | Replace alarm. Replace tilt sensor or correct electrical connection for sensor. |
| 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. |
Fault codes and symptom→remedy steps extracted from this model’s service/owner documentation; verify against the official manual before servicing.
Parts
8| Part # | Description | Qty | System | |
|---|---|---|---|---|
| 22500 | 80 | Service part / kit | PartsGeek | |
| 2602-3 | 649-34 See Pin and | 5217 | Service part / kit | PartsGeek |
| 3-01 | 2=01 | Service part / kit | PartsGeek ddtp $39.10 | |
| 4-01 | Service part / kit | PartsGeek FridayParts $1888.28 | ||
| 5-01 | Service part / kit | PartsGeek | ||
| 7-01 | Service part / kit | PartsGeek ironwing $129.22 | ||
| 9-01 | 8mOl | Service part / kit | PartsGeek ddtp $49.90 | |
| PMMR93 | SER 101. | 1 | Service part / kit | PartsGeek |
Service, wear & replacement parts referenced for this model and its engine — confirm the exact part for your serial number. See the full parts catalog to search and cross-reference.
Available documents
Engine spec — Refuse-Engine-Ops G3 99905334 (Ford)Spec sheet — 89-103317 (Ford)Spec sheet — 89-186307 (Ford)Spec sheet — 928-0120 Onan EK EM Operators-Manual (12-1995) (Ford)Spec sheet — 928-0131 Onan GGFB GGFC Operator's Manual (11-2006) (Ford)Parts manual — 194-203 CSG649 (Ford)Parts manual — csg-649-parts-manual (Ford)Service manual — 194-210 CSG649 Service Manual (Ford)Service manual — 194-210 Ford CSG649 300CID Industrial Engine Service manual Apr1982 (archive.org)Service manual — FORD O&M 1-6 Gas Engines CSG649 1981 (Ford Motor)Service manual — FORD O&M I-6 Gas Engines CSG649 1993 (Power Products Division, Geometric Results Incorporated)Service manual — Ford CSG649 (6cyld) Service Manual (Ford Motor)