Ford CSG-649 troubleshooting: 39 fault codes and symptom-cause-remedy entries from the manufacturer's own service documentation.
Ford CSG-649 — full specs, parts & maintenance.
| 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 model’s service/owner documentation; verify against the official manual before servicing.
Documented causes: Possible fault with control or starting system.. See the table for the matching fixes.
Documented causes: Possible fuel system problem.. See the table for the matching fixes.
Documented causes: Indicates engine has begun to overheat and engine temperature has risen to approximately 220°F (104°C).. See the table for the matching fixes.