The Intellisys is a generator-set controller. It is used on generator sets from Doosan, including the G44.
| Symptom | Cause | Remedy |
|---|---|---|
| Abnormal Engine Noise | Worn main or connecting rod bearing clearance | |
| Air intake restriction | Determine cause of intake restriction; repair as required. See your John Deere engine distributor or servicing dealer. | |
| Air leak on suction side of air intake system | Check hose and pipe connections for tightness; repair as required. | |
| Bearing wear | Inspect turbocharger; repair/replace as required. See your John Deere engine distributor or servicing dealer. | |
| Below normal engine temperature | Defective thermostat | Remove and check thermostat |
| Black or Grey Exhaust Smoke | See ENGINE TROUBLESHOOTING earlier in this section. | |
| Clogged fuel filter | Replace fuel filter element | |
| Clogged or dirty air cleaner | Service air cleaner. | |
| Compression too low | Determine cause of low compression and repair as needed. | |
| Coolant Temperature Below Normal | Defective thermostat(s) | Test thermostats; replace thermostats as required. |
| Coolant entering combustion chamber (failed cylinder head gasket or cracked cylinder head) | Repair or replace as required. See your John Deere engine distributor or servicing dealer. | |
| Coolant in Oil | See COOLING SYSTEM TROUBLESHOOTING later in this section. | |
| Defective aneroid control line | See your authorized servicing dealer or engine distributor | |
| Defective injection nozzles | See your authorized servicing dealer or engine distributor. | |
| Defective thermostat | Remove and check thermostat | |
| Defective turbocharger | See your authorized servicing dealer or engine distributor. | |
| Dirty or faulty injection nozzles | Have authorized servicing dealer or engine distributor check injectors | |
| Drain tube restriction | Determine cause of drain tube restriction; repair as required. See your John Deere engine distributor or servicing dealer. | |
| Engine Misfiring or Runs Irregularly | See ENGINE TROUBLESHOOTING earlier in this section. | |
| Engine Overheats | Lack of coolant in cooling system, Radiator core dirty, Engine overloaded, Too low crankcase oil level, Loose or defective fan belt | Fill cooling system to proper level., Clean radiator as required., Reduce engine load., Fill crankcase to proper oil level., Replace fan belt as required. Check belt tensioner. (See Lubrication and Maintenance Section.), Test thermostat opening temperature; replace thermostat as required., Replace cylinder head gasket. See your John Deere engine distributor or servicing dealer., Replace coolant pump. See your John Deere engine distributor or servicing dealer., Replace radiator cap as required. |
| Engine Will Not Crank | Weak battery, Corroded or loose battery connections, Defective main switch or start safety switch, Starter solenoid defective, Starter defective | Replace battery, Clean battery terminals and connections, Repair switch as required, Replace solenoid, Replace starter |
| Engine compression too low | Determine cause of low compression and repair as required. See your John Deere engine distributor or servicing dealer. | |
| Engine cranks but will not start | Incorrect starting procedure, No fuel, Exhaust restricted, Fuel filter plugged or full of water, Injection pump not getting fuel or air in fuel system, Faulty injection pump or nozzles | Verify correct starting procedure, Check fuel in tank and manual shut-off valve, Check and correct exhaust restriction, Replace fuel filter or drain water from filter, Bleed fuel system, Consult authorized diesel repair station for repair or replacement |
| Engine emits black or gray exhaust smoke | Improper type of fuel | Use proper fuel |
| Engine emits white exhaust smoke | Improper type of fuel | Use proper fuel |
| Engine idles poorly | Poor fuel quality | Drain fuel and replace with quality fuel of the proper grade |
| Engine out of time (retarded) | See your authorized servicing dealer or engine distributor | |
| Engine out of time. | See your authorized servicing dealer or engine distributor. | |
| Engine overloaded | Reduce load | |
| Engine runs irregularly or stalls frequently | Low coolant temperature | Remove and check thermostat |
| Fuel in Oil | See FUEL IN OIL TROUBLESHOOTING earlier in this section. | |
| Hard to Start or Will Not Start | See ENGINE TROUBLESHOOTING earlier in this section. | |
| High oil consumption | Crankcase oil too light | Use proper viscosity oil |
| Improper type of fuel | Use proper fuel | |
| Improper type of oil | Drain, fill crankcase with oil of proper viscosity and quality. | |
| Improper valve clearance | See your authorized servicing dealer or engine distributor | |
| Injection nozzles dirty | See your authorized servicing dealer or engine distributor. | |
| Injection pump out of time | See your authorized servicing dealer or engine distributor | |
| Intake air restriction | Service air cleaner | |
| Lack of Engine Power | See ENGINE TROUBLESHOOTING earlier in this section. | |
| Lack of power | Engine overloaded | Reduce load |
| Leaking exhaust manifold gasket | See your authorized servicing dealer or engine distributor | |
| Low engine temperature | Warm up engine to normal operating temperature. | |
| Low fast idle speed | See your authorized servicing dealer or engine distributor | |
| Low oil pressure | Low oil level | Add oil |
| Oil in Intake Manifold or Dripping from Turbocharger Housing | Excessive crankcase pressure | Determine cause of excessive crankcase pressure; repair as required. See your John Deere engine distributor or servicing dealer. |
| Oil leaks | Check for leaks in lines, gaskets, and drain plug. | |
| Oil on Turbocharger Compressor Wheel or in Compressor Housing (Oil Being Pushed or Pulled Through Center Housing) | Excessive crankcase pressure | Determine cause of excessive crankcase pressure; repair as required. See your John Deere engine distributor or servicing dealer. |
| Overheated engine | See “Engine Overheats” | |
| Poor fuel quality | Drain fuel and replace with quality fuel of the proper grade | |
| Restricted crankcase vent tube | Clean vent tube | |
| Restricted fuel hose | Clean or replace fuel hose | |
| Turbocharger Noise or Vibration | Bearings not lubricated (insufficient oil pressure) | Determine cause of lack of lubrication; repair as required. See your John Deere engine distributor or servicing dealer. |
| Turbocharger not functioning | See your authorized servicing dealer or engine distributor (Turbocharged engines only.) | |
| Turbocharger ‘Screams’ | Air leak in intake manifold. | Check intake manifold gasket and manifold; repair as required. See your John Deere engine distributor or servicing dealer. |
| Water, dirt, or air in fuel system | Drain, flush, fill, and bleed system |
Fault codes and symptom→remedy steps extracted from this controller’s service/owner documentation; verify against the official manual before servicing. Aggregated from the service documentation of generator sets built on this controller.