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 bearings | Determine bearing clearance. See your John Deere engine distributor or servicing dealer. |
| Batteries will not charge | Loose or corroded connections. | Clean and tighten connections. |
| Battery used too much water | Cracked battery case. | Check for moisture and replace as necessary. |
| Bearing wear | Oil starvation or insufficient lubrication | Determine cause of lack of lubrication; repair as required. See your John Deere engine distributor or servicing dealer. |
| Below normal engine temperature | Defective thermostat. | Remove and check thermostat. |
| Coolant Temperature Below Normal | Defective thermostat(s) | Test thermostats; replace thermostats as required. |
| Coolant in Oil | Cylinder head gasket defective | Replace cylinder head gasket. See your John Deere engine distributor or servicing dealer. |
| Engine Overheats | Engine overloaded. | Reduce load. |
| Engine Will Not Crank | Weak battery | Replace battery. |
| Engine cranks but will not start | Incorrect starting procedure. | Verify correct starting procedure. |
| 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 hard to start or will not start | Engine starting under load. | Disengage PTO. |
| Engine idles poorly | Poor fuel quality | Drain fuel and replace with quality fuel of the proper grade. |
| Engine knocks | Low engine oil level. | Add oil to engine crankcase. |
| Engine runs irregularly or stalls frequently | Low coolant temperature. | Remove and check thermostat. |
| Entire electrical system does not function | Faulty battery connection. | Clean and tighten connections. |
| Excessive Oil Consumption | Too low viscosity crankcase oil | Drain crankcase and refill with correct viscosity oil. |
| Fuel in Oil | Cracked cylinder head | Locate crack, repair/replace components as required. See your John Deere engine distributor or servicing dealer. |
| High Oil Pressure | Improper oil classification | Drain crankcase and refill with correct oil. |
| High fuel consumption | Improper type of fuel. | Use proper type of fuel. |
| High oil consumption | Crankcase oil too light. | Use proper viscosity oil. |
| Lack of power | Engine overloaded. | Reduce load. |
| Low Oil Pressure | Low crankcase oil level | Fill crankcase to proper oil level. |
| 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 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. |
| Starter cranks slowly | Low battery output. | See your authorized servicing dealer or engine distributor. |
| Starter will not crank | PTO engaged. | Disengage PTO. |
| 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 “Screams” | Air leak in intake manifold. | Check intake manifold gasket and manifold; repair as required. See your John Deere engine distributor or servicing dealer. |
| Undercharged system | Excessive electrical load from added accessories. | Remove accessories or install higher output alternator. |
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.