Marine Break-In Service

A proper break-in procedure is critical with John Deere marine diesel engines. A proper break-in will ensure optimal engine life. A proper break-in for John Deere marine engines is expected to take approximately 100 hours if performed correctly.

During this process, it is recommended that the vessel is operated in open water sufficient for safe extended operation.

Initial Run-In Procedure

1. NOTE: The sea trial procedure should not be replaced by the initial run-in procedure.

   Ideally, the initial run-in procedure is accomplished during the sea trial process with a qualified John Deere marine engine technician onboard, following a successful completion of all basic functional testing.

   Engine speeds and loads should be increased at 100 rpm intervals while simultaneously monitoring engine vitals. Engine operation should be maintained at each 100 rpm interval for a minimum of 5—10 minutes or until engine temperature stabilizes.

2. Speed and load should be increased until rated speed is achieved. If rated speed cannot be achieved abort process and review installation and application guidelines. As with the previous speed and load intervals, rated speed should be maintained for a minimum of 5—10 minutes or until engine temperature stabilizes. If a diagnostic trouble code occurs, abort this process and review installation and application guidelines.

3. Following stabilization at rated speed, proceed to test 100% throttle operation. At 100% throttle the engine should increase above rated speed to operate on the governor. As with the previous speed and load intervals, 100% throttle speed should be maintained for a minimum of 5—10 minutes or until engine temperature stabilizes. If a diagnostic trouble code occurs, abort this process and review installation and application guidelines.

   NOTE: The engine speed achieved above rated speed at 100% throttle is dependent on propeller or impeller matching and will vary accordingly.

Exceptions

Bollard pull applications such as working tugs and push boats. Due to the high power to weight ratio and hull designs, it may not be practical to achieve rated speed without bollard operation. For bollard pull applications, perform speed steps and loads as defined previously in a bollard operation with an immovable object. In bollard pull applications only, it is acceptable if 100% throttle results in an engine speed of no more than 100 rpm less than rated speed (rated speed - 100 rpm = GOOD; rated speed - 101 rpm = REVIEW). If under full bollard pull operation with an immovable object and a minimum engine speed of 100 rpm less than rated speed is not achieved, abort process and review installation and application guidelines.

Constant speed engine operation such as generators. A similar process should be followed, except instead of changing speed, the engine load should be increased until the point of maximum engine fueling (100% load or maximum generator output). These 10% steps in engine percent load should be performed for a minimum of 5—10 minutes each or until engine temperature stabilizes while monitoring all engine criticals. If a fault code should occur, abort process and review application and installation guidelines.

Break-In Oil

The engine is factory filled with John Deere Diesel Engine Break-In Oil. This is a special formulation of oil that is designated to aid with the proper break-in of engine components. If performed correctly, it is expected the break-in process will take 100 hours. During this process some make-up oil may be required. As it is not unusual for some oil consumption during the break-in process; it is critical that the oil level be frequently monitored during this process. If make up oil is required use only John Deere Diesel Engine Break-In Oil.

Following the 100 hour break-in process it is recommended that change of oil and filter should occur. If the break-in procedure has been followed and sufficient extended loading of the engine has occurred it is acceptable to proceed with normal oil changes as advised in this operator’s manual. However, if during the first 100 hours of operation the engine has operated at periods of light loading and/or idle it is recommended that the oil should be drained and replaced with John Deere Diesel Engine Break-In Oil, and the oil filter should be changed and replaced with a new John Deere oil filter. Following this, the break-in procedure should continue for an additional 100 hours.

IMPORTANT: DO NOT fill above the top of the crosshatch pattern or the FULL mark, whichever is present. Marine engines installed at an angle will have an alternate pattern as identified by the dipstick remarking process to compensate for installation angle. Oil levels anywhere within crosshatch are considered in the acceptable operating range. John Deere Break-In engine oil should be used to make up any oil consumed during the break-in period.

IMPORTANT: DO NOT use Plus-50 or Plus-50 II engine oil during the break-in period of a new engine or engine that has had a major overhaul. Plus-50 or Plus-50 II engine oil will not allow a new or overhauled engine to properly seat in during this break-in period.

IMPORTANT: If John Deere Break-In or Break-In Plus engine oils are not available, use a SAE 10W-30 viscosity grade diesel engine oil meeting one of the following:

API Service Classification CE

API Service Classification CD

API Service Classification CC

ACEA Oil Sequence E2

ACEA Oil Sequence E1

IMPORTANT: Do not use Plus-50 II, Plus-50, or engine oils meeting any of the following for the initial break-in of a new or rebuilt engine:

API CJ-4	ACEA E9
API CI-4 PLUS	ACEA E7
API CI-4	ACEA E6
API CH-4	ACEA E5
API CG-4	ACEA E4
API CF-4	ACEA E3
API CF-2
API CF

These oils do not allow the engine to break-in properly.

Break-In Procedure

During the 100 hour break-in period it is important to adequately work the engine to properly seat the engine components. Extended idle and light load operation should be minimized. Extended idle and/or light load operation intervals should not exceed 30 minutes during the break-in process. Minimum operating engine loads should be sufficient to result in coolant temperatures at or above the thermostat opening temperature.

IMPORTANT: It is critically important to properly break in the engine within the first 100 hours. Attempting a break-in at higher hour intervals may be unsuccessful. To correctly perform the break-in, extra effort is required to ensure that engine is heavily exercised and may include running the engine harder than normal usage. This is especially true with M1-M3 ratings and lightly loaded applications such as trawlers and oversized generator sets.

M1, M2, and M3 Propulsion Applications — Engine load factors¹ during the break-in period should be greater than 40%. Underway, it is recommended that the vessel is operated at a minimum engine speed of approximately 200—300 rpm below rated speed greater than 50% of the time to provide the minimum sufficient loading.

M4 and M5 Propulsion Applications — Engine load factors¹ during the break-in period should be greater than 25%. Underway, it is recommended that the vessel is operated at a minimum engine speed of approximately 400—500 rpm below rated speed greater than 50% of the time to provide the minimum sufficient loading.

Constant Speed Applications — Minimum engine load factors¹ during the break-in period should be greater than 30%. It is recommended that the engine operate between 50% and 90% load greater than 50% of the time during the break-in period.

IMPORTANT: Lightly Loaded Applications Post Break-In: Engine break-in will not compensate for the observable conditions of a lightly loaded engine such as black fuel oil residue in the exhaust system. These conditions can be common among trawler propulsion engines, oversized generator sets, applications that spend long intervals at idle, and will occur on any lightly loaded diesel engine. John Deere marine diesel engines are designed to operate at loaded conditions. To prevent exhaust system contamination in a lightly loaded application, regularly exercise the engine by periodically increasing the load.

For example, in a trawler propulsion application underway increase the throttle to achieve an engine speed of the break-in speeds defined above for a minimum of 10 minutes every 3 hours. For a generator application, increase the load to 50% load for a minimum of 10 minutes every 3 hours.