CHRIS-MARINE

WEAR EDGE MILLING MACHINE

TYPE VKS and VKS-A

INSTRUCTION MANUAL
Doc.No.: I-121-E
Rev. e
2016-11-18

Preface
The equipment described within this manual is designed and manufactured by CHRIS-
MARINE AB, Malmö, Sweden.

The company’s principal activities are in the development and production of grinding
machines and tools for use in maintenance of diesel engines in the marine, off-shore,
power generation and allied industries.

Today’s machines are the product of experience and R&D since 1962. All Chris-Marine
machines have proven performance and are continuously updated to meet the latest
standards and demands of diesel technology.

Chris-Marine reserve the right to make improvements to the equipment and it’s technical
documentation. Drawings and diagrams contained within this manual are intended for
illustrative purposes only and are not to scale.

Chris-Marine's liability for damages will only be considered, and are strictly limited to use
of the equipment and grinding wheels when operated in accordance and compliance with
the appropriate Chris-Marine instruction manual.

This manual contains copyright information of a technical nature which is the sole
property of Chris-Marine. Neither this complete manual, nor any part, or parts, or
sections of the contents, shall be copied, reproduced, scanned or duplicated in any
manner without the written consent of Chris-Marine AB.

Address: P.O. Box 9025

S-200 39 Malmoe, Sweden
2 Telephone: +46-40
671 2600. Fax: +46-40 671 2699 ©Copyright Chris-Marine AB
Contents

CONTENTS 3

1. GENERAL INFORMATION 5
1.1 EU Declaration of Conformity 5
1.2 Location of Nameplate 6
1.3 Safety Information 7
1.3.1 Manual topics 7
1.3.2 Safety Measures 8
1.3.3 Safety Instruction Labels 9

2. DESCRIPTION 10
2.1 Application 10
2.2 Features 10
2.3 Technical Information 11
2.3.1 Grinding Accuracy 11

3. MAIN PARTS AND CONTROLS 12

3.1 Main parts 12
3.2 Emergency stop 13

4. INSTALLATION 13
4.1 Delivery 13
4.2 Location of the Equipment 13
4.3 Basic Assembly 13
4.3.1 Machines smaller than Ø400 mm. 13
4.3.2 Machines larger than Ø400 mm. 14
4.3.3 Workshop machine VKS-A 15

5. MILLINGPREPARATIONS 16
5.1 Operator Care 16
5.2 Fitting or Replacing of Milling Cutter 16
5.3 Mounting of Milling Machine 16
5.4 Setting of Milling Cutter height position 17
5.4.1 Machine with wear edge positioning device 17

Address: P.O. Box 9025

S-200 39 Malmoe, Sweden
3 Telephone: +46-40 671 2600. Fax: +46-40 671 2699 ©Copyright Chris-Marine AB
 5.4.2 Machining without wear edge position device 18

6. MILLING OF THE GROOVE 19

7. MAINTENANCE 20

8. REMINDERS 21
8.2 For Best Results 21
8.2 Trouble Shooting 21
8.3 After Use 21

Address: P.O. Box 9025

S-200 39 Malmoe, Sweden
4 Telephone: +46-40 671 2600. Fax: +46-40 671 2699 ©Copyright Chris-Marine AB
 General Information

1. GENERAL INFORMATION
1.1 EU Declaration of Conformity
Dokument/ ID: dc-vks
CHRIS-MARINE AB
Datum/ Date: 2015-04-22 Rev: 0

Sida/ Page: 1 av/of: 1

Declaration of Conformity

In accordance with Machinery Directive 2006/42/EC, Annex IIA

The Manufacturer:

Chris-Marine AB
Box 9025 Phone: +46 40 671 2600
S-200 39 MALMÖ Fax: +46 40 671 2699
Sweden

declare that the following machinery:

Wear Edge Milling Machine type VKS air driven,

- is manufactured in conformity with the THE EUROPEAN PARLIAMENT AND THE COUNCIL OF THE EUROPEAN UNION
of December 29 2009 on the approximation of the laws of the Member States relating to the Machinery Directive
2006/42/EC, with particular reference to Annex I concerning the essential health and safety requirements to the
design of the machine.
- is besides the provision under a/ manufactured according to following directives and harmonized standards:

SS-EN ISO 12100

Date:2015-04-22
Place: MALMÖ, Sweden
CHRIS-MARINE AB
Signed on behalf of: BOX 9025
S-200 39 MALMÖ
Sweden
Phone: +46 40 671 2600
empowered signature and Name in block letters Fax: +46 40 671 2699
ANDERS NILSSON email: info@chris-marine.com
www.chris-marine.com

Address: P.O. Box 9025

S-200 39 Malmoe, Sweden
©Copyright Chris-Marine AB Telephone: +46-40 671 2600. Fax: +46-40 671 2699 5
General Information

1.2 Location of Nameplate

This instruction applies to machinery with details as shown in the nameplate illustrated
below.

When communicating with Chris-Marine or their representatives, always state machine

type and serial No. of the machinery.

Location of nameplate for the VKS type milling machine

Address: P.O. Box 9025

S-200 39 Malmoe, Sweden
6 Telephone: +46-40 671 2600. Fax: +46-40 671 2699 ©Copyright Chris-Marine AB
 General Information

1.3 Safety Information

1.3.1 Manual topics
This manual must be carefully studied before using the equipment. It will help you to
use the equipment to its full capacity and avoid costly mistakes. All safety instructions
must be complied with. Failure to do so may result in personal injury or damage to
equipment and the environment.

The Instruction Manual is intended primarily for the operator of the milling machine and
describes the using of it.

The manual is divided into four sections, 1) Introduction with general information (this
section), 2) a descriptive section, 3) an instructive section and 4) list of parts.

 Introduction:

These pages consisting of General Information introduce Chris-Marine equipment,

with its nameplate and safety information. It emphasises precautionary measures and
describes the safe working practices as described in the instructive section of the
manual.

 Descriptive information:

The descriptive information consists of the section Description. It provides an overall

description of the equipment, its technical data and performance, as well as its
principal technical functions.

 Instructive information:

The section Main Parts and Controls, Installation, Milling Preparations, and Milling of
the Groove provide instructions and information on handling and use of the
equipment. The sections Maintenance and Reminders provides information on the
efficient use, and servicing of the equipment ensuring it’s long and trouble free
operation

 List of parts:

This section consists of a reference sheet and a list of parts. The reference sheet
includes the serial number of the machine and should always be used when ordering
parts. Addresses of Chris-Marine representatives can be found at the end of list of
parts.

Address: P.O. Box 9025

S-200 39 Malmoe, Sweden
©Copyright Chris-Marine AB Telephone: +46-40 671 2600. Fax: +46-40 671 2699 7
General Information

1.3.2 Safety Measures

Transportation and Installation

 Ensure that the equipment is transported safely, and never lift loads above
people.

 Ensure that the emergency stop is mounted correctly according to the

instruction manual.

Use of the machine

 Always use safety goggles, breathing filter and hearing protection when
the milling machine is in operation.

 Use proper protection against hot milling particles while milling Keep
inflammable materials at a safe distance at all times.

 Protect naked skin against sharp milling particles.

 Keep the emergency stop within reach of the operator while using the
machine.

Other warnings
 Always turn off the air supply when the operation is completed, or if the
air supply is interrupted during milling.

 Beware of remaining air pressure in the stationary machine during

maintenance.

 Do not use air pressures exceeding 9 bar (130 psi).

 Keep hands and objects away from the machine whenever the machine is
in motion.

 Ensure the lighting is sufficient.

 Check regularly that all hoses are intact.

IN CASE OF ANY DOUBT, CONTACT YOUR

CHRIS-MARINE REPRESENTATIVE

Address: P.O. Box 9025

S-200 39 Malmoe, Sweden
8 Telephone: +46-40 671 2600. Fax: +46-40 671 2699 ©Copyright Chris-Marine AB
 General Information

1.3.3 Safety Instruction Labels

The safety instruction labels below contain important information concerning risks
associated with particular aspects of operating the machine. Chris-Marine strongly
recommends the operator familiarize themselves with the signs.

 Three different levels of safety instructions, as shown below, may be used in the Chris-
Marine Instruction Manuals:

Danger!
Risk of serious or fatal injury to personnel

Safety instructions in this group indicate when there is a

risk of serious injury or injury that could cause death as a
consequence of misuse.

Warning!
Risk of injury to personnel and/or damage of
property
Safety instructions in this group indicate when there is a
risk of injury or damage to property or the environment.

Caution!
Use the equipment correctly

! Safety instructions in the group indicate that there is a risk

of injury or damage if instructions are not followed.

FAILURE TO OBEY THE SAFETY INSTRUCTIONS IN THIS MANUAL CAN CAUSE ACCIDENTS,
WHICH MAY RESULT IN SEVERE INJURY TO PERSONNEL OR DAMAGE TO PROPERTY OR TO
THE ENVIRONMENT.

Address: P.O. Box 9025

S-200 39 Malmoe, Sweden
©Copyright Chris-Marine AB Telephone: +46-40 671 2600. Fax: +46-40 671 2699 9
Description

2. DESCRIPTION
2.1 Application
The Chris-Marine VKS-type milling machine is for use in
removing top piston ring wear edges in diesel engine
cylinder liners. The wear edge must be removed before
pistons are pulled.

Standard delivery is set for a specific diameter, but with

extra accessories it can be used for cylinder liners of ø 280
– 1000 mm, down to 250 mm diameter depending on
engine type.

The workshop version VKS-A covers all 2-stroke engines

from 320 to 980 mm bore. It consists of one main unit and
a range of adjustable arms which are easy to change in
situ.

The milling machine is easily mounted in the cylinder liner

and guided on the liner wall and the top-landing surface
for the cylinder cover.

The milling motor is air driven. The rotation of the

machine in the cylinder liner is hand operated.

2.2 Features
The milling machine is easy to operate and is of a robust
construction and designed as a professional tool for
removal of wear edges in cylinder liners both onboard and
ashore. An air filter and oil mist lubricator are fitted for
reliable operation. A high precision milling motor and
automatic centring assures a high quality milling result.

The Chris-Marine VKS features:

 Precision air driven milling motor.

 Fine feed adjustment for milling. Wear Edge Milling Machine type VKS

 Self-centring system in cylinder liner.

 Easy and accurate detection of wear edge position.

 Sintered carbide milling tool.

 Simple and fast set up and operation.

When not in use, the milling machine and accessories,

including the air filter and lubricator are stored in the
storage box (protective carrying case).

Due to its sturdy design and incorporated features, a high

quality milling result is achieved quickly under the most
demanding operating conditions.

Storage box

Address: P.O. Box 9025

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 Description

2.3 Technical Information

2.3.1 Grinding Accuracy
Machine capacity 320 – 980 mm
cylinder diameter.
(down to 250 mm
depending on engine type)
Working air pressure 0.6 – 0.9 Mpa
(6–9 bar)
Air consumption 500 l/min
Air hose connection 10 mm (3/8")
Milling motor speed 20 000 rpm
Rotating speed manual
Milling cutter size ø 16 mm
Main dimensions depending on size/engine type

Weight 16-20 kg

Address: P.O. Box 9025

S-200 39 Malmoe, Sweden
©Copyright Chris-Marine AB Telephone: +46-40 671 2600. Fax: +46-40 671 2699 11
Main Parts

3. MAIN PARTS AND CONTROLS

3.1 Main parts

1 Main air supply valve 7 Positioning device

2 Emergency stop 8 Rotational pressure adjuster
3 Feeding wheel 9 Oil mist adjuster
4 Groove position adjuster 10 Water drainage valve
5 Locking lever for height position 11 Milling cutter
6 Milling motor

Address: P.O. Box 9025

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 Installation

3.2 Emergency stop

When the emergency stop (36) is pressed it will stop all air
supply. Restart the machine according to instructions in
chapter 6.

4. INSTALLATION Emergency stop

4.1 Delivery
W equipment is partly dismantled and stored in a
customised steel cornered wooden box. Metal parts are
coated to prevent corrosion. Before assembling and using
the equipment, clean it carefully with a suitable solvent.

4.2 Location of the Equipment

The milling operation produces small sharp metal chips,
which can be dangerous.

 Avoid operating areas where the metal chips can

damage other machines.

 If milling is done with the cylinder liner mounted on

the engine, cover and seal off all sensitive areas.

4.3 Basic Assembly

4.3.1 Machines smaller than Ø400 mm.
Wear edge milling machines for cylinder liner diameters
less than 400 mm are stored assembled in the storage box.
Milling machine in storage box
1. Remove the air filter unit from within the storage box.
Should always be used and stored upright.

2. Cut the supplied air hose in three sections and

assemble according to illustration. The part between
the lubricator and milling motor should not exceed 2m
in length, as this will affect the lubrication of the air
motor.

3. For air supply, use a 3/8” rubber hose.

CAUTION!
Unintentional start up! Emergency stop connection
Shut off main air supply valve in order to
avoid unintentional start up when the air
hose is connected.

Address: P.O. Box 9025

S-200 39 Malmoe, Sweden
©Copyright Chris-Marine AB Telephone: +46-40 671 2600. Fax: +46-40 671 2699 13
Installation

4.3.2 Machines larger than Ø400 mm.

Wear edge milling machines for cylinder liner diameters
larger than 400 mm are stored partly dismantled in the
storage box.

1. Mount the milling head (15) with arm on the hub (16)
with the supplied screws (17)

2. Mount the square shaped arm (18) on the hub with

screws (17).

3. Mount the three round arms (19) on the hub in the

pre-machined holes. Fasten with screws (20).

4. Remove the air filter unit from within the storage box.
Should always be used and stored upright. Cut and
assemble the air hose according to instructions in
chapter 4.3.1. Milling machine in storage box

Basic assembly

Address: P.O. Box 9025

S-200 39 Malmoe, Sweden
14 Telephone: +46-40 671 2600. Fax: +46-40 671 2699 ©Copyright Chris-Marine AB
 Installation

4.3.3 Workshop machine VKS-A

Workshop version VKS-A is delivered partly dismantled in
the storage box. Arms mounted on the machine when
delivered are covering the bore range 500 – 700 mm. Also
delivered in the box are following arm kits:

 Small kit covering bore 320 – 350 mm

 Medium kit covering bore 400 – 520 mm

 Large kit covering bore 700 – 980 mm

When preparing machining for a specific bore ensure the

correct arm kit is mounted. The arms must be adjusted to
fit the specific bore.

1. Loosen the fastening screws (38) for “landing

arms” (39) and fastening screws (42) for
“steering arms” (41).

2. Measure the radius (R) from the center of the

machine and adjust the “landing arms” (39) to
get the bearings (40) to land on the liner landing
surface.

3. Measure again from the center of the machine

and adjust the “steering arms” (41) until the
bearings (43) are touching the inside of the liner.

4. Tighten screws (38) and (42).

Address: P.O. Box 9025

S-200 39 Malmoe, Sweden
©Copyright Chris-Marine AB Telephone: +46-40 671 2600. Fax: +46-40 671 2699 15
Milling Preparations

5. MILLING PREPARATIONS
5.1 Operator Care
Before and during each milling operation the following
must be observed:

 Clear pipes and hoses of accumulated water.

 Drain the filter when the air pressure is connected.

Turn knob (10) clockwise and pull it downwards.

 Check the oil level. Refill the oil reservoir (21) if

necessary. Pull the ring (37) upwards, turn the
reservoir anticlockwise and pull it down. Fill up with oil
recommended in section 7.

 Control the oil flow in the lubricator. Visual control is Air filter and lubricator
done through the sight glass (22) after the milling
motor has been started. Adjust the oil flow to 4-5
drops per minute with screw (9) on the lubricator
body.

IMPORTANT!

Always keep oil flow set at 4–5 drops per minute.

5.2 Fitting or Replacing of Milling

Cutter
1. Loosen chuck (25) using spanners from tool set.

2. Fit the milling cutter (11), or replace an already existing

cutter if necessary. Push it to the bottom of the chuck
and tighten securely.

5.3 Mounting of Milling Machine Fitting or replacing of milling cutter

1. Turn the pressure adjuster (8) clockwise and the

feeding wheel (3) anti-clockwise, until the machine can
be lowered into the liner without problems.

2. Turn the pressure adjuster (8) anti-clockwise until the

guiding wheel (26) is in contact with the liner wall. Turn
the cylinder two more turns to make sure that the built
in spring is activated.

Mounting of milling machine

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 Milling Preparations

5.4 Setting of Milling Cutter height

position
5.4.1 Machine with wear edge
positioning device
1. Make a rough height positioning by removing screws
(14) and raise or lower the complete milling head (15).

2. Mount the position device (7) on the milling head with Rough height positioning
screw (27) Ensure that the milling cutter (11) touches
the surface at position (28).

3. Loosen handle (5) and adjust the milling cutter height

position with wheel (4). One turn anti-clockwise
moves the milling cutter 1.5 mm upwards.

4. Feed the milling cutter upwards, passing the wear

edge. When the dial gauge (29) passes the wear edge,
the reading makes a sudden step. Immediately after
the dial gauge reading is stable, the correct height
position of the milling cutter is reached.
Height positioning adjustment
5. By using this method the centre of the milling cutter
will be positioned 1mm above the wear edge. If the
relation between groove position and gauge needs to
be changed, loosen screw (30) and raise or lower the
gauge with holder. If the groove position should be
higher up in the cylinder liner, lower the dial gauge.

6. Before milling, remove the positioning device by

loosening locking lever (31).

CAUTION!
Unintentional start up!
Shut off main air supply valve (1) in order
to avoid unintentional start up when the
air hose is connected. Wear edge detection

Correct height position

Milling cutter position

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Milling Preparations

5.4.2 Machining without wear edge

position device
1. Make a rough height positioning by removing screws
(14) and raise or lower the complete milling head (15).

2. Move the cutter towards the cylinder wall with the

feeding wheel (3).

3. Loosen handle (5) and adjust the milling cutter height

position. with wheel (4). Dependent of milling dept,
the centerline of the cutter should be about 0-1 mm
above the wear edge. Lock with handle (5).

CAUTION! Height positioning

Unintentional start up!
Shut off main air supply valve (1) in order
to avoid unintentional start up when the
air hose is connected.

Milling cutter height position

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 Milling of the groove

6. MILLING OF THE
GROOVE
Make sure that the emergency stop is correctly
connected and keep it within reach while using the
machine.

1. Before starting the machine make sure that the valve

(1) is closed. If needed release the emergency stop
button (36) and press the start button (35). Make sure
that lever (34) is in closed position.

2. Hold the machine firmly by either one, or both, of the

bars (33) to prevent the machine from rotating. Start
the milling motor by opening valve (1).

3. Slowly turn the feeding wheel (3) clockwise until the

milling cutter touches the wall. Prevent the machine
from rotating by itself.

4. Take a cut of approximately 0.2-0.4 mm and rotate the

machine slowly clockwise by hand. After the first cut is
completed, adjust for new cuts until the wear edge is
removed, but not more than the total wear accepted
by the engine builder.

In case of an emergency:

1. Press the emergency stop button (36).

2. Close valve (1).

3. Pull the emergency stop.

4. Press the start button (35). The machine is ready

to start according to instructions.

WARNING!
Protective accessories
Always use safety goggles, breathing filter
and hearing protection when the milling
machine is in operation.

Address: P.O. Box 9025

S-200 39 Malmoe, Sweden
©Copyright Chris-Marine AB Telephone: +46-40 671 2600. Fax: +46-40 671 2699 19
Maintenance

7. MAINTENANCE
Check the following regularly to ensure good milling result and safe operation.

 Drain connecting pipes and hoses of accumulated water before each milling
operation.

 Keep the milling machine clean and protected with a thin layer of oil.

 Check the oil level. Refill the oil reservoir (21) if necessary. Unscrew the
container and fill up with one of the lubricants listed below.

RECOMMENDED AIR MOTOR OILS:

BP Esso Gulf Q8

Energol RDE 46 Arox EP 46 Merit 100

Energol RDE 100 ALMO 525

OK Shell Texaco

Pneutool oil S Torculla 32 ARIES 32

Mobiloil Statoil Valvoline

Almo 525 Rockway EP 46 ATO No 10

Air filter and oil mist lubricator

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 Reminders

8. REMINDERS
8.2 For Best Results
 Secure adequate air supply (Section 2.2).

 Secure adequate lubrication of milling motor (Section 5.1)

8.2 Trouble Shooting

Problem Possible cause Remedy

Bad cutting or milling motor feels To low air pressure Check air pressure
week or stops
Milling motor not lubricated Check oil mist lubricator and pour oil directly
into the motor

Vibrations High speed cutter worn Change high speed cutter

Cuts too deep Reduce cutting depth

Groove to deep Widen groove up to ½ mm

High speed cutter breaks in half or Over heating Do not let machine get overheated.
falls off shaft
Change cutter

Reduce cuts

Milling motor does not start Emergency stop activated Release stop button and press start button

8.3 After Use

 After completing the milling operation, disconnect the air supply hose and pour in a few drops of air motor oil.
Reconnect, and allow the air motor to operate for a few seconds, this will ensure a good internal lubrication for
storing.

 Clean the machine thoroughly and apply anti-corrosion fluid on all metallic parts.

 Always store the machine and it’s accessories in the storing box. The box should be stored in a dry, clean place.

 By following these precautions, the machine will remain in good condition and ready for use.

Address: P.O. Box 9025

S-200 39 Malmoe, Sweden
©Copyright Chris-Marine AB Telephone: +46-40 671 2600. Fax: +46-40 671 2699 21