ne way cutter manual

7/29/2019 Ne Way Cutter Manual

1/16

InstructIon Man

ual

ValVe

seat cutt

er

NEWAY MANUFACTURING, INC. P.O. Box 188 Corunna, Michigan 48817 USAPhone: (989) 743-3458 Fax: (989) 743-5764

Email: [email protected]

Web: www.newaymfg.com


2/16

V a l V e S e a t C u t t e r I n S t r u C t I o n M a n u a l

Before using the tools,

please read this entire manual carefully.

NARROWING

CUTTER

EXPANDABLE

PILOT

SOLID

PILOT

SEATCUTTER

PILOT

PULLER PIN

T-HANDLE

WRENCH

BRUSH FOR

CLEANING

BLADE

SERRATIONS

5/64" HEX KEY

(Blade Lock)

3/32" HEX KEY

(Hub Lock)

HEAD

STANDS

POWER

UNIT


3/16


c

Why Pp Vv sig i Imp. 4

Objectivesovalveseatreconditioning

IntererenceAngle

Ppi cig Vv s. 4

si d u Pp Pi. 5

SolidPilots

ExpandablePilots

si d u Pp Vv s c. 68

AdjustmentoCarbideBlades GeneralInstructions

DetailedInstructions BottomNarrowingCut TopNarrowingCut

FinalSeatCut

InspectingtheSeat

chgig h li d/ Widh h s. 9

chkig Vv s ciiy d c. 9

ToleranceorRunout(Concentricity)

spi appii cbid Bd. 10

RadiusBlades

SteppedBlades

Pw ui. 10

Bi P li. 1112

Hp sggi. 1314

tbhig. 15


4/16


Why Pp Vv sig i Imp

Goodvalveseatsarecriticaltomaintainingcompressionandhorsepower.Poorlyseatedvalveswillnotonlycause

compressionloss,butwillalsocompromisetheabilityothe

exhaustvalvetocoolitselbytranserringheatthroughcontactwiththevalveseat.Further,ivalveseatconcentricity

isoutsideotheallowablelimit,mechanicalstressesmaycause

valveailure.Agoodvalveseat:

Isconcentrictothecenterlineothevalveguide(withinOEMspecs).

Isproperlylocatedonthevalveace.

Istheproperwidth. Hasasuracetexturewhichisconducivetoecientsealing

andheattranser.

Hastheproperangles(contactsuraceandrelieanglesaboveandbelowcontactsurace,alsoreerredto

asnarrowingangles).

UnlessotherwisespeciedbytheOEM,Newayrecommends

theuseoanintererenceangle(e.g.45valve,46seat).Thiswillcausemaximumpressurebetweenthevalveandseat

tooccurattheoutermostdiameter.

Ppi cig Vv s

Cleanthecylinderheadthoroughly,includingtheseatsandvalveguides.

Checktheconditionothevalveguides(reertoOEMspecs

andinspectionprocedures).

Badlywornvalveguidesmustbereplacedorreconditioned

priortovalveseatreconditioning.

EXHA

UST

COMBUSTION

CHAMBER

PISTON

CUTTER

TOP

NARROWING

BOTTOM

NARROWING

SEAT

VALVE

SEAT

INTERFERENCE

ANGLE

VALVE

FACE

BADLY WORN

GUIDE AREA


5/16


si d u Pp Pi

solID PIlots

Selectapilotthesamediameterasthevalveguide

interiordiameter(ID).

Insertthepilotintothevalveguide,twisting

slightly,untilsnug.Pilotshouldershouldnottouch

thevalveguide.

eXPanDaBle PIlots

SelectapilotthesamediameterasthevalveguideID.

Insertthepilotintovalveguidemakingsurethatthe

expandingsectionothepilot(collet)iscompletelywithinthevalveguide.

The pilot will not center properly if the collet extendsoutside of the valve guide even slightly. The collet

may also be damaged if expanded while extendedoutside of the guide.

Pilotshouldershouldbeabout1/8"(3mm)abovethevalveguide.

Usingthepilotpullerpin,turnthepilotasthenutisheldast

attheopposingend.Thiswillexpandthecolletandsecure

thepilotintoposition.

Colletsare.003"smallerthanstateddiameterandcanexpandupto.020"(0,5mm).

Theconcentricityothevalveseatreliesonatighttt ingpilot

inaround,straight,guide.

SHOULDER

SHOULD

NOT

TOUCH

VALVE

GUIDE

PILOT

PILOT PULLER PIN

SHOULDER

EXPANDABLE PILOT

HOLE FOR

PILOT

PULLER

PIN

NUT

COLLET

1/8" (3 mm)

EXPAND PILOT

BY TURNINGPILOT

PULLER

PIN

NUT

COLLET


6/16


si d u Pp Vv s c

aDJustMent of carBIDe BlaDes

Beoreusingcutters,checkbladeadjustment.Itisnot

necessarythatallthebladesbesettothesameposition.Simplycheckthatthebladesdonotcutorgougethe

combustionchamberwallandthateachbladeextends

entirelyoverthesuracetobemachined.Donotovertightenscrews.

Whenadjustingbladesinwardoroutwardbesurethatthe

blademaintainsullcontactwiththefatothewedge.

Whenchangingblades,besurethatthepointedendothebladepointstowardthecenter,orhub,ocutter.

General InstructIons

Selectacutterapproximatelythesamesizeasthevalveheaddiameterandwiththecorrectangle.

Placethecutteroverthepilotandcareullylowerthecutter

ontotheseat.DONOTDROPTHECUTTER.

PlaceT-handle,easy-turnwrench,orhexsocketopowerunitoverthepilotandontothehexothecutter.

Turnclockwise,applyinglightdownwardpressure.

UsetwohandsontheT-wrench.Releasethedownwardpressureattheendoeachcut.Makeoneortwoturnswithnopressure.

Besuretomaintaindownwardpressureoverthecenterline

othepilot.Payspecialattentiontomaintainingcenterlinepressureinsituationswherethecutteriscuttingononlyone

sideotheseat(e.g.aterinstallationoanewvalveguide).

Excessivedownwardpressuremaycausethepilottofexo

center.Letthecutterollowthepilot.

HEAD

DIAMETER

MOST BLADES

ARE ADJUSTABLE

HEX KEY

BLADEPOINTED

END

FLAT HEADSCREW

ALWAYS TURN

CLOCKWISE

APPLY

VERY

LIGHT

PRESSURE


7/16


DetaIleD cuttInG InstructIons

Inspecttheseat.Thesizeothepits,burnsouts,andblowbyeswilldeterminetheamountomaterialthatmustbe

removed.

Bottom Narrowing Cut

Begintheprocessbycuttingthebottomnarrowingangle

(usually60or75)usinglightpressure.Cutuntilsome

amountosuracehasbeencutallthewayaround,orming

acontinuouslinewiththevalveseat.Thisoperationraisesthebottomedgeothevalveseat.

Note:Somenarrowingcuttershavemoveablehubsandwillrequireadjustment.Thesehubsareheldinpositionbyaset

screw.Donotovertightenthissetscrew.

Top Narrowing Cut

Repeatasaboveusingthetopnarrowingangle(usually

30or15).Again,cutuntilsomeamountosurace

hasbeencutallthewayaround.Thisoperationlowersthetopedgeotheseat.

Final Seat Cut

Beoremakingthenalcut,makesurethatthewidtho

theseat(i.e.theuncutsuracebetweenthetopand

bottomnarrowingangles),isslightlylessthandesirednishedwidth.Also,thisuncutsuraceshouldappear

uniorminwidthbeoremakingthenalcut.Ithewidthotheuncutsuracevariessignicantlyromonesidetothe

other,continuecuttingboththetopandbottomnarrowing

anglesuntilthewidthisuniorm.

si d u Pp Vv s c (continued)

BOTTOM

NARROWING

SEAT

BOTTOM

NARROWING

CUTTER

TOP

NARROWING

TOP

NARROWING

CUTTER

SEAT

BOTTOM

NARROWING

SEAT

TOP

NARROWING

SEAT CUTTER


8/16


DetaIleD cuttInG InstructIons (continued)

Cuttheseattotheproperwidth.Letthecuttermakeaew

turnswithnopressure.

Thenishedvalveseatwillhaveamachinetexturednish(nothighlypolishedorshiny).Thisprovidesasotsuraceor

nalmatingwiththevalveaceintherstsecondsoengine

operation.Itisnotnecessarytolapthevalve.

Inspecting the Seat

Removethepilot,usingthepilotpullerpin.

Insertthevalveintothevalveguide.

Usingyourngers,tapthevalvermlyagainstthevalveseat,upanddowninthevalveguide,holdingthevalveaboveand

belowthecylinderhead.Dothisuntilaringmarkappearson

theaceothevalve.

Thevalveseatshouldbelocatedinthemiddleotheaceothevalve,orjustslightlyo-centertowardthemargin.

Whenthevalveseatisproperlylocatedonthevalveace(in

themiddle),theringmarkshouldappearabout1/4to1/3othewaydownthevalveaceromthemargin.Thisring

markiscreatedbytheridgeattheouterdiameterothe

46surace,wherethe46and31anglesmeet.Whena1intererenceangleexistsbetweenthevalveaceand

thevalveseat,the46seatdoesnotmakeullcontactwith

valve.Whentheenginerstresthesesuraceswillmatetogetherandullcontactwilloccur.Whencuttinganon-

intererenceseat45valveto45seattheullwidtho

thevalveseatwillcontactthevalveatercutt ing.Inthiscase

itmaybeuseultousePrussianblue,orasimilarmachinistslayoutfuid,tovisuallycheckthelocationotheseatonthe

aceothevalve.

si d u Pp Vv s c (continued)

LIFT WITH

PILOT PULLER PIN

PILOT

VALVE

GUIDE

RING-MARK

TAP UP AND DOWN

ONTO SEAT BY HAND

VALVE FACE

VALVE

SEAT

MARGIN


9/16


chgig h li d/ Widh h s

Itheringmarkistoohighonthevalveace(i.e.toocloseto

themargin),thencutmorewiththetopnarrowingangle.This

willlowertheringmarkontheaceothevalve.However,itwill

alsoreducethewidthotheseat.Itmaybenecessarytocutthe46suraceagaintorestoredesiredseatwidth.Similarlyi

theringmarkistoolowonthevalveace,properseatlocation

canberestoredbyeithercuttingabitmorewiththe46cutteror,iseatingsuracebecomestoowide,bycuttingwithboth

thebottomnarrowingangle(usually60)andthe46angleto

obtainproperseatwidthandlocation.

chkig Vv s ciiy d c

Valveclosurereliesonboththeconcentricityothevalveitsel

andtheconcentricitybetweenthevalveguideandthevalveseatingsurace.Measuringtheamountoconcentricity,or

runout,oreachotheseandaddingthemtogetherprovidesus

withthetotalamountorunout.Itisthistotalrunoutwhichwill

determinehowperectly,orimperectly,thevalveseats.Therewillalmostalwaysbesomeamountorunout,itisthereore

importanttounderstandtheallowablelimit,ortoleranceor

runout.Thereisasimpleruleothumb:oreveryinchovalveheaddiametertheOEMwillallowor0.0015"ototalrunout.

Higherrevvingengineswilldemandtightertolerances.

Valveclosurecanbecheckedbypaintingtheaceothevalve

withPrussianBlue.Besurethatthevalveyouuseistrue.Insert

thevalveintotheguideandapplylightpressure,turningthevalvebackandorth1/8"orso.Acontactpatternwillappear

onthevalveace.Oneormoreopenspotsmayappear.Veryshortintermittentopenspots(shorterthanthedistancerom

12to1onaclock)donotindicateaproblemandwillpeenout

immediatelywhentheengineres.Largeropenspots(rom12oclockto2oclockor3oclock)canberemediedbyreturning

thecuttertotheseatandlightlyturningthecutteraew

revolutionswiththengers.Itheopenspotislargerthan90(12oclockto3oclock)repeatthethreecuttingsteps,making

verylightcuts,orcontactNewayManuacturingortechnical

assistanceat(800)248-3889.

DIAL INDICATOR

CHECKS CONCENTRICITY

ALL AROUND SEAT

PUT

"BLUE"

ON VALVE FACE

"BLUE" RUBS

OFF AS CLEAN

LINE ON THE

VALVE FACE


10/16

V a l V e S e a t C u t t e r I n S t r u C t I o n M a n u a l1 0

spi appii cbid Bd

Newayradiusbladesareusedtosmoothlyblendtheouter

diameterothetopnarrowingangle(usually30or15)into

thecombustionchamberwall.Stepsorridgesmayexist

attheouterdiameteroseatsduetoarecessedseatorahemisphericallyshapedcombustionchamber.Theradius

bladeisinstalledinatopnarrowingangleandpositioned

tocutoutthestepusingtheradiusedendotheblade.Onebladeormultiplebladesmaybeused.

Specialsteppedbladesmaybeusedonrecessedseats

whenitisnecessarytoclearthecasting.

Pw ui

ANewaypowerunitwilldramaticallyincreaseyourproductivity.

Thedriveunitrollsreelyalongthetrackorpositioningover

thevalveseat.Thevariablespeedcontrolallowsorsetting

themosteectiveturningspeed.Mostseatmaterialsarecutbetweenturningspeedso20RPMto50RPM.Forharder

seatmaterialsuseslowerspeed.ExcessiveRPM(70ormore)

maycauseprematuredullingoblades.

Thetransmissionunitromthemotortothecutterhastwo

universaljointsandatelescopingsection.Thesocketshouldbe

positioneddirectlyoverthevalveseatbeingcut.

oPeratInG I nstructIons

Placecylinderheadontoheadstands.

Insertpilot,asdescribedpreviously.

Adjustcylinderheadsuchthatthepilotisalignedtothetransmission.

Placecutterontopilotandcareullylowercutterontothevalveseat.Donotdropthecutterasthismaygouge

theseatand/orchipthecarbideblades.

GEAR MOTOR

TRANSMISSION

TROLLEY

TRACK

SOCKET

HEAD STANDS

HEAD STANDS

CYLINDER

HEAD

PILOT

TOP

NARROWING

SEAT

TOP

NARROWING

INSERT


11/16

V a l V e S e a t C u t t e r I n S t r u C t I o n M a n u a l 1 1

Pw ui (continued)

Placesocketontothecutter.Besurethetransmissionis

linedupoverthepilot.Thetransmissionshouldbe

asstraightaspossible.

Usingtheootswitch,startthemotortoproceedwithseatcuttingaspreviouslydescribed.Holdingthehandleapply

onlylightdownwardpressure.Excessivepressuremayfexthepilotand/orcauseprematuredullingoblades.

Formoreaggressivestockremovalalternatebladesmaybe

used.ContactNeway.

Bi P li

solID PIlots

100 SeriesForusewith100SeriesCuttersonly.297"(7,5mm)HubI.D.

140 SeriesForusewith200/600/700SeriesCuttersonly3/8"(9,5mm)HubI.D.

HUB: 1.Adjustableonlyontwo-sidedNarrowing

Cutters200and

600Series.

2.Fixed(notmovable)onallotherCutters.

5133/8" (9.5mm) Hexor100SeriesHeads

5051/2" (12.7mm) Hexor200,600,700SeriesHeads

503-13/8" Adaptor1/2"to3/8"

FLAT HEAD

SCREW

WEDGE

SET SCREW

3/32" HEX KEY

5/64" HEX KEY

HUBHEAD


12/16

V a l V e S e a t C u t t e r I n S t r u C t I o n M a n u a l1

Bi P li (continued)

eXPanDaBle PIlots

Colletdiametersare,1mm(.003")lessthanstated,andexpandupto,5mm(.020")

120 SeriesForusewith100SeriesHeadsonly.297"(7,5mm)HubI.D.

150 SeriesForusewith200/600/700SeriesHeads3/8"(9,5mm)HubI.D.

200 SeriesForusewith200/600/700SeriesHeads3/8"(9,5mm)HubI.D.

(Theyareorengineswithlongvalveguides)

tunGsten carBIDe BlaDes

PART # LENGTH USED IN

152 . . . . . . . . . . . . . . . . . . . 1/2" . . . . . . . . . . . . . . Non-serratedBlade(correctioncutters)

154 . . . . . . . . . . . . . . . . . . . 3/4" . . . . . . . . . . . . . . Non-serratedBlade(correctioncutters)250. . . . . . . . . . . . . . . . . . .3/8" . . . . . . . . . . . . . .0thru46SeatCutters

250LC. . . . . . . . . . . . 3/8" . . . . . . . . . . . . . .0thru46SeatCutters(hardseats)

251 . . . . . . . . . . . . . . . . . . . 1/2" . . . . . . . . . . . . . . 0thru46SeatCutters

251LC . . . . . . . . . . . . 1/2" . . . . . . . . . . . . . . 0thru46SeatCutters(hardseats)

252 . . . . . . . . . . . . . . . . . . .1/2" . . . . . . . . . . . . . . 60thru80CorrectionCutters

253. . . . . . . . . . . . . . . . . 5/16". . . . . . . . . . . . . 0thru46SeatCutters

254. . . . . . . . . . . . . . . . . . . 3/4" . . . . . . . . . . . . . . 60thru80CorrectionCutters

352. . . . . . . . . . . . . . . . . . . 1/2" . . . . . . . . . . . . . . RadiusBlade(blendingpurpose)

354. . . . . . . . . . . . . . . . . . . 3/4" . . . . . . . . . . . . . . RadiusBlade(blendingpurpose)

355. . . . . . . . . . . . . . . . . . .3/8" . . . . . . . . . . . . . .RadiusBlade(blendingpurpose)

353. . . . . . . . . . . . . . . . . 5/16". . . . . . . . . . . . . HondaPowerProducts(stepped)

553. . . . . . . . . . . . . . . . . 5/16". . . . . . . . . . . . . SuzukiMotorcycles(short-angled)

* LC(largecoursetooth)bladestendtobemoreeectiveonthehardestseatmaterials.Theymayalsobeusedormore

aggressivestockremovalonregualrorsotseatmaterials

(e.g.toenlargeseatoroversizedvalve).

152, 154

250, 251, 253

250 LC, 251 LC

252, 254

352,354, 355

353

553

STEM COLLET EXPANDER NUT

*

*


13/16

V a l V e S e a t C u t t e r I n S t r u C t I o n M a n u a l 1

Hp sggi

c .

Washorrinsethoroughlywithacleaningsolution.

tk .

Toolsshouldbekeptintoolcase.Whenremovedromcase,

theyshouldbeplacedonaclothorpad.Theseprecision

instrumentswilllastalongtimeireasonablecareisused.

tk b.

Serrationsonthebladesshouldbecleanedregularlywiththebrushprovidedwitheachkit.Atoothbrushmayalsobeused.

HANDLE

WITH

CARE


14/16

V a l V e S e a t C u t t e r I n S t r u C t I o n M a n u a l1

Hp sggi(continued)

c .

NewayCuttingFluid(awettingsolution)isrecommendedwhencuttingsotseats.Thiswillreducechatterandimproveseatnish.Neverusepetroleum-basedcuttingfuid.

c .

Neway'sL.C.(largecourse)bladesarerecommendedorcuttingespecially

hardseats.Ingeneral,theyshouldnotbeusedonaveragetosotseatmaterials.However,theymaybeusedonaveragetosotseatswhereaggressivestockremovalis

theobjective.Increasingcuttingpressure(eed)anddecreasingcuttingspeedwillalso

improveresultsonhardseats.

r w k b.

ThecuttingbladesdoNOThavetobeinthesamerelativepositionothehead.Bladesmaybeup,down,orcenteredintheirslots.Theywillalwaysbeonthesame

planeandangle.However,bladesmustextendovertheseatareatobecut,withpointed

endstowardhub.Allbladesonthesamecuttingangleshouldbereplacedtogether.Sinceeachbladeisadjustable,wornportionsoranickcanbeadjustedawayromthe

bladecontactarea.DONOTOVER-TIGHTEN.

ab b .

Alwaysbesurepointedendsoncarbidebladesarepointingtowardthehub,orcenterothehead.

HUB

ALWAYS TURN

CLOCKWISE

HUB

POINTED ENDS OF BLADES


15/16

V a l V e S e a t C u t t e r I n S t r u C t I o n M a n u a l 1

tbhig

o b . h .

s pbb c s

Gouging Toomuchpressure.Turningspeedtooast.

Applyonlylightpressure.Slowdown.UsetwohandsonTWrench.

Chatter Incorrectpressure. Applyonlylightpressure.

Loosepilot. Selectsnug-ttingpilotor

replacevalveguide.

Verysotseats. ApplywettingsolutionsuchasNewayCuttingFluidonseats.DoNOTusepetroleum-basedcuttingfuids.

Eccentricity Toomuchpressure. Applyonlylightpressure.

Sideloadpressure. Applypressureovercenterlineopilot.

Loosepilot. Selectsnug-ttingpilot,orreplacevalveguide.

Excessivevalveguidewear. Replacevalveguide.

Load-up in bladeserrations

Toomuchpressure. Applyonlylightpressure.

Dirtoroil. Cleanserrations.

Excessive blade wear Toomuchpressure. Applyonlylightpressure.

Wrongbladeposition. Pointedendsobladesmustbepointedtowardhub.

Blade chipping or breakage Roughhandlingorcutterdroppedontoseat.

Tungstencarbidebladesareveryhard,butbrittle,andshouldbehandledwithcare.

tbhig

o b . h .

s pbb c s

Gouging Toomuchpressure.Turningspeedtooast.

Applyonlylightpressure.Slowdown.UsetwohandsonTWrench.

Chatter Incorrectpressure. Applyonlylightpressure.

Loosepilot. Selectsnug-ttingpilotor

replacevalveguide.

Verysotseats. ApplywettingsolutionsuchasNewayCuttingFluidonseats.DoNOTusepetroleum-basedcuttingfuids.

Eccentricity Toomuchpressure. Applyonlylightpressure.

Sideloadpressure. Applypressureovercenterlineopilot.

Loosepilot. Selectsnug-ttingpilot,orreplacevalveguide.

Excessivevalveguidewear. Replacevalveguide.

Load-up in bladeserrations

Toomuchpressure. Applyonlylightpressure.

Dirtoroil. Cleanserrations.

Excessive blade wear Toomuchpressure. Applyonlylightpressure.

Wrongbladeposition. Pointedendsobladesmustbepointedtowardhub.

Blade chipping or breakage Roughhandlingorcutterdroppedontoseat.

Tungstencarbidebladesareveryhard,butbrittle,andshouldbehandledwithcare.


16/16

Neway has been in business since 1952 manufacturing

and distributing tools and equipment for valve seat

reconditioning and valve reconditioning.

Our trademark product is the Neway valve seat cutter.

Neway seat cutters are almost standard equipment

in shops that rebuild engines, whether the work is

automotive, motorcycle, power equipment, or heavy

duty. Our tools are used all over the world in shops bothbig and small, by DIYers and production engine builders

alike. Neway cutters can be found at the track, in high

performance test labs, and in use on OEM assembly lines.

We believe that our product has been so successful for

one simple reason: it offers value. It's extremely easy to

use, is accurate enough for high performance engine

work, and is inexpensive to purchase.

1-800-248-3889

ne way cutter manual

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