Flush Mount Sensor

Installation/Check Kit

E-2012-7-18

Flush Mount Sensor

Installation/Check Kit

Reorder Information

Part Number Description

Carrying Case

M8 x .75 Plug Tap

4 mm Test Block

4 mm Pocket Form Tool

4 mm Concentricity Checker

4 mm Go No-Go Gauge

2.5 mm Concentricity Checker

2.5 mm Go No-Go Gauge

PA-BSPK-CAS

89-00M8-TL1

MA-0040-BLK

MA-6157-SPM

MA-6157-CCK

MA-6157-GNG

MA-6159-CCK

MA-6159-GNG

GR

2.5 mm

4 mm

GR

4 mm

2.5 mm Flush Mount Sensor

Check Tools

Check Sensor

hole using both

sides of Go No-

Go Gauge

Check sensor

pocket using the

concentricity

check tool

2.5 m

m

G

R

2.5 m

m

4 mm Flush Mount Sensor

Installation/Check Tools

Cut 4mm Pocket

using carbide

Pocket Form

Tool

Tap nut threads

using included

M8 x .75 plug

tap

Check Sensor

hole using both

sides of Go No-

Go Gauge

Check sensor

pocket using the

concentricity

check tool

Drill

Clearance Hole

Mill cable

channel

G

R

4 m

m 4 m

m

4 mm Pocket Form Tool Instructions

Step One:

Drill a .406" minimum

diameter clearance hole

1.0" from cavity.

1.0"

[25.4 mm]

4" [102 mm] MAX

.406" [10.31 mm] min.

DIA

.3150" [8.00 mm]

32 Rockwell Max*

Cavity Face

More

* 45-50 rc with much care and flood coolant

Note Form

Tool depth.

Step Two:

Use the Form Tool to form pocket.

1680 rpm

Bridgeport (or similar) type milling

machine with a light hand feed

Recommended .035 .055 depth of cut

pecking cycle used to clear material

Attention!

This tool is

for 6157

4mm sensor

installation

only!

.433" [11.00 mm]

.38" [9.6 mm] x .24" [6 mm] DP

4 mm Pocket Milling

Instructions Contd

Step Three:

Use the M8 x .75 Plug Tap

to form the Retaining Nut

threads

Step Four:

Mill sensor cable channel.

Yes

Sensor hole

is too small

No

Sensor hole

is too big

Yes

Sensor hole

is correct

size

No

Does

concentricity

tool fit

Sensor hole

is not

aligned or

not

concentric

No

Sensor hole

is properly

aligned

Failure Modes

Order of TestsTools

Go No-Go Gauge

Alignment Tester

No-Go

Gauge Fit?

Go Gauge

Fit?

2.5 mm, 4 mm Pocket Testing Instructions

Yes

Green

Red

G

R

Attention!Tolerances are tight.

Keep all components

dry and free of

particulate.

Use 2.5 mm tools for 6159

or 4 mm tools for 6157

Go No-Go Gauge InstructionThe Go No-Go Gauge checks for the correct sensor hole size

The green side should fit in

the hole easily

The red side should jam

easily or not fit in the hole

G

R

R

G

Use 2.5 mm tool for 6159

or 4 mm tool for 6157

Concentricity Checker Instructionchecks the alignment and concentricity of the sensor pocket

Step TwoTry pressing the

plunger

Step OneFully thread checker

into the retaining nut

threads

Pocket OKPin Slides freely

into pocket

Pocket BadPin Binds

Use 2.5 mm tool for 6159

or 4 mm tool for 6157

Test Block

Instruction

Go Gauge Fit?

No-Go Gauge

Fit?

Concentricity

Tool Fit?

Yes

(Hole not too

small)

No

(Hole not too

big)

No

(Hole off

center)

Pocket Fail

No

(Hole too

small)

Pocket Fail

Yes

(Hole not too

small)

Yes

(Hole too big)

Pocket Fail

Yes

(Hole not too

small)

No

(Hole not too

big)

Yes

(Hole is on

center)

Pocket OK

Order of

Tests

The 4 mm test block reproduces a variety

of pocket conditions so familiarity with the

4mm test equipment can be obtained.

This knowledge can then be applied to

the 2.5 mm tools.

Installation Problems to be avoided

Avoid Pinched Wires

Ensure Pocket Concentricity

Avoid sharp

Corner Here

Ensure

Correct

Sensor

Hole Size

Avoid Steel Shut Off

Conditions

Avoid Kinked Wires

Sensor Cable Retention Tools

Use Cable Retention Putty to retain sensor wires when the use of the

cable guides supplied with our sensors will not work for your

application. Example: Multiple wires per channel.

Cable Retention Putty