Installation Procedures for KLH Series KOR-LOK™ Side-Action Systems

Congratulations on your purchase of PFA’s new KOR-LOK™ System! You will find that installation and adjustment of the unit will be relatively simple and when properly installed, you will have a method of holding your core slide that will last and last.

Read the following instructions carefully, paying close attention to the sections that pertain to the model and associated hardware you have purchased. (see separate procedures for sensor connections.) You may also want to review how the system works.

If you have any questions or need technical assistance, please call our support staff at (262) 250-4410. Our normal office hours are from 8am to 4:30pm Monday - Friday. In the event you require assistance after normal business hours, please call our After Hours Emergency Help Line at 1-888-296-6663. This service is available 24 hrs. a day, 7 days a week.

Please take inventory of your new KOR-LOK™ system to ensure the contents of your shipment balance with the packing slip.

A. KL-_ _ _ -AS and AC ALIGNMENT SCREWS AND COUPLERS
If you require alignment screws and/or couplers install these first. Install the alignment coupler in the core and the alignment screw into the piston rod until fully seated. A thread locking compound may be utilized if desired. (See Fig 1)

B. KL-_ _ _-SF or -RF MOUNTING FLANGES
As each mold has coolant passages in various locations and you may require a mounting pattern that is different from standard, your mounting flange is provided without pre-drilled mounting holes. Review the bolt circle recommendations specified in the catalog when considering a bolt pattern. Custom machining of your flange to accommodate installation can be done, but should be kept to a minimum to ensure proper performance. When the flange is ready, install it on the mold and snug bolts. Ensure threaded hole is centered relative to the core attachment point as alignment is critical. Torque flange bolts to appropriate specifications.

C. KL-_ _ _-JN JAM NUT
Install the jam nut onto the KOR-LOK™ unit with the flat side toward the main body of the unit (beveled edge toward mold). Thread the nut approximately 3/4 of the way on.

D. PREPARATION FOR INSTALLATION – On the Bench

1. Remove port plugs from one extend and retract port. There are three options for the retract port (A, B and C) and two options for the extend port (D and E) as shown in Fig 1.
   
   

   CAUTION! Fluid may eject from retract port as rod extends. Observe proper safety precautions.

2. Apply a pressure source (minimum of 80 psi pneumatic or hydraulic) to the open extend port (D or E) until the unit is fully extended and locked. (see Fig 1.)
3. Remove extend pressure (disconnect line and ensure port is open or vented).

E. INSTALLATION OF KOR-LOK™ UNIT OR RESETTING OF UNIT.

1. If initial install, with the system extended, locked, and vented (slide unit threaded out so core will not hit stop), connect the core/slide mechanism to the rod of the KOR-LOK™ Unit. If using the KL-__-AS and KL-__-AC, install the alignment coupler into core/slide body, then connect the Alignment Screw with the Alignment Coupler.
2. If resetting unit, thread unit out to point where core does not hit stops when extended, then extend unit, then disconnect lines – retract line first – and ensure unit is vented.
3. Thread your unit in until the core is almost seated. Ensure you have thread engagement equivalent to the thickness of the flange and space beyond flange for unit to thread through for adjustment. See required flange thickness for your model size (refer to "Recommended Accessories" section of catalog).
   
   

   NOTE With the system extended and locked, open an extend port (D or E) and a retract port (A, B or C) to allow venting of any trapped hydraulic pressure during adjustment. VENTING IS CRITICAL TO PROPER SET-UP.

F. ADJUSTMENT PROCEDURES (If resetting unit start at part E step 2).

1. With ports vented and core not hitting stops, thread the KOR-LOK™ Unit in until fully seated. (Core will hit stops and unit will continue turning in about a half turn to until the lock is seated – removes endplay between lock and cylinder section).
2. Place mark on flange and unit body to mark position location for reference.
3. Replace the plugs or lines previously removed for venting.
4. Cycle the KOR-LOK™ unit to the "core out" position. Thread the unit IN the recommended pre-load amount in the chart below to set your KOR-LOK™ inside the lock-up window. (Remove lines, if desired, for ease of rotation.).
5. Connect sensors using appropriated procedures for the style utilized in your application. Documentation is provided separately.
6. Extend unit HYDRAULICALLY (1500 psi minimum) and verify lock sensor activates (turns on) verifying unit locks as expected. Failure to lock is one indication of an adjustment problem.
7. With unit extended and locked, tighten the jam nut. (Note: future loosening of the jam nut will require extending the unit hydraulically again due to thread loading when retracted). Cycle unit hydraulically and verify complete operation.
8. Test Mold during injection and note part quality and unit operating as intended. If flash occurs, additional adjustments (1/16 turn increments) INWARD may be needed at normal operating temperature to achieve the desired final adjustment in the lock-up window. If unit does not operate as intended when run, call PFA for assistance. Applications vary widely and this procedure may not exactly cover your case. 24/7 assistance is available. 

KOR-LOK™ PRELOAD ADJUSTMENT CHART

These procedures have been written in an effort to address as many configurations as possible. If your particular application requires set up procedures that are not covered in the preceding documentation, please contact PFA at (262) 250-4410 for assistance.

How It Works

PFA’s new KOR-LOK‘ system is the ultimate bolt-on solution to complex and costly cam or slide activated molding requirements. Employing a positive mechanical lock with a built-in hydraulic cylinder, this compact system offers a simple and economical method of securing your core slide at any angle! The mechanical lock is comprised of a tri-sectional locking ring, a locking slide, and an annular groove in the piston rod. When pressure is applied to the extend side of the piston (from your choice of 2 ports), internal porting also routes pressure to the locking slide. As the cylinder rod reaches full extension, the locking slide forces the three segments of the tri-sectional locking ring into the annular groove of the piston rod. Once the lock is engaged, the force holding capacity of the unit is determined by the column strength of the rod. This mechanical lock greatly enhances the performance of the unit and allows KOR-LOK‘ systems to hold forces equal or greater than standard cylinders 5-10 times as large! When pressure is applied to the retract side of the piston (from your choice of 3 ports), internal porting also routes pressure to the release side of the locking slide, forcing it off the locking segments. As the segments are released, the rod freely retracts.