Product Name: Coned Insert / Double Cone HP Insert (40k-60k) – Part No. 400013-1

Description:
This component is a high-pressure coned insert, also referred to as a double cone HP insert, specifically designed for use in ultra-high pressure (UHP) waterjet cutting systems rated at 40,000 to 60,000 PSI (approximately 2,758 to 4,137 bar) . It is a precision-machined metal sealing component, typically manufactured from high-strength stainless steel, engineered to create a reliable metal-to-metal seal within a high-pressure fitting assembly.

The coned insert, often described as a "double cone" due to its symmetrical tapered geometry, functions as the intermediate sealing element between two sections of high-pressure tubing or between a tube and a component port . When the assembly's gland nut is tightened, the cone is compressed, deforming slightly to fill the space between the outer tube and the inner wall of the fitting. This action creates a leak-proof, blowout-proof connection capable of withstanding extreme pressure spikes, vibration, and mechanical shock .

Standard sizes for these inserts are typically 1/4 inch, 3/8 inch, and 9/16 inch, corresponding to the common high-pressure tubing sizes used in waterjet systems . The "double cone" design is particularly robust because the seal is formed on two opposing conical surfaces, distributing stress evenly and allowing the insert to be reused multiple times if not damaged.

Applications:

• Critical sealing component in high-pressure fittings for waterjet intensifier pumps and cutting heads .

• Used in unions, elbows, tees, and straight couplings to connect high-pressure tubing .

• Joins high-pressure lines to components such as on/off valves, check valves, and manifold blocks.

• Standard sizes (1/4", 3/8", 9/16") fit the standard high-pressure plumbing configurations of most major waterjet systems, including KMT, AccuStream, H2O Jet, FLOW, OMAX, and WSI .

Features:

• Double Cone Geometry: The symmetrical tapered design creates a highly effective, concentric seal on two opposing surfaces, ensuring even load distribution .

• High-Strength Stainless Steel: Machined from corrosion-resistant stainless steel to withstand the extreme cyclic pressures and hydraulic shock of waterjet operation .

• Metal-to-Metal Seal: Provides a blowout-proof, vibration-resistant seal without the need for elastomeric O-rings, ensuring high reliability under continuous, high-cycle operation .

• Reusable Design: Unlike soft seals, a coned insert can be reused across multiple maintenance cycles if the metal cone surfaces remain free from nicks, scratches, or deformation.

• OEM Compatibility: A direct OEM replacement part (cross-referenced to KMT #1-12978), ensuring a precise fit for standard HP fittings .

Maintenance:

Inspection:

• Critical Surface Check: Before each use, carefully inspect the cone's sealing surfaces for any signs of nicks, galling, deep scratches, or deformation. A damaged cone will create a high-pressure leak path and must be replaced.

• Thread Condition: Inspect the threads of the associated gland nut and fitting body, as cross-threading or galling will prevent the cone from seating correctly.

Installation Best Practices:

• Full Depressurization (Critical): Before any maintenance, always fully depressurize the waterjet system, shut off the high-pressure water supply, and follow lockout/tagout procedures. Never loosen a fitting while the system is under pressure.

• Surface Preparation: Ensure the cone insert and the mating cones inside the nut and fitting body are perfectly clean and free of debris, grit, or old sealant.

• Thread Lubrication: Apply a thin, even layer of high-pressure anti-seize compound (e.g., "Silver Grade" or "Blue Goop") to the male threads of the gland nut only. Do not apply any lubricant to the cone insert or its mating sealing surfaces, as this can prevent the necessary metal-to-metal friction seal.

• Proper Seating: Slide the cone onto the high-pressure tube with the correct orientation (double cone is symmetric). Ensure the tube is fully bottomed out in the fitting or component port.

• Torque Compliance: Tighten the gland nut to the specific torque value listed in your equipment service manual. Use two wrenches (one to counter-hold the fitting body) to prevent twisting stress on the assembly. Over-tightening can crack the insert or fitting, while under-tightening will cause a high-pressure leak.

• Replacement: Due to its precision nature, if the cone insert shows any sign of damage, it must be replaced. Do not attempt to repair or "re-face" a worn insert.