Crimping machines are essential equipment for hydraulic hose assembly shops, construction firms, automotive workshops, mining operations, oil & gas facilities, and industrial maintenance teams across Nigeria. When these machines fail or produce inaccurate crimps, operations slow down, hoses fail under pressure, and companies lose time and money.

The good news? Most crimping machine faults are predictable, preventable, and easy to fix when diagnosed correctly.
This comprehensive troubleshooting guide crafted by GZ Industrial Supplies, Nigeria’s leading supplier of crimping machines, hydraulic hoses, fittings, and workshop equipment will help you identify issues quickly and restore smooth operation.

Why Troubleshooting Knowledge Matters

Understanding crimping machine problems before they escalate helps you:

• Reduce costly equipment downtime

• Prevent hose blowouts and fitting failures

• Extend machine lifespan

• Maintain consistent, safe crimp quality

• Prevent repeat customer complaints

• Reduce maintenance and repair expenses

A properly maintained crimping machine is more accurate, more reliable, and safer for technicians to operate.

How a Crimping Machine Works 

Before troubleshooting, it helps to understand the basic components:

• Hydraulic Pump: Generates pressure for crimping

• Electric Motor: Powers the hydraulic system

• Die Set: Compresses the hose and fitting

• Pusher / Head: Applies force onto the die

• Control Panel: Sets crimp diameter, pressure, and modes

• Hydraulic Oil: Transfers power efficiently

• Valves & Sensors: Ensure proper pressure control

If any part malfunctions, crimp quality suffers.

Common Crimping Machine Problems and How to Fix Them

Below are the most frequent issues operators face in Nigeria and practical fixes recommended by GZ Industrial Supplies technicians.

Inconsistent Crimp Diameter

Symptoms:

• Fittings leak during pressure test

• Under-crimping (loose fitting)

• Over-crimping (cracked ferrule or restricted flow)

Causes & Solutions:

• Wrong die size selected: Match die to hose/fitting specifications

• Calibration drift: Recalibrate machine using factory settings

• Worn or damaged dies: Replace immediately (GZ stocks genuine Kaida dies)

• Low hydraulic pressure: Check oil level, pump condition, and leaks

Professional Tip: Always test 2–3 sample crimps after calibration.

Machine Not Building Hydraulic Pressure

Symptoms:

• Crimping head barely moves

• Machine stalls during operation

Causes & Solutions:

• Low hydraulic oil: Top up with ISO 46 or ISO 68 hydraulic oil

• Dirty or contaminated oil: Drain, flush, and refill

• Pump failure: Inspect pump or replace if worn

• Air in hydraulic system: Bleed air through designated valves

• Blocked suction filter: Clean or replace filter

Machine Overheating

Symptoms:

• Motor becomes extremely hot

• Machine shuts off automatically

• Oil temperature rises unusually

Causes & Solutions:

• Continuous operation without rest: Allow cooling intervals

• Blocked ventilation areas: Clean air passages and install cooling fans

• Wrong oil viscosity: Use recommended oil grade

• Faulty cooling fan or motor: Replace components

Overheating is a serious problem, never ignore it.

Dies Not Closing Evenly

Symptoms:

• Hose looks oval after crimp

• Fittings show uneven compression

Causes & Solutions:

• Dirty die segments → Clean thoroughly

• Worn dies → Replace

• Die holder misalignment → Realign and tighten bolts

• Bent die pusher → Replace the pusher

Uneven crimping compromises hose integrity—fix immediately.

5. Excessive Noise During Operation

Symptoms:

• Grinding, knocking, or rattling sounds

Causes & Solutions:

• Worn bearings in motor → Replace motor

• Low oil level → Top up hydraulic oil

• Loose bolts in machine frame → Tighten securely

• Pump cavitation due to air → Bleed system

Noise is often the first sign of mechanical wear.

6. Hose Bursts After Crimping

Symptoms:

• Hoses fail pressure testing

• Hose separates from the fitting

Causes & Solutions:

• Wrong die size → Recheck die chart

• Poor-quality hose or ferrule → Use certified brands from GZ

• Over-crimping → Reduce crimp diameter

• Mismatched hose-ferrule combination → Follow manufacturer specifications

A hose burst can be dangerous—strictly follow correct crimping procedures.

7. Control Panel Malfunctions or Error Codes

Symptoms:

• Machine refuses to start

• Incorrect crimp readings

• Error alerts on display

Causes & Solutions:

• Loose electrical connections → Inspect wiring

• Faulty pressure sensor → Replace sensor

• Damaged control board → Replace board

• Software glitch → Reset machine to factory mode

Digital control units require careful handling—avoid moisture and impact.

8. Machine Fails to Open After Crimping

Symptoms:

• Dies remain closed

• Hose or fitting gets stuck inside machine

Causes & Solutions:

• Stuck pressure release valve → Clean or replace valve

• Hydraulic blockage → Flush hydraulic lines

• Faulty auto-open switch → Replace switch

• Electrical issue in solenoid valve → Inspect wiring

Never force the dies open manually—you may damage the die head.

9. Hydraulic Oil Leaks

Symptoms:

• Oil dripping under machine

• Reduced hydraulic pressure

• Wet hoses or joints

Causes & Solutions:

• Damaged seals → Replace seals (GZ stocks seal kits)

• Loose hydraulic fittings → Tighten connections

• Cracked hoses → Replace damaged hoses

Ignoring leaks causes pump failure—repair immediately.

Preventive Maintenance Checklist

To avoid most problems, follow this GZ-recommended maintenance routine:

Daily Maintenance:

• Clean dies after each job

• Remove hose residue from crimp head

• Check for unusual noises

• Verify oil level

Weekly Maintenance:

• Lubricate moving parts

• Tighten all bolts

• Inspect dies for cracks or wear

• Test calibration accuracy

Monthly Maintenance:

• Inspect hydraulic hoses and seals

• Check motor brushes (if applicable)

• Clean ventilation systems

• Examine the electrical panel

Preventive maintenance increases machine lifespan by up to 40%.

Recommended Spare Parts and Consumables (Available at GZ)

GZ Industrial Supplies provides genuine factory-grade components such as:

• Complete die sets (Kaida DX68, DF68, HP51)

• Hydraulic oil ISO 46 / ISO 68

• Hydraulic pump assemblies

• Motor units

• Seal kits and O-rings

• Insert pusher blocks

• Hose ferrules and fittings

• Hose cutting and skiving machines

Buying genuine components prevents repeat failures and ensures safe operations.

When to Call a Professional Technician

Seek expert help if:

• Machine loses pressure repeatedly

• Control panel shows severe errors

• Dies are misaligned beyond manual correction

• Hydraulic leaks continue after seal replacement

• Motor emits burning smell

• The machine vibrates excessively

GZ technicians are available nationwide for diagnostics, repair, installation, and calibration.

Why Choose GZ Industrial Supplies for Your Crimping Machine Needs

GZ Industrial Supplies stands out as Nigeria’s most reliable source for hydraulic hose crimping machines and accessories.

We offer:

• Genuine Kaida crimping machines (DX68, DF68, HP51)

• Nationwide delivery to workshops and factories

• Technical support & training

• Spare parts always in stock

• Highly competitive pricing

• In-house technicians for troubleshooting & repairs

Whether you are running a high-volume hose shop or maintaining heavy equipment, GZ has the products and expertise to keep your operations running smoothly.

Related Article

Top 10 Mistakes to Avoid When Operating a Crimping Machine

Conclusion

Crimping machines are powerful and precise tools, but like all mechanical systems, they require proper care and timely troubleshooting. By understanding the common problems and their solutions, you can protect your equipment, improve crimp quality, and avoid downtime.

For spare parts, technical support, or to purchase a new Kaida crimping machine, GZ Industrial Supplies is your trusted partner.