Using the Wrong Die Set

This is the most common mistake operators make. Each hose and fitting combination requires a specific die size, and using the wrong die leads to:

• Under-crimping → weak joints that leak under pressure

• Over-crimping → fittings damaged or cracked

• Slippage or hose pull-out during operation

Why it happens:
Many operators try to “match by eye” instead of checking the crimp chart.

Correct approach:

• Always use the die set recommended for the exact hose model and fitting brand.

• Verify using the manufacturer’s crimp chart or GZ Industrial Supplies technical guide.

Hydraulic Hose crimping machine YMC 102

Incorrect Hose and Fitting Selection

A high-quality crimp can only be achieved when the hose, fitting, and die are fully compatible. Mixing different brands, pressure ratings, or hose types often leads to:

• Mismatched crimp diameters

• Weak or uneven crimping

• Structural failure under pressure

Examples of bad pairing:

• Using a 2-wire hose with a fitting designed for 4-wire

• Using fittings from a different manufacturer

• Choosing hoses not rated for the application environment

Skipping Proper Hose Measurement and Marking

Every hose assembly must be measured accurately before crimping. Cutting too long or too short affects the final system layout and may compromise performance.

Critical step many skip:
Marking insertion depth — the exact point where the fitting must seat inside the hose.

If insertion depth is not marked:

• The fitting may not sit deep enough → causing blowouts.

• The hose may twist during crimping → weakening the connection.

Correct approach:

• Measure with a calibrated hose measuring tool.

• Mark insertion depth clearly before placing into the crimp head.

Poor Hose Preparation

A clean, properly prepared hose ensures a perfect crimp. Poor preparation includes:

• Leaving debris, rubber particles, or wire ends inside the hose

• Not cleaning after cutting

• Using a dull cutting blade

• Not lubricating the fitting insert when required

Consequences:

• Contamination enters the hydraulic system

• Hose reinforcement is damaged

• Crimp does not seat uniformly

At GZ, we advise operators to use professional hose cutting saws and compressed air cleaning before assembly.

Hydraulic Hose crimping machine PM16

Incorrect Crimp Diameter

Even with the correct die, operators may produce a wrong crimp diameter if they fail to measure the final crimp.

A wrong crimp diameter leads to:

• Leaks during pressure spikes

• Hose ends pulling out

• Over-compressed hose reinforcement

Correct approach:

• Use a crimp OD caliper to measure the final diameter

• Compare with the manufacturer’s specified tolerance

• Never rely on visual inspection alone

GZ Industrial Supplies provides calibrated measuring tools to help technicians verify each crimp.

Ignoring Machine Calibration

A crimping machine must be calibrated regularly to maintain accuracy. When calibration is off—even slightly—the machine produces crimps that are outside specification.

Consequences of poor calibration:

• Every crimp becomes inconsistent

• Crimp diameters drift over time

• High risk of batch failures during pressure testing

Why calibration drifts:

• Natural wear of crimping dies

• Hydraulic pressure variation

• Long-term usage without servicing

Correct approach:

• Follow the manufacturer’s calibration schedule

• Perform semi-annual calibration checks

• Replace worn dies and damaged crimp heads

• Request GZ Industrial Supplies calibration support services when needed

A well-calibrated machine ensures consistent results across hundreds of hose assemblies.

Operating the Machine at the Wrong Pressure

Each crimping machine is designed to operate at a specific hydraulic pressure, ensuring uniform compression. Running at low or excessive pressure leads to poor crimp integrity.

If pressure is too low:

• Crimp does not tighten fully

• Fittings may slip off

• Hose fails during high-pressure operation

If pressure is too high:

• Over-crimping damages fittings

• Reinforcement wires crush and break

• Increased risk of hose bursting

Correct approach:

• Always verify machine pressure before starting a job

• Inspect the hydraulic pump and fluid level

• Replace seals or pressure regulators showing wear

GZ Industrial Supplies offers hydraulic pressure gauges, pumps, and service kits to maintain optimal machine performance.

Hydraulic Hose Crimping Machine 220V DX68 KAIDA

Poor Alignment of Hose and Fitting

Even if the correct die and pressure are used, misalignment during crimping leads to a defective assembly.

Symptoms of misalignment:

• Crimp marks are uneven

• One side of the fitting compresses more than the other

• Hose becomes twisted or stressed

Results of misalignment:

• Premature failure under pressure

• Reduced burst rating

• Fitting fatigue and cracking

Correct approach:

• Ensure hose and fitting sit straight in the crimp head

• Use alignment guides when available

• Do not force a bent hose into the machine

Proper alignment ensures that compression is even throughout the fitting circumference.

Not Inspecting the Finished Crimp

A crimp is not complete until it is inspected. Skipping inspection is a major cause of field failures.

What operators should inspect:

• Crimp OD measurement using a precision caliper

• Smooth and even crimp pattern

• No cracks, pinching, or bulging

• Proper insertion depth visible after crimp

• No exposed reinforcement wires

For high-pressure hydraulic systems, using a Go/No-Go gauge is strongly recommended.

Correct approach:

• Document crimp diameter for quality control

• Inspect every batch before sending hoses to the field

• Reject any hose assembly that fails visual or dimensional checks

GZ Industrial Supplies offers quality inspection kits for hose assembly workshops.

Ignoring Machine Maintenance

Lack of maintenance is one of the main reasons crimping machines lose accuracy or fail completely.

Common maintenance issues:

• Dirty dies that accumulate metal and rubber debris

• Worn hydraulic seals

• Low hydraulic oil levels

• Unlubricated machine components

• Loose bolts and alignment pins

Consequences of poor maintenance:

• Inconsistent crimps

• Machine overheating

• Expensive long-term repairs

• Safety risks for operators

Correct approach:

• Clean dies after every batch

• Lubricate moving parts weekly

• Replace hydraulic oil as recommended

• Check calibration and pressure settings regularly

GZ Industrial Supplies provides maintenance consumables, replacement parts, and technical service for crimping machines of all sizes.

Additional Common Mistakes (Often Overlooked by Operators)

While the top 10 mistakes are the most frequent, several additional errors also compromise the quality and safety of crimped assemblies:

Skipping Operator Training

Even experienced technicians benefit from periodic training. New crimping machines, die sets, and hose technologies require updated knowledge.
GZ Industrial Supplies offers operator orientation and technical support upon request.

Using Counterfeit or Low-Quality Fittings

Cheap fittings may not match standard crimp charts, resulting in dangerous failures.
Always source original fittings and hoses from reputable suppliers.

Operating in Dirty Work Environments

Dust, metal shavings, and oil contamination can enter the hose or damage the machine.
A clean workspace = safer, stronger crimps.

Relying on “Experience” Instead of Specifications

Visual judgment is not a substitute for:

• Crimp charts

• Calipers

• Machine calibration

• Proper die selection

Precision, not assumption, prevents system failures.

Hydraulic Hose Crimping Machine 800W DF68 KAIDA

Best Practices for Safe and Effective Crimping

To ensure reliability and maximize hose lifespan, follow these industry best practices:

Follow Manufacturer Crimp Charts

Each hose brand and fitting model has specific crimp dimensions. Never guess.

Use Only Compatible Hose–Fitting Systems

Mixing brands increases the chance of incorrect seating and diameter mismatch.

Keep the Crimping Machine Clean and Calibrated

Dirt affects die movement, while calibration affects uniformity.

Document and Inspect Every Crimp

For quality control, especially in oil & gas, construction, or manufacturing sectors.

Maintain a Proper Workspace

Good lighting, clean floors, and organized dies reduce operational errors.

Train New Operators Regularly

Even minor mistakes can lead to major safety issues in high-pressure systems.

Essential Tools and Accessories Every Crimping Operator Should Use

GZ Industrial Supplies stocks all required accessories and replacement parts for professional crimping operations.

Why Choose GZ Industrial Supplies for Your Crimping Machines & Tools?

GZ Industrial Supplies is one of the largest distributors of industrial tools, hydraulic hose fittings, and crimping equipment in Nigeria. Customers trust us because:

Wide Range of Crimping Machines

Hydraulic, electric, workshop, and portable crimpers for all applications.

Certified, High-Quality Hoses and Fittings

Compatible with major brands and compliant with global standards.

Technical Expertise and Support

Our team provides installation guidance, calibration support, and operator training.

Nationwide Delivery

Fast, reliable supply to Lagos, Port Harcourt, Abuja, Kano, and all major cities.

Competitive Pricing

Affordable for workshops, factories, and industrial plants.

Genuine Replacement Parts

Dies, hose fittings, ferrules, hydraulic pumps, and maintenance kits.

Whether you're a workshop technician, maintenance engineer, or procurement manager, GZ Industrial Supplies ensures you get the right equipment, the right tools, and the right support.

Related Article

Hydraulic Hose Crimping Machines: Types, Applications, and Best Practices

Conclusion

Crimping machines are powerful and essential tools across hydraulic, industrial, and electrical applications. But to achieve safe, reliable, and long-lasting results, operators must avoid the common mistakes outlined in this guide. Proper die selection, hose preparation, machine calibration, accurate measurement, and consistent inspection make all the difference.

By following these best practices and partnering with a trusted supplier like GZ Industrial Supplies technicians can significantly reduce equipment downtime, prevent leaks and blowouts, and ensure high-performance hose assemblies.

Looking for crimping machines, dies, hoses, fittings, or technical support?

Call: +234 8053390129

Email: sales@gz-supplies.com

Shop Online: https://www.gz-supplies.com/