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» How to Safely Operate Crimping Machines

The RYCO Crimper Series are compact and efficient swaging machines, equally suitable for repair shop applications and high-volume production of hose assemblies.

The RYCO Safety Zone provides an increased margin of operational safety when using RYCO matched hose and fittings. That’s why this article aims to inform you on the safe use of crimping machines.

Safety Zones

RYCO crimping machines present very minimal risk to operators. As with any machine, there is a potential of risk to an operator if due care is not shown.

To minimise the chances of injury, Safety Zones must be identified and implemented around the crimp dies. The Safety Zones incorporate two areas, an Exclusion Zone, and a Caution Zone.

RYCO Crimper Machines Safety Zone

The Exclusion Zones, (the red shaded areas), represent areas where there is a direct risk of a crushing injury to the operator. Hands, tools and other items must be kept well clear of these areas during operation of the crimping machine. Regardless of the crimping machine make, type or design, body parts or foreign objects MUST not contact the crimping dies or master dies.

The Caution Zone, (the yellow shaded area), represents an area where there is minimal potential of injury to the operator. However, a potential for injury is considered to exist due to the close proximity of this area to the Exclusion Zone. For this reason, it is recommended that hands are kept clear of the Caution Zone whenever possible. Operators hands may enter the Caution Zone once the risk of injury to the operator has been minimised.

Safe Operation

The majority of these machines incorporate a slow die movement with semi-automatic operation. Semi-automatic operation means that the dies will stop moving when the operator releases the “Die Close” button. This means that the operator is in complete control of the die movement.

The machine movement is considered to be controlled. Therefore, an operator may position his or her hand within the Caution Zone during operation, but only when:

  1. Total machine controllability has been established.
  2. The operator is fully alert and is not distracted in any way.
  3. The person positioning the assembly within the dies is the only person in control of the machine.
  4. The position of the operator’s hands are always fully visible to the operator.
Crimping Methods

Couplings MUST be crimped over the whole length of the ferrule including the nose crimp where the ferrule Is attached to the insert.

  1. Rear Insertion Method

Due to the necessity of correctly positioning the ferrule collar within the crimping dies, and the obvious importance of operator safety, one recommended method is inserting the hose from the rear of the machine.

This practice allows the position of the coupling ferrule nose crimp to be more easily viewed, whilst keeping the operator’s hands at a safe distance. The supporting hand must be outside of the Exclusion Zone at all times, and should be visible to the operator whenever practical.

RYCO Rear Insertion Crimping Method

  1. Front Insertion Method

A second assembly method is one where the hose is inserted from the front of the machine. This method ensures the safe placement of hands during the crimping operation, thereby reducing the risk of the operator placing his or her hands within the rear exclusion zone.

RYCO Front Insertion Crimping Method


Extra care must be exercised when crimping with this method, as it can be more difficult to verify that the coupling is correctly positioned within the dies.

In some cases, straight end style couplings with small ends will allow the coupling to be safely crimped without an accurate prior positioning of the coupling within the crimp dies. In such cases, the ferrule can be crimped anywhere within the length of the dies, as long as the full ferrule is crimped in one operation.

RYCO Large Small End Styles

In these cases where the dimensions of the coupling end style negate the need for accurate coupling positioning within the crimping dies, the front insertion method is the preferred method.

Safety Warnings

Be aware of the published warnings stated explicitly on the crimping machine, in the corresponding crimping machine operating manual.

RYCO Crimper Machines Safety Warning

Maintenance & Calibration

Crimpers must be regularly inspected and maintained to ensure safe and effective operation. Any electrical works or repairs like changing seals or the pump must only be carried out by a qualified specialist.

Crimpers must also be regularly calibrated to ensure accurate and effective crimps. If the machine shows signs of erratic operation or unexpected movement, remove the machine from service immediately and consult the RYCO Technical support department.

Want more information?

If you would like to know more about operating your crimper, contact our RYCO Hydraulics Customer Service team or fill out our contact form.