'CoRifleman' - I was not saying anything was defective.

Things are built to different tolerances: Reloading Dies, cartridge brass, rifle chambers, and rifle bolts.

Rifles are subject to differences in the amount of use and wear they receive.

The manufacturer standards for .30-40 Dies were established about 30 years after Springfield Armory built its last Krag!

I imagine there are differences in the dimensions used by each Die Manufacturer.
There will be differences in each set of .30-40 Dies made by the same manufacturer.

A rifle cartridge Die Maker has to make a product to accommodate chambers made by Springfield Armory, Remington, Winchester, Harry Pope, and Ruger.

A cartridge manufacturer has to size their brass to chamber in just about any .30-40 chamber ever made.

Brass gets "work hardened" and more brittle with being reformed and with age. Annealing the case-neck and shoulder restores 'pliability'.

FWIW - If you have a Die that is toward the maximum in dimensions and a rifle chamber/bolt combination that is at the minimum of dimensions, you may have a problem with reformed brass, (that was fired in a different gun with a more 'liberal' chamber), fitting the tighter or shorter chamber.
Trying a different set of Dies or a slightly different dimensioned Bolt may correct the 'clash of tolerances'.

There were minor changes made by Springfield Armory to the dimensions of U.S. Krag chambers in 1899. There was a change of .002 or .003 inches in head diameter and length from breech-face to shoulder. (Information attached).

Currently, I only have to separate brass for one of my Krags, a model 1896 rifle with a chamber that allows more expansion of the cartridge-case body.

My other Krags get fed reloads that are partially 'neck-sized' with a LEE - Collet Die for 7.5X55mm Swiss, no lube necessary. Once in a while, I may close the Bolt on a reloaded round with slight resistance, but, no problem.

I'm lazy and it ain't rapid-fire at Camp Perry!

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