Correct installation and routine maintenance are critical to ensure your castors swivel freely, handle heavy loads safely, and deliver long-lasting performance. Whether you are outfitting industrial trolleys or upgrading machinery, follow this comprehensive guide to install, inspect, and maintain your castors correctly.

Plate-Mounted Castor Installation

Heavy-duty trolleys and machinery generally require industrial plate mounted castors. Always ensure the base of your trolley or equipment is structurally rated to withstand your intended maximum load.

• Mount vertically: Castors must be mounted strictly vertically. Off-angle mounting causes tracking issues and prevents smooth swiveling.
• Use all bolt holes: Never secure a plate castor with fewer bolts than provided (e.g., using only three bolts instead of four). Fasten every hole securely.
• Leveling adjustments: Up to 8 mm of adjustment can be achieved using washers or a tightly fitted tube sleeve between the leg and castor. Ensure the adjustment component cannot float or move.
• Fastening torque: Tighten fittings firmly, but avoid over-tightening which can deform the base plate.

Checking Castor Fittings

Inspect castor fittings after the first 3 months of operation and annually thereafter. Ensure all hardware remains secure.

Pro Tip: As a general guide, target "3-finger tightness" — the amount of torque you can apply to a standard spanner using your three middle fingers. Always defer to manufacturer torque specifications when available.

Tube Fittings & Tubular Legs

Medium-duty castors are commonly fitted into tubular trolley legs. Keeping the legs vertical is vital for proper swivel alignment.

• Extension limits: The trolley leg should not extend more than 125 mm below the nearest structural support point.
• Wall thickness: Except for light-duty applications, use tubing with a wall thickness of at least 1.4 mm. Thinner tubing risks splitting under heavy load.
• Reinforcement: If using lighter-gauge tubing elsewhere, insert a sleeve extending at least 150 mm at the castor mounting point for extra support.

Round vs. Square Tube Adaptors

Never force a round expanding adaptor into a square tube. Impact from bumps will deform square tubing, causing the castor to loosen or fall out entirely.

Always select the exact castor fitting designed for your tube profile. If installing a round fitting into square tubing is unavoidable, weld a round-tube sleeve inside the square tube first (minimum 3/4 inch internal diameter required).

Stem Options & Directional Locks

When installing Directional Lock (DL) castors or larger 175 mm and 200 mm castors, use a solid swivel stem (welded or bolted) rather than screwed fittings, which can work loose or become misaligned over time.

Step-by-Step: Fitting Expanding Stem Castors

1. Ensure the tube sits firmly down onto the castor head rivet.
2. Inspect the tube interior and clear any burrs that could obstruct full insertion.
3. Check for internal weld seams and align them with the slots on the adaptor fitting.
4. Insert the fitting completely into the tube.
5. Apply sideways pressure to help the fitting grip the tube's interior wall.
6. Tighten the stem bolt firmly without over-tightening, ensuring future removal remains possible.

How to Grease and Lubricate Castors

Regular lubrication extends castor life, reduces operational noise, and prevents rusting and galling in the raceways. A liberal smear of grease is sufficient — excess grease attracts dirt and grit.

Lubrication Steps for Fleet Maintenance

1. Preparation: Invert the trolley and remove the wheels.
2. Swivel Head: Apply grease via the grease nipple or a needle-tip grease gun. For heavy-duty units with seals, carefully lift the seal edge with a fine screwdriver. Apply two full squirts, ensuring grease penetrates the center and reaches the lower race.
3. Bearings & Axle: Inspect the axle bushing for wear and replace if necessary. Work approximately 1 teaspoon of No. 2 non-sodium bearing grease into the roller bearings before reassembling.
4. Reassembly: Clean the axle bushing, protect the lip seal during reinsertion, re-fit the wheel, and apply a small drop of threadlocker (e.g., Loctite) to the axle thread for added safety.

Castor Maintenance Summary

Routine checks on mounting bolts, tube fittings, wheel bearings, and swivel heads will maximize the lifespan of your hardware. Explore our complete range of heavy-duty castors and standard castors to find the ideal load capacity, mounting style, and wheel material for your shop floor.

Need help selecting the right replacement fitting or wheel size? Contact the SWC technical team in Auckland for expert guidance.