Applicable to: Pallet trucks for use in factory workshops, warehouses, and similar environments. / Forklift / Industrial-duty cart, suitable for common flat-type casters (including models with brakes).

I. Pre-installation Preparation (First confirm) “ Match ” Take action again!

Although installing casters may seem straightforward, whether they operate smoothly and last long hinges on whether the mounting hole positions, fastener specifications, and chassis strength are properly matched. We recommend completing the following checks before installation:

• Hole spacing / Hole diameter: Confirm that the hole spacing on the turnover cart chassis matches the hole spacing on the caster mounting plate; the hole diameter should be compatible with the bolt specifications (commonly used). M8/M10/M12 ).
• Mounting surface flatness: The chassis mounting surface must be flat and free of deformation to prevent uneven loading on the casters, which could lead to uneven wear, loosening, or unusual noises.
• Caster selection verification: The wheel diameter, wheel width, and installation height must match the equipment’s ground clearance. A safety margin should be reserved for the load capacity (it is recommended to evaluate based on dynamic operating conditions).
• Fastener Preparation: Bolts, nuts, washers (flat washers) / Lock washers or lock nuts—prepare threadlocker if necessary.
• Tool: Socket wrench / Open-end wrench, torque wrench (recommended), marker, steel ruler.

II. Standard Installation Steps (Flat-Mounting Plate with Casters)

The following steps apply to most swivel caster wheels on pallet trucks. It is recommended that two people work together: one person positions the wheel, and the other person tightens it securely.

1. Positioning: Align the caster bracket mounting plate with the chassis holes, and confirm that the wheels’ rotation does not interfere with the steering direction (for swivel casters, ensure that the swivel plate can rotate freely). 360° Free spin.
2. Insert the bolt from the chassis or caster side, then add a flat washer (and an elastic washer if necessary), ensuring that the bolt fits snugly into the hole without any misalignment.
3. Diagonal Pre-tightening: First, hand-tighten the nuts, then pre-tighten them in two to three stages following a diagonal sequence to prevent the mounting plate from becoming skewed under stress.
4. Torque tightening: Use a torque wrench to gradually apply force diagonally until the specified torque is reached. (Even when a torque wrench is unavailable, apply even pressure to avoid... ) “ Only tighten one side. ” ).
5. Re-inspection: Check whether the caster mounting plate is fully aligned with the chassis; push the vehicle body to see if it drifts, shakes, or makes unusual noises.
6. Brake Test (for models equipped with brakes): Test separately whether the brake pedal’s braking and releasing actions are smooth and flexible. After locking, the equipment should be able to come to a stable stop.

III. Key Points and Frequently Asked Questions (Avoiding Rework)

• Inconsistent hole positions: Do not forcibly enlarge the holes or apply excessive force when tightening. First, verify the specifications of the caster mounting plate or replace it with a matching caster. If hole modification is absolutely necessary, ensure that the modified holes maintain both strength and symmetry.
• Looseness after installation: First check whether any washers are missing. / Anti-loosening measures: It is recommended to use spring washers or nylon lock nuts, and apply threadlocker if necessary.
• The vehicle body is drifting. / Unable to move: Check whether the four casters are of the same model and have the same wheel diameter; verify that the combination of fixed wheels and swivel wheels is appropriate; and confirm whether the chassis is deformed.
• Unusual noises or stiff steering: These are often caused by uneven tightening, uneven mounting surfaces, or contaminated bearings. First, re-tighten and clean the components; if necessary, replace the bearing or casters.
• Brake reliability: Ensure that the brake pads are properly seated against the wheel surface. The brake controls should be easy for personnel to operate and should be positioned to avoid accidental activation from being bumped by cargo.

IV. Usage and Maintenance Recommendations (To Extend the Lifespan of Casters)

Casters are high-frequency consumable parts; proper maintenance can significantly reduce the failure rate. Recommendation:

• Regular tightening inspection: After new installation 1-2 Tighten once per week, then inspect and tighten the fastening condition monthly or according to the intensity of use.
• Observe wheel surface wear: If the wheel surface shows uneven wear, cracks, or chipped areas, replace it promptly to avoid damaging the floor or causing impact on the bearings.
• Clean away entangled materials and foreign objects: String, film, and debris can easily get lodged in the wheel axle area, increasing resistance. It is recommended to clean high-frequency equipment once a week.
• Use according to operating conditions: Avoid overloading, sudden lateral pushes, and forcefully driving over steps. For equipment that needs to cross thresholds, it is recommended to select wheels with larger diameters or wheel surface materials that are more suitable.
• Humid / Corrosive Environment: Prioritize waterproof and dustproof bearings with corrosion-resistant brackets, and regularly check for rust or jamming.

V. Conclusion

Proper installation of industrial casters not only enhances the efficiency of material handling and transportation but also reduces equipment wear and minimizes safety risks. When purchasing or replacing casters, it is recommended to select the appropriate model based on factors such as load capacity, floor conditions, environmental factors, and frequency of use. Furthermore, follow standard procedures for installation and maintenance to ensure that your material-handling operations are smoother, more stable, and hassle-free.