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Industrial casters are essential components for industrial production, warehousing and logistics, medical equipment, commercial carts, and other fields. Their installation quality and maintenance directly impact the stability and safety of equipment operation. Whether lightweight or heavy-duty, from initial installation to long-term use, scientific methods and regular maintenance are crucial for extending their lifespan and reducing operating costs.
As a professional caster supplier, Giessen Casters has accumulated extensive practical experience in industrial caster installation and maintenance through long-term customer service. This article provides a comprehensive analysis of installation preparation, installation steps, maintenance methods, common problems and solutions, and tips for extending service life, ensuring stable and reliable casters for your equipment.
For wholesale or purchase requests, please contact Giessencasters@gmail.com or visit our official website at https://www.giessencasters.com.
Before installing casters, you must first determine the equipment's intended use, load requirements, and operating environment. These factors will directly influence the choice of caster model, size, and material.
Load requirement: Calculate the weight a single caster must support (total weight divided by the number of casters multiplied by the safety factor).
Operating environment: Environments with high humidity, chemical corrosion, or uneven surfaces require casters made of corrosion-resistant and wear-resistant materials.
Mobility: Whether the caster will rotate in a single or multiple directions determines whether a swivel or fixed caster is appropriate.
Recommendation: In most industrial applications, a load margin of at least 20% should be maintained to accommodate unexpected overloads.
Efficient installation requires a complete set of tools and accessories. We recommend preparing the following items in advance:
Wrench, screwdriver, electric drill
Fixing bolts, nuts, washers
Caster mounting plate or flange
Level, ruler
There are three common mounting methods for industrial casters:
Bolt-on: Suitable for flat equipment bases, provides secure installation and easy replacement.
Stem-mount: Suitable for lightweight equipment, featuring a simple structure.
Welded: Suitable for heavy equipment and harsh working conditions, offering enhanced stability but difficult replacement.
| Installation Method | Applicable Scenarios | Advantages | Disadvantages |
| Bolt-on Type | Most industrial equipment | Easy to install and replace | Drilling required, base plate requires sufficient thickness |
| Pole-on Type | Lightweight carts, display stands | Easy to install | Lower load-bearing capacity |
| Welded Type | Heavy machinery, permanently fixed industrial equipment | High strength, less prone to loosening | Inconvenient for replacement and repair |
Use a ruler and level to confirm the mounting hole locations, ensuring that each caster is evenly spaced from the bottom edge of the equipment to prevent tilting.
When marking the drill hole locations, consider the caster's rotation radius to avoid interference with other equipment components.
Drilling: Drill holes according to the caster base plate diameter, with the hole diameter slightly larger than the bolt diameter by 0.5-1mm.
Placing Shims: Place shims between the bolts and the base plate to prevent loosening due to uneven load.
Tightening the Bolts: Tighten evenly in a cross-section to avoid overtightening on one side, which may cause the caster to tilt.
Ensure all casters are level. Otherwise, some casters may become suspended, increasing local loads.
Check the caster's rotational flexibility to ensure there is no binding.
Anti-loosening treatment: Use anti-loosening nuts or apply threadlocker on the bolts.
Lubrication: During installation, you can perform preliminary lubrication on the bearings to reduce initial wear.
Directional Setting: For fixed casters, ensure they are installed in the same direction to ensure stable straight movement.
Regularly clean dust and oil from the caster surface, especially the bearing area.
In humid or chemically corrosive environments, choose stainless steel or polyurethane casters and perform regular rust prevention treatment.
Industrial casters experience friction and wear on bearings and rotating parts during long-term operation. Regular lubrication can extend their lifespan.
It is recommended to grease the bearings every 2-3 months.
In high-frequency operation, the lubrication interval should be shortened to 1 month.
| Inspection Location | Possible Problems | Suggested Solutions |
| Wheel Tread | Cracks, Chipped Blocks | Replace Immediately |
| Bearings | Stiff Rotation, Noise | Clean or Replace Bearings |
| Mounting Parts | Loose Bolts, Cracked Welds | Tighten or Reweld |
| Steering Mechanism | Sticking, Limited Rotation Angle | Lubricate or Replace Steering Components |
Cause: Bearing Lacks Lubrication or Obstruction
Solution: Remove Obstructions and Add Lubricant
Cause: Worn or Loose Bearing
Solution: Replace Bearings or Tighten Bolts
Cause: Uneven Floor or Overload
Solution: Replace Casters Made of Highly Wear-Resistant Material and Control Load
Appropriate Load Distribution: Avoid Excessive Load on a Single Caster
Control Operating Speed: High Speeds Increase Wear
Regular Maintenance: Develop an annual maintenance plan to promptly identify potential problems.
Although industrial casters are small components in equipment, the quality of their installation and maintenance determines the overall equipment's mobility and service life. Through scientific installation methods, regular maintenance, and access to high-quality caster suppliers, you can significantly reduce equipment failure rates and repair costs.
If you need to purchase or wholesale high-quality industrial casters, please contact Giessen Caster Supplier at Giessencasters@gmail.com or visit their official website at https://www.giessencasters.com for more information and technical support.
