Fitting Instructions Fallshaw HOME
Castors will not roll easily if they are not big enough for the load and floor conditions, Castors 75mm (3") should only be used on light weight, seldom used equipment. Even diameters of 100mm (4") are only useful on smooth floors. Any trolley wheeled quickly, or on uneven floors, needs 125mm (5") or larger. The heavier the load, the larger the wheel.
Hard treads roll most easily on smooth floors, but may damage them, and are also hard to roll over obstructions.
Most people can exert 17kg of push to get a trolley rolling, and about 12kg to keep it moving. This reduces to 6kg over long distances. This is the reason that ball bearings are more popular than plain bearings, as they allow more load for the same push effort.
Castors will not swivel properly unless they are mounted vertically. Otherwise they will track to one side.

SOME RECOMMENDATIONS
• Heavy trolleys need plate mountings, but the base of the trolley must be strong enough to withstand strains. Never mount a plate castor by 3 bolts only. Never skimp on the mounting base.
Remember - if the castor does not stay mounted squarely, it will not swivel freely.
• Medium duty castors ("K", "M", "Q" or "D" series) are often mounted into tubular legs, but again it is important that these legs stay vertical. We recommend that the leg never extend more than 125mm (5") below the nearest support, and (apart from the lightest uses), the tube should be 1.4mm (1.7G) thick or more. Thinner gauges often split. If you wish to use lighter gauge in the rest of the trolley, insert a sleeve for at least 150mm (6") where the castor is mounted. Never put a round expanding fitting into a square tube. The first time a trolley hits a bump, the tube will elongate, and the castor will fall out. We do have square fittings, and ask that you do use them. If for some reason you need to put round into square, then weld an insert sleeve of round tube (remember - our smallest fitting needs 3/4"ID). When using Directional Lock (DL type castors) it is best to use the solid swivel stem (A type) and weld or bolt it in - screwed types can become misaligned. To achieve the best performance from the larger 175mm and 200mm castors, use solid stems. If rigid and swivel castors are to used together, have the rigid castors at the front, making it easier for it to turn.

When fitting expanding stem castors, make sure the adaptor is fully inserted into the tube before tightening the stem up. Remove the burr on the tube before you try to push the adaptor into the tube. Make sure the weld on the inside of the tube is not excessive, and, if necessary, align it with one of the slots down the inside of the stem fittings. Put the adaptor into the tube ALL THE WAY, then put some sideways pressure on to it to help the fittings grip, then tighten the stem nut firmly, tight, but NOT over tight, or you will make it hard to remove it later.

Never try to get the unevenness out of a warped trolley by half inserting fittings. You can get up to 8mm of adjustment with washers, or an offcut of tube tightly jammed between leg and castor - but do not let it float. Tighten tubular fittings firmly, but do not over tighten.

You should re-tighten castors after 3 months of use, and annually after that. We recommend "3 finger" tightness, i.e. the amount of torque you can get onto a standard spanner using your 3 middle fingers. (Ask for our separate detailed "Fitting Instruction" sheet.)

Tube Fittings to Suit K, M, Q & D
Tubing Size Add after E in Model No
e.g. DNN75/DZE-ES19		 Theoretical Inside Diameter
when wall thickness (gauge)		 Colour Range
of use
Actual
outside
diam.		 Nominal
inside
diam.
Round Square 1.6
(16G)		 1.4
(17G)		 1.2
(18G)		 0.9
(20G)
22.2 (7/8") 19 -ER19 -ES19 19.0 19.4 19.8
round only		 20.4
round only		 White 18.5
- 21.0
25.4 (1") 22 -ER22 -ES22 22.2 22.6 23.0
round only

Not
recommended

 Grey 21.5
- 24.0
31.8 (1 1/4") 28 -ER28 -ES28 28.6 29.0 Not
recommended		 Not
recommended		 Black 25.0
- 30.0
For more info on Expanding Adaptors see also "Expanding Adaptors and the Price List" or "Installing Expanding Adaptors".