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Caster Failure Diagnosis Tool (Root Cause + Fixes)

Free engineer-led diagnosis

Caster Failure Diagnosis Tool.

Wheel cracked? Bearing seized? Kingpin sheared? Brake won’t hold? Send us photos + spec, and an application engineer diagnoses root cause and recommends a replacement that won’t fail again.

Common Failure Modes

What Failed?

If your symptom matches one below, the root cause and replacement spec is usually predictable. Submit your situation and we’ll confirm.

#1 cause: heavy impact

Kingpin Sheared

Caster yoke separated from mounting plate; central bolt sheared. Common after dock-plate or threshold impacts at speed.

→ Upgrade to kingpinless construction
#2 cause: wrong material

Wheel Cracked / Chunked

Hard nylon or polyurethane wheel split or pieces broken off. Often from cold temperature + hard floor + impact load.

→ Spec correct durometer + temperature range
#3 cause: lubrication

Bearing Seized

Wheel won’t spin freely. Bearings dry, contaminated, or worn. Common in high-cycle applications without re-lube schedule.

→ Sealed bearings + lubrication schedule
#4 cause: floor friction

Brake Won’t Hold

Side-lock or total-lock brake slips under load. Usually friction-grip mismatch with floor surface or load exceeds brake spec.

→ Upgrade to total-lock or friction-rated brake
#5 cause: undersized

Plate Bolt Holes Cracked

Plate metal cracked at bolt holes from cyclic loading. Plate too small for actual load, or hardware grade too low.

→ Larger plate + Grade 8 hardware
#6 cause: chemical exposure

Wheel Material Degraded

Polyurethane swollen or soft from oil/solvent exposure. Rubber cracked from UV. Iron core rusted from caustic cleaner.

→ Match material to chemical environment

What to Send for Diagnosis

More info = faster, more accurate diagnosis. Anything you don’t have, leave blank — engineer will follow up.

📷 Photos of failed casterTop, side, close-up of failure point. Wheel, axle, yoke, plate — all angles helpful.
🏷️ Original SKU or part numberIf known. Stamped on plate or available from purchase records.
⚖️ Cart weight + load per casterTotal cart weight (loaded) + estimated load per caster.
🏭 Application + environmentWhat’s the cart used for? Floor type, temperature, chemical exposure, push speed?
⏱️ Service life before failureHow long was the caster in service? Days, months, years.
🔢 Quantity needed for replacementHow many casters need replacing? One unit or fleet-wide?

Submit Failure for Diagnosis

Engineer review within 4 business hours. We’ll diagnose root cause and recommend replacement spec.

📷 To send photos: Submit this form first, then reply to our confirmation email with attached photos. Top view, side view, and close-up of the failure point all help.

Where to Send the Diagnosis

Engineer diagnosis within 4 business hours
Free · root-cause analysis · replacement spec recommendation

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