Castle nut should only be finger tight.
When I put the hub and bearings back on the spindle after servicing them, I tighten the castle nut down snug with a wrench, then back it off to finger loose, then tighten it back with my fingers. If it is too tight, the hub will get hot, which is not good at all.
As for repacking, once a year is pretty conservative. Usually every two years or even more is adequate if you're maintaining good grease in there or have bearing buddies. I highly recommend bearing buddies, because they allow you to maintain a check on the seals and grease level with just a quick glance. If something if failing, the bearing buddies will let you know.
You should be able to place the back of your hand on the hubs and be able to leave it there as long as you want.




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