Overhead Crane Breakdown Response Perth – Diagnosing and Repairing a Long Travel Motor Failure
Matt Weight
7/6/20263 min read
When an Overhead Crane Starts Making Noise, Don't Ignore It
One of the most common calls we receive is:
"Our overhead crane has started making a noise when travelling."
Sometimes it is only a bearing beginning to wear.
Other times it is the first sign of a much larger failure that could stop production completely.
Recently our team attended a 10-tonne STAHL overhead travelling crane in Perth after the customer reported abnormal noise and tracking issues during long travel operation.
The crane had also recently undergone a comprehensive 10-year major inspection, giving us an excellent understanding of its overall condition before carrying out the breakdown repair.
Initial Breakdown Investigation
Our technicians attended site to investigate the reported long travel fault.
The symptoms included:
Excessive noise during long travel
Rough travel movement
Concurring tracking concerns
Evidence that further investigation was required before continued operation
Rather than simply replacing parts, the long travel motors were removed and transported to our Perth workshop where they could be completely dismantled and inspected.
This approach allows us to accurately identify the root cause rather than treating the symptoms.
What We Found
Once dismantled, the cause became immediately apparent.
One of the long travel motors had suffered catastrophic bearing failure.
Inspection revealed:
Bearing rollers had broken apart
The bearing race had been destroyed
Internal contamination was present
Bearing lubrication had failed
The second motor was also dismantled.
Although it had not yet failed, its bearings already showed wear and the stator exhibited similar age-related deterioration.
This allowed both motors to be rebuilt before another failure occurred.
The Root Cause Was More Than Just a Bearing
The investigation uncovered something more important than simply replacing a damaged bearing.
The seal between the electric motor and the brake assembly was missing.
Without this seal, fine brake dust had been able to migrate into the bearing cavity.
Brake dust acts as an abrasive contaminant.
Over time it mixes with lubricant, reducing its effectiveness and dramatically accelerating bearing wear until eventual failure occurs.
Finding the underlying cause is one of the most important parts of any crane breakdown investigation.
Simply replacing the bearing without addressing the missing seal would likely have resulted in another failure.
The Repair
Following inspection, both travel motors were rebuilt.
The repair included:
Complete motor disassembly
Inspection of stators and windings
Replacement of damaged bearings
Installation of new seals
Reassembly and testing
Reinstallation onto the crane
Functional testing in both travel directions
Following repair, the crane travelled smoothly and all long travel functions operated correctly before being returned to service.
Earlier Major Inspection Helped Build the Bigger Picture
Only weeks earlier, SLA Cranes had completed a comprehensive 10-year major inspection on the same crane.
As part of this inspection, our technicians assessed every major mechanical, structural and electrical component.
Items identified included:
Worn wire rope guide
Hoist brake wear
Cross travel brake wear
Wheel wear requiring monitoring
Perished long travel buffers
Minor gearbox oil leakage
General age-related wear expected from a 2005 crane
The crane remained suitable for continued service with monitoring and planned rectification works recommended.
This demonstrates the value of major inspections.
Not every future failure can be predicted, but documenting equipment condition allows maintenance to be prioritised and provides an excellent baseline should an unexpected breakdown occur.
Why Major Inspections Matter
Many people assume a 10-year inspection simply satisfies Australian Standards.
In reality, it is one of the most valuable maintenance activities an owner can undertake.
A major inspection helps identify:
Wear before catastrophic failure
Components approaching end of life
Brake deterioration
Rope guide wear
Wheel condition
Structural issues
Drive system condition
Electrical defects
This information allows maintenance budgets to be planned instead of reacting to unexpected downtime.
Don't Ignore Unusual Crane Noises
A crane rarely fails without warning.
Common signs include:
Grinding noises
Rumbling during travel
Intermittent vibration
Difficulty tracking
Excessive brake noise
Oil leaks
Increased motor temperature
Early investigation often prevents a relatively minor repair becoming a major rebuild.
Overhead Crane Breakdown Response Across Perth
SLA Cranes provides rapid response breakdown services throughout Perth and regional Western Australia.
Our technicians diagnose faults on all major crane brands including:
STAHL
KITO
GIS
Verlinde
Demag
ABUS
SWF
Street
Conductix systems and associated controls
Whether the issue involves bearings, motors, brakes, gearboxes or electrical faults, our goal is always the same—identify the true cause, complete a quality repair and return the crane to service safely and efficiently.
Need Emergency Crane Repairs?
If your overhead crane is making unusual noises, travelling roughly or has stopped operating altogether, don't wait until production comes to a halt.
SLA Cranes provides:
Emergency breakdown response
Fault diagnosis
Motor and gearbox repairs
Bearing replacement
Brake overhauls
Major inspections
Preventive maintenance
Complete crane servicing throughout Perth and regional Western Australia.
☎ 1300 141 109
☎ +61 1300 141 109 (International)
✉ service@safelifting.com.au
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Safe Lifting Australia Pty Ltd
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Across Australia and the Asia-Pacific Region - Over 100 Years Combined Crane & Lifting Industry Experience
☎ 1300 141 109
☎ +61 1300 141 109 (International)
✉ service@safelifting.com.au
Head Office Perth, Western Australia
Directors
Matt Weight - 0473 874 474
Dan Curchin - 0439 094 755
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