Emergency Long-Travel Wheel and Axle Renewal

Rapid Crane Repair Restores Production at Victorian Manufacturing Facility

A major Victorian manufacturing facility suffered a critical overhead crane breakdown when a bearing failure on a 500 mm long-travel wheel caused severe mechanical damage to the wheel and axle assembly. Despite routine maintenance, the incident brought the facility’s main production line to a standstill — threatening costly downtime and lost productivity.

Recognising the urgency, Crane Aid was engaged for its rapid-response capability and in-house machining expertise. Within just 24 hours, our technicians had the crane fully operational again, allowing the facility to safely resume production with minimal disruption.

The Challenge

The bearing failure resulted in significant structural and mechanical damage to the crane’s long-travel wheel and axle assembly. With no off-the-shelf replacement components available, the repair required a custom-engineered solution manufactured entirely in-house.

The facility’s operations run continuously, meaning that every hour of crane downtime directly impacted output and efficiency. The client needed a fast, compliant, and technically precise repair that met the stringent requirements of AS1418.1 while maintaining full site safety and operational reliability.

Crane Aid’s Solution

Crane Aid immediately mobilised its engineering, service, and machining divisions to deliver a coordinated response.
Using our 200-tonne hydraulic press, the damaged axle was safely removed and inspected by our mechanical engineers. A new axle was precision-machined in-house at our Dandenong South workshop, and the long-travel wheel was fully refurbished and reinstalled by our service technicians.

All work was carried out under approved Safe Work Method Statements (SWMS) and Job Safety Analyses (JSA) in accordance with ISO 9001 quality procedures. Once reassembled, the crane underwent a full load test and operational verification, confirming compliance and readiness for recommissioning.

The Results

Within 24 hours, the facility’s main overhead crane was back in operation — restoring productivity and preventing further disruption to the manufacturing process.
The newly machined axle and refurbished wheel delivered smooth, reliable performance, extending the equipment’s service life and reducing future maintenance risk.

By performing all engineering, machining, and fabrication in-house, Crane Aid eliminated external lead times and ensured total quality control from start to finish. The result was a cost-effective, compliant, and durable repair solution that reinforced our reputation as a trusted partner in industrial crane maintenance.

Key Outcomes

• Crane fully operational within 24 hours

• Axle and wheel assembly rebuilt and installed in-house

• Compliance achieved with AS1418.1 and ISO 9001

• Zero safety incidents during repair and testing

• Fast, cost-effective solution with extended equipment lifespan

About Crane Aid

Crane Aid Pty Ltd provides comprehensive crane servicing, repairs, inspections, modernisations, and engineering support for clients across Victoria, New South Wales, and South Australia. With fully equipped workshops in Dandenong South, South Albury, and Strathdale, and complete in-house machining and fabrication facilities, we deliver fast, compliant, and cost-effective crane repair solutions for industries including manufacturing, power generation, logistics, and construction.

Crane Aid — keeping Australia’s lifting equipment safe, compliant, and operational.