Great question! Intermittent overload faults can be really frustrating since they seem to come and go randomly. Here's my systematic approach beyond checking mechanical binding:

1. First, check the fault history in your servo drive's diagnostic logs - modern drives record detailed fault histories including current levels, voltage fluctuations, and temperature data that can reveal patterns you might miss.

2. Investigate power quality issues - intermittent faults often come from 'dirty power' (spikes, voltage sags, or electrical noise). Use a power quality analyzer to check for voltage fluctuations that might be causing the drive to see phantom overloads.

3. Check thermal conditions - intermittent overloads can occur when the motor heats up during operation. Monitor temperature trends and check for proper cooling, ventilation, and heat dissipation.

4. Examine wiring and connections - loose or corroded connections can cause intermittent power supply issues. Pay special attention to encoder cables and feedback wiring, as signal integrity problems here can make the drive think it's overloaded.

5. Test under actual load conditions - many feedback and signal problems only appear when the system operates under real-world conditions, not during bench testing.

6. Check for software or programming issues - review the machine control program for potential errors that might be sending incorrect commands to the motor, especially during specific operations or sequences.

7. Isolate components systematically - swap drive channels with a known-good axis to see if the problem moves with the wiring/encoder or stays with the motor/drive.

The key is to look for patterns in the randomness - intermittent faults usually have triggers that aren't immediately obvious but follow some pattern when you dig deeper into the data!