Case Background

In a German automobile welding workshop in Sao Paulo, Brazil, a 100-ton double-beam crane suddenly broke down:

• Fault phenomenon : The main lifting mechanism slipped out of control and the trolley travel motor burned out

• Impact : Production line shutdown, R$85,000 (about $160,000) per hour

• Environmental challenges : workshop temperature 42°C + acidic welding gas corrosion

Emergency Response Process

1. 4-hour emergency response

   • The local service team arrives with FLIR thermal imaging cameras and vibration analyzers

   • Preliminary diagnosis: brake hydraulic valve stuck + motor insulation breakdown (caused by 90% humidity)

2. 48-hour critical repair

   Faulty parts	Emergency measures	Long-term solution
   Main lifting brake	Temporarily activate the spare friction plate	Replacement of IP65 protection grade wet brake
   Travel motor	Calling for spare parts from Rio de Janeiro bonded warehouse	Upgraded F-class insulation winding
   Control Cable	Bonding temporary shielding lines	Use acid-resistant CY type cable instead

Special treatment for tropical climate

1. Corrosion protection

   • All bolts are replaced with A4-80 stainless steel

   • The junction box is filled with 3M Scotchcast moisture-proof gel

2. Heat dissipation modification

   • The motor is equipped with a German EBM axial flow fan (air volume increased by 40%)

   • Parallel backup circulation pump for reducer oil cooling system

Localization Service Highlights

1. Compliance and fast customs clearance

   • Priority customs clearance with Brazilian INMETRO certified spare parts

   • Maintenance personnel hold NR-12 Mechanical Safety Operation Certificate

2. Preventive advice

   • Weekly forced cooling system dust removal (for South American poplar season)

   • The brake hydraulic oil replacement cycle is shortened to 800 hours (50% of the original factory standard)

Maintenance results

• Downtime : Reduced from an estimated 72 hours to 51 hours

• Cost control : Save 19% of tariffs through bonded warehouse spare parts

• Subsequent improvement : Install Siemens S120 drive system fault pre-diagnosis module

South American market experience

1. Technical warning labels in Portuguese are mandatory

2. Priority is given to localized certified spare parts (such as wire ropes certified according to ABNT NBR 14753)

3. For rainy season humidity, polyether grease (compatible with mineral oil) is recommended.