DEMAG Repair Services India
DEMAG is a global leader in material handling, lifting equipment, and industrial automation with over 160 years of engineering excellence. Founded in Germany, DEMAG designs and manufactures electric chain hoists, wire rope hoists, cranes, and advanced motion control systems used across heavy manufacturing, automotive, and logistics sectors. DEMAG has a strong footprint in Indian steel mills, automotive plants, and warehousing operations, making it a trusted name in Indian industrial infrastructure.
DEMAG is a global leader in material handling, lifting equipment, and industrial automation with over 160 years of engineering excellence. Founded in Germany, DEMAG designs and manufactures electric chain hoists, wire rope hoists, cranes, and advanced motion control systems used across heavy manufacturing, automotive, and logistics sectors. DEMAG has a strong footprint in Indian steel mills, automotive plants, and warehousing operations, making it a trusted name in Indian industrial infrastructure.
Synchronics Electronics specializes in repairing all 19 product lines in DEMAG's industrial catalog — including DC hoists, AC chain hoists, trolleys, control pendants, frequency converters, and safety systems. Our 180+ engineers have extensive hands-on experience with DEMAG hoist electronics, brake systems, and motion controllers. We understand DEMAG's precision engineering standards and deliver repairs that restore equipment to OEM performance, keeping Indian manufacturing facilities running without costly downtime.
DEMAG hoist repair, brake electronics, and motion control system specialists.
DEMAG Equipment We Repair — By Category
DEMAG Product Lines We Repair
Our engineers are trained on the full DEMAG product range. Below are the major product families we service.
DC Chain Hoists & Motors
DEMAG DC chain hoists with integrated motor-brake units are workhorses in Indian steel, foundry, and automotive plants. Common faults include brake slippage, motor coil burnout, and control circuit failures. These hoists demand precision repair to maintain load safety and lift accuracy.
AC Wire Rope Hoists
Heavy-duty AC wire rope hoists used in crane systems and overhead material handling. Repair issues include limit switch faults, frequency converter problems, drum motor failures, and electrical control board degradation. These hoists require certified testing post-repair for safety compliance.
Frequency Converters & Motion Controllers
DEMAG frequency converters regulate speed and torque for smooth hoist operation. Faults include capacitor bank failures, thyristor damage, soft-start circuit failures, and firmware crashes. Synchronics reconditions these controllers to OEM specifications with full load testing.
Control Pendant Systems
Wireless and hardwired control pendants for remote hoist operation. Common failures are joystick drift, button contact corrosion, radio receiver faults, and circuit board water ingress in mill environments. Synchronics rebuilds pendants with sealed connectors for harsh industrial conditions.
Brake Systems & Mechanical Components
Spring-applied hydraulic brakes and mechanical fail-safe brake assemblies in DEMAG hoists. Brake drag, release delays, and partial engagement are costly issues that halt production. Synchronics overhauls brake electronics, solenoids, and pressure switches with precision calibration.
Safety & Load Cell Systems
Load monitoring, overload limit switches, and safety relay modules in DEMAG systems. Faults include sensor drift, relay chatter, signal conditioning board failures, and communication link errors in networked hoist systems. Critical for regulatory compliance in Indian factories.
Why Choose Synchronics for DEMAG Repairs?
PCB-Level Expertise
We repair down to the component level — not just swap boards. Our engineers identify root causes, replace failed IGBTs, capacitors, processors, and gate drivers on DEMAG equipment.
Fast Turnaround
Standard 7–10 working days. Express 3–5 days available for critical breakdowns. Emergency same-day/next-day service for unplanned downtime.
6-Month Warranty
Every repaired unit ships with a 6-month comprehensive warranty on parts and labour. Our repair success rate is over 94% across all brands.
All-India Service
Couriered repairs accepted from any city in India. Doorstep pickup available in Vadodara, Mumbai, Pune, Ahmedabad, Surat, Chennai, and more.
Common DEMAG Equipment Faults We Fix
Based on 30+ years of repair data, these are the most frequent failure modes we see in DEMAG equipment arriving at our workshop.
- ✓Brake not releasing or dragging continuously — DEMAG brake solenoid coil burnout or voltage supply drop below 24V DC nominal. Spring tension misalignment after years of mill vibration also causes partial engagement. Rust and scale buildup on brake armature is common in high-humidity Indian foundry environments.
- ✓Hoist stutters or jerks during lift — DEMAG DC motor commutator wear, brush degradation, or weak brush springs result in uneven torque delivery. Frequency converter soft-start thyristor faults cause sudden current surges, triggering jerk. Contaminated lubricant in gearbox also contributes to irregular motion.
- ✓Control pendant does not respond or intermittent signal loss — DEMAG wireless pendants suffer radio frequency interference in industrial environments with multiple WiFi/4G sources. Joystick potentiometer contamination or dry solder joints on control circuit boards cause intermittent contact loss. Water ingress near cable glands is common in open-pit mining and steel mills.
- ✓Frequency converter trips or goes into fault lockout — DEMAG converters detect line voltage sag, capacitor bank ESR increase, or phase imbalance common in Indian power grids with poor distribution. Over-temperature shutdown occurs if cooling fins accumulate foundry dust or mill scale. Thyristor gate drive circuit failures trigger protection mode.
- ✓Load cell or overload limiter shows zero or erratic readings — DEMAG load cell connectors corrode from moisture in humid mill air; shielded cables degrade if routed near high-current hoist motor cables. Signal conditioning board Op-Amp failure or offset reference drift causes calibration loss. Mechanical damage to load cell during maintenance or crash stops is common.
- ✓Motor winding burnout or short to ground — DEMAG DC motors in continuous-duty hoist service suffer thermal cycling stress; insulation varnish cracks over 10-15 years. High inrush current from weak soft-starters or direct-on-line starters accelerates winding failure. Moisture ingress and contamination in seal breather creates conductive paths between phases.
How We Repair Your DEMAG Unit
Receive & Log
Your unit is logged into our tracking system with a unique job number. You receive WhatsApp / email updates at every stage.
Fault Diagnosis
Board-level diagnosis using oscilloscopes, LCR meters, and thermal cameras. Root cause identified before any repair begins.
Component Repair
Faulty ICs, capacitors, MOSFETs, IGBTs, and gate drivers replaced with genuine or equivalent-spec components.
Full-Load Test
Unit tested under rated load with original or equivalent motor. All parameters verified. 6-month warranty issued.
Industries Using DEMAG Equipment
We serve plant maintenance teams across all major industries where DEMAG automation is deployed.
Frequently Asked Questions — DEMAG Repairs
Do you repair DEMAG equipment anywhere in India?+
Yes. Synchronics repairs the full DEMAG product range — DC and AC hoists, wire rope systems, frequency converters, control pendants, brake units, and safety load cell systems. We offer PAN India door pickup and courier from Mumbai, Delhi, Pune, Bangalore, Chennai, Hyderabad, Kolkata, Ahmedabad, and all other industrial centers. All repairs are completed in our ISO 9001 certified Vadodara facility and tested before return shipment.
What is the typical turnaround time for DEMAG hoist repair?+
Standard DEMAG repairs (motor rewind, brake service, converter recap) take 5-7 working days from receipt. Urgent repairs are expedited in 2-3 days if components are in stock. Complex failures requiring mechanical overhaul or custom controller programming may extend to 10-14 days. We provide daily updates and conduct pressure tests post-repair to ensure load-safe operation before dispatch.
Can Synchronics repair DEMAG frequency converters with control board failures?+
Absolutely. DEMAG frequency converter boards (soft-starters, motor controllers, and PLCopen logic boards) are a core repair competency. We perform component-level diagnostics to identify failed thyristors, capacitors, and microcontroller faults. Synchronics can reflow solder joints, reprogram firmware from backups, or design custom control logic. We have spare converter modules in stock for temporary substitution to minimize your production downtime.
How do I know if my DEMAG hoist motor can be rewound or must be replaced?+
Synchronics performs free insulation resistance and megohm testing on received DEMAG motors. If winding resistance is below 0.5 ohm or megohm insulation is below 1.0 megaohm at 500V DC, motor is a rewind candidate. Frame distortion, rotor damage, or bearing seizure may require replacement. We provide transparent diagnostic reports and cost comparison for both options, allowing you to choose based on motor age and criticality for your plant.
Does Synchronics test DEMAG hoists for safety compliance after repair?+
Yes. Post-repair, all DEMAG hoists undergo load testing at 125% rated capacity, brake effectiveness verification, limit switch calibration, and emergency stop function validation. We also test hoist communication with wireless pendants in your facility's RF environment if applicable. A compliance test report is provided, confirming adherence to Indian Factory Act lifting equipment standards. This ensures your repaired DEMAG hoists are safe and audit-ready.
How do I send my DEMAG unit for repair?+
Pack the unit securely and courier it to our Vadodara workshop. Include a note with the fault description and your contact details. We will log it into our system and WhatsApp you a job number within 24 hours of receipt. Doorstep pickup is available in Vadodara, Ahmedabad, Surat, Mumbai, and Pune.
What is the cost of repairing a DEMAG drive or PLC?+
Repair cost depends on the model and the fault. We offer a free diagnosis — once we identify the fault, we provide a fixed quotation before proceeding. Typical repairs cost 20–40% of the new unit price. We will never repair without your approval.
What warranty do you provide on DEMAG repairs?+
All repaired units carry a 6-month comprehensive warranty covering the same fault and related issues. If the fault recurs within the warranty period, we repair it free of cost.
Do you provide a no-fix, no-fee guarantee?+
Yes. If we cannot repair your DEMAG unit after diagnosis, you pay only the diagnosis fee (₹500–₹1,500 depending on the product). The unit is returned to you at no additional charge.
DEMAG Repair Catalog
Showing 1–19 of 19 DEMAG products
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Send us your faulty industrial electronics. Our engineers will diagnose it and provide a detailed quote within 24 hours — with no obligation to proceed.
Free Evaluation
No obligation
48hr Turnaround
Fastest in India
6-Month Warranty
Every repair
No Fix, No Charge
Zero risk policy
Pan-India Pickup
Doorstep service