If you're like me, you've been handed a Demag parts list and told to order something. Maybe it's for an overhead crane that's been running since the 90s. Maybe it's a hoist motor that just gave out. The list is intimidating—all those numbers and diagrams.
When I took over purchasing in 2020, I had no idea what a 'hoist limit switch assembly' was. I just knew it cost $400 and my operations guy was breathing down my neck. After a few expensive mistakes, I built a simple checklist. Here are the 5 steps I use every time.
Step 1: Identify the Correct Part Number
This sounds obvious, but it's where most errors happen. A Demag parts list isn't like an Amazon catalog. The numbers are specific to your crane's model year and configuration.
What to do:
- Find the model plate on your overhead crane. It's usually on the bridge beam or the hoist itself.
- Write down the serial number and model number. Don't guess—take a photo.
- Cross-reference this with the Demag parts list for that specific model.
The surprise wasn't the price. It was that the same part number from a 2005 model didn't fit a 2008 model. The revision letter was different. I learned that the hard way—ordering two units that sat in storage for a year.
Check point: Does the part number match the revision level of your crane? If the list shows 'Rev B' and your crane is 'Rev C,' stop and verify.
Step 2: Read the Diagram First, Not the List
Most people jump straight to the text list. Don't. Start with the exploded diagram.
On paper, the part number looks right. But in the diagram, you see it's a left-hand assembly, and you need a right-hand one. Demag cranes often have mirrored components for different sides of the bridge.
What to do:
- Locate the assembly you're working on in the diagram.
- Count the parts. If the diagram shows 8 bolts and your list has 6, something's off.
- Match the diagram callout number to the parts list number.
Put another way: The diagram is the truth. The list is the index. I only believed this after ignoring it and ordering an incorrect brake coil. The 'cheap' fix cost me an extra $200 in return shipping and a week of downtime.
Check point: Does the diagram match the physical layout of your crane? If you can't find the part visually in the diagram, you might have the wrong list.
Step 3: Verify the Quantity and Unit of Measure
This step sounds boring. It's not. Demag parts lists sometimes list quantities in strange ways.
Example: The list says '1' for a wire rope assembly. But is it one wire rope, or one set? In our 2024 vendor consolidation project, I found that some parts are sold in sets (like a complete brake kit) while others are single units. The price difference is massive.
What to do:
- Check the 'Unit of Measure' column. 'EA' means each. 'KT' means kit. 'PR' means pair.
- If it's ambiguous, call the supplier. I always ask: 'Is this price per unit or per set?'
- Factor in quantity discounts. For fast-moving parts like hoist motors, buying 2 instead of 1 can save 10-15% per unit.
The most frustrating part of this step: the same part number can be ordered in different quantities with different packaging. You'd think a 'brake disc' would be one disc, but I've seen kits with 4 discs listed as 1 line item. After the third time getting the wrong quantity, I started double-checking every line.
Check point: Does the quantity match your actual need? If you need 4 bolts and the list says 1 'kit' of 4, that's fine. If it says 4 'each,' you might be over-ordering.
Step 4: Check Availability and Lead Time Before Approving
I've made the mistake of approving a purchase order based on price, only to find the part has a 12-week lead time. Operations was not happy.
What to do:
- Ask your supplier for current stock status. Demag parts are widely available, but some older or specialized components have longer lead times.
- For mobile or crawler crane parts, factor in inspection and testing time. Hydraulic components often need certification.
- If the part is 'special order' with no return policy, flag it. I've been burned on non-returnable parts that ended up being the wrong fit.
The total cost of ownership includes more than the base price. If a $500 part takes 8 weeks to arrive and your crane is down, the real cost is lost production. I've paid more for a faster-shipping option from a Demag-authorized distributor and saved my team's schedule.
Check point: What's the lead time? If it's over 4 weeks, do you have a temporary solution or an alternative part?
Step 5: Verify Invoicing and Shipping Details
This is the step I skipped once. Once.
I found a great price from a new vendor on a Demag brake assembly. $200 cheaper than our regular supplier. I ordered 3 units. They couldn't provide a proper invoice—handwritten receipt only. Finance rejected the expense report. I ate $600 out of the department budget. Now I verify invoicing capability before placing any order.
What to do:
- Confirm the vendor can provide a purchase order-friendly invoice with your company's requirements (PO number, tax ID, delivery address).
- Check shipping: Is it FOB origin or delivered? Who covers damage in transit? Fragile Demag electrical components need proper packaging.
- Get the estimated delivery date in writing. Verbal promises don't help when your VP asks why the part didn't arrive.
Check point: Can the vendor provide an invoice that will pass your finance team's review?
Common Mistakes and How to Avoid Them
I've been doing this for 5 years now. Here are the patterns I've noticed:
- The 'It looks like' mistake: Ordering a part because it resembles the broken one. Demag cranes have subtle variations. Always verify with the serial number.
- The 'I'll save money' mistake: Buying a generic or third-party part without checking specs. Sometimes it works. Sometimes the tolerance is off and you waste labor installing a part that doesn't fit.
- The 'I'll figure it out later' mistake: Not checking the manual first. The Demag overhead crane manual is your best friend. It documents the parts list for your specific model. If you don't have a copy, most are available online for free from the manufacturer's website.
One last thing: If you're ordering for a Demag crane that was transferred to Konecranes or acquired by Tadano, parts availability is generally good. But the catalog numbers can change between brands. A part that says 'Demag' on the list might be a 'Konecranes' or 'Tadano' part number now. The vendor should be able to cross-reference. If they can't, that's a red flag.
This checklist has saved me from at least 4 major ordering mistakes in the last two years. Hopefully it does the same for you.
