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It all started with an old pickup truck, a piece of rope, a small slope, and a man with an idea to transport skiers uphill. All you had to do was make sure the truck had gas and that you turned off the key at the end of the day. That evolved into chairlifts with a couple of switches, a board full of relays and a single-speed motor controller. Chairlifts required mechanics with wrenches and electricians who could read schematics and troubleshoot electrical circuits.

Today, new lifts are as much computer as they are mechanical, with multiple safety circuits, variable speed drives, and programable logic controllers that oversee the whole operation of the lift system. Electrical training for mechanics has always been a plus, but even more so now.

At the turn of the century, when lift technology was rapidly progressing, many lift-maintenance managers worried they’d have to hire a computer programmer to work on their lifts. However, the IT component is not much a part of lift maintenance teams’ day-to-day—the programming is done by the manufacturer. 

That said, the digitization of many functions is real, and that has required technicians to learn new ways of doing things. The same is true for the mechanical components on detachable lifts, which have become more complex with the addition of acceleration and deceleration mechanisms, variable speed tire banks, multiple input axillary engines, etc. 

Requirements

These evolutions have affected the training requirements for your lift maintenance staff. Mechanics are now “mechtricians,” as they need to be capable of navigating digital devices like computers and HMIs (human-machine interfaces)/touchscreens just to perform some of the most basic duties—start-up, pre-operational inspections, brake tests, daily monitoring of lift functions, and monthly and annual testing—in addition to working with mechanical components. 

Plus, all mechanics should at least be familiar with basic DC electrical concepts for simple troubleshooting and resolution of common low voltage problems, such as stop gates and operator control panel button issues.

This shouldn’t challenge the younger generation since, as digital natives, they’ve been raised navigating computer systems and working with HMIs. Digitization has been harder on the more seasoned mechanics who didn’t grow up on screens. In any case, the training to work on newer lifts is the same.

Be aware that the electrical knowledge your staff needs is specific to your resort. What works for a medium-sized Western resort with three fixed grip lifts, two detachables, and two carpets doesn’t necessarily equate to what works for a medium-sized area in the Midwest with five fixed grips, three carpets, and a tubing operation.

Dedicated, trained lift electrical staff is highly desirable for troubleshooting and quick resolution to minimize guest impact. In days past, when older lifts had fewer electrical parts, a ski area could often get by with one electrician who worked on electrical systems across the entire ski area. With the increase in use of electronic technology, it’s better to have a dedicated lift electrician (who can also serve as a mechanic) as well as a general electrician. If you only have one electrician for the whole resort and the frialator and your lift both go down at noon, which gets fixed first?

“I know many areas get by on the well-rounded mechanic that can do almost everything, but there is a safety and predictive maintenance benefit to having someone whose critical thinking is always aligned with electrical theory, process(es), techniques, and familiarity with the NEC (National Electric Code) to ensure basic, or higher, system integrity,” says Mark Kramer, lift and electrical senior manager at Copper Mountain, Colo.

In other words, the lift maintenance team should include someone who is focused on, and trained for, electrical work.

“It also goes a LONG way when collaborating with the manufacturer on more complex issues,” Kramer advises. “A qualified electrical technician can most likely follow directives from engineering to provide additional troubleshooting that can pinpoint a problem, and even implement repairs under direction. That avoids lengthy travel for a service visit, or at least ensures the visiting service technician has the right tools, parts, and equipment for an efficient visit.” 

Training

Training is needed to keep your lift maintenance staff up to date on the latest technology, both mechanical and electrical, so you can provide safe, reliable uphill transportation.

Training is offered by a variety of different organizations, associations, colleges and universities, and businesses, and comes in different forms: manufacturer training sessions, classroom sessions at regional maintenance conferences, hands-on training offered by various state associations, digital programs, and outside vendors that deal with your specific components.

Manufacturers. Manufacturers provide training in various ways, such as classroom sessions at their headquarters, presentations at conferences, or on-site training on your own equipment.

“Each year, Doppelmayr offers training sessions at our Salt Lake City office to provide in-depth, hands-on experience for each new lift that is installed,” says Doppelmayr sales manager Scott Geno Leslie. The company holds classes for each lift type—fixed-grip, detachable, and D-Line—covering mechanical and electrical components both in the classroom and during site visits to local Utah resorts. “Attendees get a thorough training on their new equipment,” he says. 

Leitner-Poma of America tries to engage customers with a new product during installation, and especially during startup and testing. “After the acceptance test, we typically provide approximately 7-10 days of on-site technical support to existing customers, and a new customer may get as many as 3-4 weeks,” says technical support rep Robbie Saavedra. “We like to spread the support out and get a few days prior to opening to get the personnel comfortable with the equipment, and then a week or two after the season to do hands-on training regarding required maintenance.” 

As a further step, have someone on your staff available during the last 2-4 weeks of the installation process, so they can participate during station adjustments, carrier installation, electrical set up, and final testing before the acceptance test. This provides invaluable, free training. Plus, the sooner you become involved with your new lift, the smoother the transition will be.

Manufacturers also offer fee-based maintenance training and service. Many resorts invest in this training, some opting to do it on an annual basis as part of an overall preventive maintenance program. With the rapid changes in technology and the constant turnover of staff, this is a way to ensure that your lifts have been thoroughly fine-tuned and tested and your staff is ready for the coming season. 

Amos Bennett, mountain manager at Timberline Mountain, W.Va., likes this approach. “I brought the manufacturer back in at a cost, but it was worth every penny we spent. Mostly because you are hands-on doing the work and in a familiar environment. Your team is working inside their comfort zone, at home.” 

Whatever you do, it is important for your staff to develop relationships with the manufacturer representatives so they know who to call when the going gets tough. The best time to develop these relationships is when the manufacturer is on site working on your equipment.

Regional Conferences, State Associations, and Colleges. The National Ski Areas Association works with the many regional conferences providing education content and, in some cases, administrative support. All of them have sessions relating to lift mechanical and/or electrical topics. Lift Maintenance Seminar (LMS), Mass.; Pacific Northwest Ski Areas Association Mountain Works; Intermountain Ski Areas Association, Utah; Rocky Mountain Lift Association, Colo.; and Midwest Ski Areas Association are a few of the annual regional conferences held nationwide. Similarly, Ski California hosts its annual Lift Maintenance and Operations Education conference each year.

The NSAA Lift Safety Bootcamp classroom is one of several places mechanics can recieve lift training.

Manufacturers present sessions at these events and cover a variety of topics, including current service bulletins and common problems that have occurred recently. These often become roundtable discussions that are of great value to technicians, including as a means of establishing a network of peers to communicate with in the future.

In addition, several state associations hold annual hands-on training programs for member ski area personnel. The Pennsylvania Ski Areas Association’s lift training program, for example, is hosted by two different ski areas during the off-season. Each ski area provides free, structured training for attendees from other in-state ski areas—or even for-fee training for out-of-state areas—with a curriculum that covers the latest best practices and requirements in accordance with ANSI B.77 standards. 

In addition to providing needed, and often required training, sending lift maintenance staff to these events promotes job satisfaction and retention.

Colleges and universities also offer lift maintenance courses—either in-person or online—to advance the skills of current employees. Oregon State University, for example, developed an interactive online ski lift maintenance technician training program that can be completed at participants’ own pace. Gogebic Community College, Mich., offers an intensive three-week, in-person Ski Lift Maintenance Technology course at its campus. Participants receive credentials, or certificates, verifying completion and compliance. 

Outside Assistance. For older lifts that may no longer be supported by a manufacturer, you may need an outside specialist to assist with a project. Examples: a gear reducer inspection or rebuild, bullwheel bearings inspection or rebuild, drive calibrations or upgrades, haul rope inspections, replacements, or rigging, or components on newer lifts that are covered by pass-through warranties from the manufacturer, such as auxiliary/evacuation engines, transmissions/torque converters, or some hydraulic components. 

Whatever the need, there are knowledgeable specialists that deal directly with ropeways. Make sure the specialist knows all the details of the component that needs to be fixed, inspected, rebuilt, calibrated, or upgraded, and what its function is on your lift.

A site visit to Deer Valley, Utah, with Doppelmayr.

Staying Current

As lift technology requirements change, lift “mechtricians” must adapt and keep up. Fortunately, the evolution of equipment has made bridging the knowledge gap simpler and more achievable. Pre-programmed systems now allow less knowledgeable staff to complete certain functions with the simple touch of a button. Knowing which button to touch is part of training.

One key strategy: Take ownership of your new equipment as it starts to arrive as this can initiate a strong relationship with your manufacturer. If staff spend time with the installation team during pre-assembly of tower heads and sheave assemblies, for example, they pick up beneficial knowledge. It’s easier for technicians to maintain and fix the equipment once the lift is running if they see how everything is put together from the start. 

And, again, spending time with manufacturer installation teams—as well as manufacturer reps, personnel from other ski areas, outside experts, and education providers—will help develop valuable relationships that will benefit the technicians and, ultimately, the ski area.