Lift and Escalator Mechanic

ITI Lift and Escalator Mechanic Syllabus 

Course Overview

• Trade Name: Lift and Escalator Mechanic
• Duration: 2 Years (4 Semesters)
• NSQF Level: Level 5
• Eligibility: 10th Grade Pass with Science and Mathematics
• Objective: To train candidates in installing, maintaining, troubleshooting, and repairing lifts and escalators, preparing them for roles as lift technicians, escalator mechanics, or service engineers in construction, maintenance firms, or manufacturing units, or for self-employment in lift maintenance services.
• Certification: National Trade Certificate (NTC) by NCVT

Detailed Syllabus

Semester 1

Trade Theory

• Introduction to Lifts and Escalators: Types (passenger, freight, home lifts, escalators), applications, and industry standards.
• Safety Practices: Electrical safety, fall protection, PPE (helmets, harnesses), fire hazards, first aid.
• Basic Electricity: AC/DC fundamentals, Ohm’s Law, circuits, transformers, earthing systems.
• Workshop Tools: Spanners, screwdrivers, multimeters, crimping tools; usage and maintenance.
• Mechanical Components: Gears, pulleys, bearings, ropes; principles and functions in lifts.
• Materials and Fasteners: Types of steel, bolts, nuts, rivets; selection for lift structures.
• Engineering Drawing: Reading blueprints, lift shaft layouts, assembly diagrams.

Trade Practical

• Safety Drills: Using PPE, practicing lockout-tagout, handling electrical shocks.
• Electrical Measurements: Measuring voltage, current, resistance using multimeters; testing continuity.
• Tool Handling: Operating spanners, torque wrenches; maintaining tools for precision.
• Mechanical Practice: Assembling gears, pulleys; lubricating bearings, checking rope tension.
• Fastener Application: Tightening bolts, riveting components, ensuring alignment.
• Drawing Practice: Interpreting lift installation drawings, sketching basic components.
• Project Work: Assembling a mock lift pulley system with safety checks.

Hours: Theory: 160 hours | Practical: 240 hours

Semester 2

Trade Theory

• Lift Components: Car, counterweight, guide rails, hoist ropes; functions and specifications.
• Electrical Systems: Motors (AC/DC), relays, circuit breakers, wiring standards (IS/IEC).
• Control Systems: Push-button controls, floor sensors, limit switches; operation principles.
• Escalator Mechanics: Steps, handrails, drive systems, trusses; design and working.
• Hydraulics and Pneumatics: Hydraulic lifts, cylinders, pumps; maintenance basics.
• Welding and Fabrication: Arc welding, gas cutting; applications in lift installation.
• Troubleshooting Basics: Identifying electrical/mechanical faults, reading error codes.

Trade Practical

• Lift Component Assembly: Installing guide rails, aligning car frames, securing ropes.
• Electrical Wiring: Connecting motors, relays; testing circuit breakers for safety.
• Control Setup: Wiring push-button panels, testing floor sensors and limit switches.
• Escalator Practice: Adjusting step alignment, checking handrail tension, lubricating drives.
• Hydraulic Tasks: Inspecting hydraulic fluid levels, testing pump operation.
• Welding Jobs: Performing basic arc welding for lift brackets, ensuring joint strength.
• Project Work: Setting up a lift control panel with wiring and sensor testing.

Hours: Theory: 160 hours | Practical: 240 hours

Semester 3

Trade Theory

• Advanced Lift Systems: Traction lifts, machine-room-less (MRL) lifts, governor systems.
• Electronics in Lifts: Microprocessors, VVVF drives, PLC-based controls; applications.
• Escalator Control Systems: Safety sensors, emergency stop mechanisms, speed regulators.
• Installation Standards: Lift codes (EN 81, IS 14665), shaft preparation, load testing.
• Maintenance Practices: Preventive maintenance, lubrication schedules, log keeping.
• Power Backup Systems: UPS, battery backups, emergency rescue devices (ARD).
• Quality Control: Inspecting installations, ensuring compliance with BIS standards.

Trade Practical

• Lift Installation: Erecting traction lift components, aligning governor systems.
• Electronics Practice: Configuring VVVF drives, testing PLC inputs/outputs.
• Escalator Maintenance: Replacing worn steps, calibrating safety sensors.
• Load Testing: Conducting weight tests on lifts, verifying balance and stability.
• Maintenance Tasks: Lubricating hoist ropes, checking brake pads, updating logs.
• Backup Systems: Installing and testing UPS for lift emergency operations.
• Project Work: Installing and testing a mock traction lift system with safety features.

Hours: Theory: 160 hours | Practical: 240 hours

Semester 4

Trade Theory

• Modern Lift Technologies: Smart lifts, IoT integration, destination control systems.
• Escalator Advancements: Energy-efficient designs, regenerative drives, modular systems.
• Troubleshooting and Repair: Diagnosing complex faults, replacing controllers, motor rewinding.
• Erection and Commissioning: Planning lift/escalator installation, loop testing, handover protocols.
• Entrepreneurship: Starting a lift maintenance firm, costing, market trends in vertical transport.
• Environmental Practices: Energy-efficient lifts, recycling metal scraps, reducing noise pollution.
• Regulations and Safety: Lift Act compliance, annual inspections, emergency evacuation procedures.

Trade Practical

• Smart Lift Setup: Configuring IoT-based lift controls, testing remote monitoring.
• Escalator Repair: Replacing drive chains, recalibrating regenerative drives.
• Fault Diagnosis: Troubleshooting PLC errors, repairing VVVF drive faults.
• Commissioning Tasks: Performing final loop checks, simulating lift startup.
• Field Exposure: Hands-on training in lift/escalator maintenance firms (4-6 weeks).
• Maintenance Planning: Developing a preventive maintenance schedule for a lift system.
• Project Work: Installing and commissioning a complete lift system with IoT features and safety compliance.

Hours: Theory: 160 hours | Practical: 240 hours

Additional Components

• Workshop Calculation and Science
  
  • Calculations: Load capacity, motor power, rope tension, energy consumption.
  • Science: Mechanics of motion, electrical circuits, hydraulic principles.
  • Hours: 80 hours/year
• Engineering Drawing
  
  • Drawings: Lift shaft layouts, escalator trusses, electrical schematics.
  • Hours: 80 hours/year
• Employability Skills
  
  • Communication: Client interaction, technical reporting, teamwork.
  • IT Literacy: Using lift diagnostic software, online troubleshooting resources.
  • Soft Skills: Time management, resume writing, interview preparation.
  • Hours: 60 hours/year

Assessment and Certification

• Exams:
  
  • Theory: Written exams per semester (MCQs, descriptive questions).
  • Practical: Tasks like installing components, troubleshooting faults, commissioning lifts.
• Evaluation Criteria: Installation accuracy, repair efficiency, safety compliance, system functionality.
• Certification: NCVT National Trade Certificate (NTC) upon passing all semesters, globally recognized.

Career Opportunities

• Employment: Lift technician, escalator mechanic, service engineer in construction, maintenance, or manufacturing firms.
• Self-Employment: Lift maintenance services, consultancy, annual maintenance contracts.
• Further Studies: Diploma in Mechanical/Electrical Engineering, certifications in lift automation or IoT systems.