KTD GmbH Seite 1

Bodywork

Training Program

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Foreword In order to accomplish bodywork repairs qualitatively at reasonable prices, fundamental technical skills as well as a comprehensive knowledge of modern repair technologies are required. What has been learned within "basic education" is often no longer sufficient to meet the rapid technological progress.

If bodywork and paint repairs are not professionally handled, the calculated profit simply remains on the line. The losses to be recorded are not due to the fact that the calculations are too low, but rather to the inefficiency of the operating business.

The car body and paint specialists of the KTD GmbH have developed a modular training concept, which leads step by step to the individual qualification of interested or generally technically savvy personnel due to the many years’ experience for workshop personnel. At the same time, the "professionals" can further qualify in the new current repair techniques and test available tools and materials.

Due to the modular training structure, "interested newcomers" in the body shop are not overwhelmed and professionals are only confronted with topics which serve their further qualification.

Note: Before you select employees for a training, please check their suitability or prerequisite. This means that you can already make sure that the costs for the respective training are sensibly placed and that the „Return off investment” is then made for the investment.

Training description

The developed trainings are specifically geared to the current requirements in the repair business. Thus, the finding of water leakage and disturbing noise is trained as well as the craft aspect in the repair of high-strength steel plates. The reliable recognition of the total scope of damage and the exact determi-nation of the repair costs can be learned as well as the precise capture of measuring points using mod-ern measuring technology.

The spectrum of the body training is rounded off by qualification measures in the painting preparation and the paint repairs. In all trainings, we attach great importance to "practical proximity", as it occurs in the real repair business. During the trainings the participants can work with up-to-date equipment and try new tools and materials. Depending on the requirements and the intensity, the trainings are carried out in smaller groups, so that the intensive supervision by the respective trainer is ensured. This ap-proach guarantees the greatest possible training success and certainly leads to the desired training goal.

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Ford – Bodywork and assembly techniques – new Ford models Model specific information about manufacturing and assembly features as well as repair tips for the latest vehicle models. Models and dates upon request!

Target group

Technical shop personnel with experience in bodywork.

Description – Benefit In the training course for auto body and assembly techniques on new Ford models, only current topics from the auto body repair manual and construction and manufacturing characteristics will be taught. Further elements are assembly techniques of attachments and individual repair tips for an expert and economical repair.

Content

Current auto body repair techniques

Information on manufacturing and assembly characteristic

Mounting and dismounting of auto body attachments

Adjustment and calibration work

Repair materials and the latest tools

Model specific repair tips

Influence of modern assistance systems on body- and assembly work

Applications and work with the IDS diagnostic tool in bodywork

Handling of vehicle-specific repair instructions Ford Etis

Duration: 2 days

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Ford – Basic diagnostics for bodywork and paint specialists

Diagnosis of electrical vehicle systems

Target group This course is designed for auto body and paint specialists who have little or no previous knowledge in automotive electrical systems. This course gives you an overview of the fundamentals of automotive electric and electronic technology in order to be able to perform simple electronic work yourself and be able to assess problems. The content is also suitable for employees whose training took place some time ago.

Description - Benefit Description and benefit of the training course Electrical Assistant and Comfort Systems is an integral part of modern vehicle construction. For timely accident repairs, it is therefore important to master the fundamentals of automotive electrical diagnostics. Together with Ford we have developed a two-day training course.

Content

Basics of automotive electrical systems

Measuring with the multimeter

Determining simple electrical errors with the multimeter

Important terminal designations

Circuit symbols and their functions

Reading and using circuit plans when Troubleshooting

Repair of electrical cable damage

Reading and deleting errors with the diagnostic device

Adjustment work (headlight systems, rain sensor,…) with the help of the diagnostic tester

Networked systems and their advantages and disadvantages

Diagnostic strategies and case studies

Duration: 2 days

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Ford – Professional vehicle preparation Practical training for professional vehicle preparation

Target group

Personnel for vehicle preparation / vehicle assessment

Description – Benefit Optimally prepared used vehicles, in addition to new vehicles, represent the quality standards of your dealership. Thus, you can already show your customers from your used vehicle lot what they can ex-pect once inside.

The goal of the training course is to increase the sales and value of your used Ford vehicles through effective and targeted preparation methods. In the training course, methods and products to be pre-sented for vehicle preparation are available. These can of course be extensively tested by the partici-pants. The training course also includes the limits of preparation and the source of possible errors.

Content Paint treatments (polishing and sealing)

Interior cleaning (upholstery, floor coverings)

Repair of upholstery and leather damage

Plastic Treatments

Removal of small scratches

Possible spot repairs

Duration: 2 days

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Ford – Tips and tricks for paint refinishing and repairs

Professional and economical painting methods, timely and efficient repairs.

Target group

Experienced painting personnel, service advisors body and paintwork.

Description - Benefit The participants receive the latest Ford information relating to the area of painting.

In this hands-on training course, problems with technical applications are discussed. The participants then have the possibility to apply and expand on what they have learned with hands-on exercises. The impact of the current structure of factory paint on warranty repairs and tips for efficient paint refinishing are part of the training course.

Through the use of current industry examples, participants are able to see how economic efficiency can increased without reducing refinishing quality.

Content Effective implementation of Ford Repair Directives

Tips and tricks in working with special effect colours

Measures for colour matching

Working with colour matching devices

Touch-ups and Smart-Repair

Working with matt coatings

Instructions for foiling techniques

Duration: 2 days

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Ford – MIG soldering in auto body repair

Introduction to the material- and corrosion-resistant joining technology

Target group

Experienced bodywork professionals

Description - Benefit Due to the increased use of high-strength heat-treated or galvanized steel sheet metal, classic welding methods with process-related high heat input function only partially.

MIG soldering offers the advantage of being able to work with much lower temperatures. The negative effects on the material strength from structural changes are thus reduced. Similarly, anti-corrosion coat-ings (aluminium coating, galvanizing) show significantly less damage.

Despite all the advantages, it should be remembered that the solder used has generally a lower strength than the material to be joined. It is therefore particularly important to ensure a quality connection of the solder joint with MIG soldering.

The course teaches all methods necessary to produce a professional solder joint. The predominantly practically-oriented course offers each participant the opportunity to practice and improve his soldering skills.

Content Practical welding exercises for all solder types used in auto body repair

Use of various MIG soldering devices

Error detection and avoidance

Material science

Theoretical fundamentals

Duration: 2 days

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Ford – Dent repair without paint damage

Removal of parking and hail damage

Target group

Experienced painting or body work personnel

Description - Benefit The participants are taught through intensive training the various repair techniques for dent repair with-out paint damage. In addition to teaching theoretical fundamentals and commonly available tools, our focus is on the acquisition of technical skills gained by ongoing practice on auto body parts.

Dent repair without paint damage serves as a supplement to the existing portfolio of services offered by every Ford body specialist operation. Comprehensive customer service and improved customer loyalty are the main advantages of this repair method in addition to the additional business that it generates.

Content Assessment of the damage pattern and determination of the optimal repair path

Use of various dowel-press Tool

Use of gluing technology for dent repair

Repair work on original vehicle parts

Repair work on complete vehicles

Duration: 2 days

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Ford – Exterior dent repair

Practical training for current repair techniques

Target group

Experienced auto body personnel, service advisors body and paintwork

Description - Benefit Just as auto body techniques have changed in recent years, repair technology for auto body exteriors has radically evolved. Through constantly updated joining techniques in vehicle production, it is becom-ing increasingly important in auto body repair to preserve the original bond of the chassis. The trend in auto body repair is thus to regenerate rather than replace body parts.

Decisive advantages of regenerating rather than renewing are:

No or reduced assembly work

Preserving the original chassis bond from the manufacturer

Preserving the original corrosion protection of the manufacturer

Reducing loss of value on the sale of the vehicle

Reduced repair time when using the correct technology

Shock-free removal of the damaged area, thus less tension on the material

Content Theoretical fundamentals of materials science and dent repair techniques

Assess and remove dents and bumps

Additions to vehicle and problem analysis

Practical exercises with different technologies

Removing dents - grazing damage

Reshaping work on wheel arches, sills

Manufacture of edges and contours

Removal of wide-area damage

Usage and combination of various tools

Assessment of paint damage and its repair and care

Duration: 2 days

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Ford – Aluminium repairs

Practical training for the repair of aluminum vehicle parts

Target group

Experienced auto body personnel

Description - Benefit The use of aluminium as an auto body work material has been steadily on the rise for years. The main advantage of weight reduction is offset by the disadvantage of a higher price. This means that the repair of a damaged auto body part is often preferable to exchanging it. Aluminium repair is much different from classic steel repair.

Significant differences already exist in the design of the workplace and also in the selection of appropri-ate tools and machines. Basic technical skills and capabilities must be learned. There are limits on repair work which must be observed if one wants to avoid high costs.

Content Fundamentals and materials science

Repair and machining of aluminium body panels

Introduction to dent repair techniques

Exterior dent removal for small dents

Exterior bodywork for major damage

Thermal retraction

Fundamentals of aluminium welding techniques

Assessment of the damage image and determining the appropriate repair method

Duration: 2 days

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Ford – Bonding and riveting in auto body repair

Practical training of the current repair techniques

Target group

Experienced body work personnel

Description - Benefit Cold joining method, commonly called “bonding and riveting”, is increasing used in auto body repair. The advantages of cold joining are obvious:

No heat distortion of the components thereby reducing rework

No temperature-related damage to the factory applied corrosion protection

No structural changes and resulting alteration in strength properties of high and highest strength steel components

Reduction in work times

This course is designed by the manufacturer, but focuses on Ford's already released adhesive repair solutions, for example the roof repair of the current Ford Mondeo. In addition, the training prepares the participants for the future challenges in the body repairs. Through a very practically oriented course, participants will learn all the requirements and skills necessary for professional auto body repairs in the area of bonding.

Content Fundamentals of cold joining techniques

Materials and tools for professional repairs

Necessary preparatory work

Various joining techniques (bonding and riveting)

Recognizing and avoiding errors in cold joining

Development of metal spatulas and spongy-material substitutes

Installation of glued outer skin

The course is based on the manufacturer’s repair requirements. The participants have the ability to perform all of the work steps themselves thus acquiring the knowledge and skills to perform the various repair methods. Realistic bodywork repairs carried out on the basis of the manufacturer’s specifications.

Duration: 2 days

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Ford – Advanced bodywork training

Mechanical sheet metal work, bodywork and measuring technology, using common joining techniques

Target group

Technical shop personnel with entry level body work experience

Description - Benefit This training is intended to provide an introduction to body repair. Smaller car body damage can often be repaired without the use of expensive straightening systems. It is important to master the necessary techniques and to use the appropriate tools. The training gives you an overview, but cannot replace our themenity-specific courses.

Content

Instruction in working and safety precautions

Professionalism cutting of welded components

Application of mechanical and thermal sheet processing techniques

Use of different welding techniques

Production of continuous surfaces

Introduction to electronic body measurement techniques

Replace a welded body part

Duration: 2 days

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Ford – In-depth bodywork training

Replacement part repair, repair in auto body structure area, high and higher-strength materials, spe-cific joining techniques

Target group

Technical shop personnel with experience in bodywork

Description - Benefit This training is a continuation of the advanced training course and gives the participants knowledge for further repair work. The Intervention in the vehicle bodywork or the structure area of a vehicle does not mean everyday work and therefore requires extensive knowledge and skills.

These include: partial replacement of structural and load-bearing body parts, return deformation to orig-inal dimensional accuracy with straightening and measuring systems, handling and treatment of high-strength car body materials and light metal constructions as well as the safe mastery of the different-specific joining techniques.

The training serves as a continuation for graduates of the construction training or as a refresher for the trained bodybuilder who carries out rare structural repairs.

Content Instruction in working and safety precautions

Partial replacement in bodywork composite and structural area

Re-forming using classic and electronic straightening and measuring systems

Handling and treatment of sensitive auto body materials, for example highly resistant steels

Duration: 2 days

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ZKF 1 Aluminium repair on outer skin parts

Together with ZKF, we offer a two-day course "Aluminum repairs on outer skin parts".

The course is designed for experienced body personnel with experience in steel / sheet metal processing.

Content Repair and machining of aluminium outer skin parts

Introduction to dent repair techniques

Exterior dent repair to minor dents

Exterior repairs for major damage

Exterior repairs for major damage with the use of heat

Thermal retraction

Damage image and repair procedure

Perform repair with use of bonding and riveting techniques

Duration: 2 days

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ZKF 2 Cold-joining technique in auto body repair

Together with ZKF, a 2-day course in “cold-joining methods in auto body repair” is conducted on cur-rent BMW vehicles.

Cold joining processes have decisive advantages

No temperature application, no change in material structure and strength

No heat distortion in the connection area

No destruction of surface corrosion protection (sheet metal coatings)

Connection of different materials possible (for example steel with aluminum or plastic)

Higher strength, stability and durability than conventional welded joints

Through a very practically oriented course, participants will learn all the requirements and skills neces-sary for professional auto body repairs in the area of bonding.

Content Basics of cold joining Technology

Materials and tools for professional repairs

Necessary preparation work

Various adhesive techniques

Various riveting techniques (punch riveting, full riveting)

Recognizing and avoiding errors in cold joining

Removal of glued body parts in case of repetitive repairs

Appropriate loosening of rivet connections and new riveting

Working and special features in high-strength rivet Joints

Processing metal spatula instead of tin

The course is based on the manufacturer’s repair requirements. The participants have the ability to perform all of the work steps themselves thus acquiring the knowledge and skills to perform the various repair methods. Realistic bodywork repairs carried out on the basis of the manufacturer’s specifications.

Duration: 2 days

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ZKF 3 Electrical system diagnostics in auto body repair - basics

Electrical assistance and comfort systems have maintained an ever-increasing role in modern vehicle construction. For timely accident repairs, it is therefore important to understand these systems and mas-ter the fundamentals of automotive electrical diagnostics. Together with ZKF, we have developed a two-day training course.

This course give you insight into networked vehicle systems. It teaches you the skills and fundamentals that you need to to bring a vehicle after body repair back into operating condition electronically.

The objective of the course is to increase your shop capacity and keep a lucrative diagnostics business in house.

The course has a 70% practical content and offers the opportunity to become familiar with various diag-nostic units and be able to compare them directly with one another. Devices from Bosch, Gutmann and AVL

Content Fundamentals of vehicle electrical / electronics

Measurement methods using a multimeter

Networked systems in motor vehicles and the impact on the diagnosis

Reading circuit diagrams, recognizing connections and performing practical applications

Structured approach in error diagnosis (test plan)

Practical work with various diagnostic devices on modern European vehicles

Read error codes, evaluate and remedy

Re-program vehicle

Duration: 2 days

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ZKF 4 Electrical system diagnostics in auto body repair – advanced training

For participants with good fundamental electronic knowledge, for example, participants who have al-ready attended the basic course, we developed a new advanced course.

Content Use of the oscilloscope in diagnostic devices

Signal types of sensors and actuators

Differences between various data bus Systems

Use of electric circuit diagrams

Modern lighting Systems

Modern driver assistance Systems

Modern on-board power Systems

Measuring exercises on the vehicle of the mentioned Systems

Performing programming, basic settings and adjustments with diagnostic Equipment

Possibilities of re-programming the control Units

Developing diagnostic strategies

Duration: 2 days

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ZKF 5 Specialist for work on HV intrinsically safe vehicles

ZKF arranged 2-day courses “Specialist for work on HV intrinsically safe vehicles” exclusively for ZKF member companies. Due to the expected future increase in hybrid vehicles, the professional association has called for a specialist for working on HV intrinsically safe vehicles such as hybrid vehicles.

Course requirements The course “Specialist for work on HV intrinsically safe vehicles” is open to bodywork and chassis builder Masters as well as Master automotive technicians. Further participants could be vehicle electri-cians, vehicle mechanics and vehicle mechatronics with training completed after 1973. Auto body and vehicle mechanics with training qualifications after 2002 are also eligible for the course.

Content Fundamental electro-technical knowledge

Alternative fuels and Propulsion

Structure, function and operation of HV vehicles

Protective measures against electrical shock and electrical arcs

Electrical hazards and first aid

Definition "HV intrinsically safe vehicles”

Professional responsibility

General safety rules and safety instructions

Practical procedures when working with HV vehicles and Systems

Practical exercises and demonstrations

Course execution Level 1: The course participants must complete a written entry test prior to the start of the course. Should a participant lack technical knowledge, the theory portion must be learned through self-study. Level 2: 2 day course “Specialist for work on HV intrinsically safe vehicles” at KTD in Calw. Level 3: Examination at the end of the course

Duration: 2 days

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ZKF 6 Function and adjustment of the assistance and lighting systems depending on

the chassis geometry

Again, and again experts point out how important the wheel alignment is as the basis for all

the settings of driver assistance systems. But how important is the adjustment of axles re-

ally? In which form and to what extent does it actually become noticeable when you change

the axle geometry with respect to adjusting sensors?

This training is to attract workshop personnel that have already attended the course “Diagno-

sis of Electrical Systems in Body Repair – Advanced Training”. In a very detailed manner,

participants will deal with topics on driver assistance system and adjusting them. Issues on

innovations and approaches to modern headlight systems and how to adjust them will also

be dealt with. In addition, the treatment of vehicles with tire pressure monitoring systems

(TPMS) in body shops will be covered with regard to the current legal situation and the re-

sulting regulations.

Goal of the course

Participants are able to establish the direct connection between adjusting the chassis and as-

sistance systems and are able to substantiate the arising expenses with arguments.

Participants are able to make adjustments on assistance systems and are able to apply the

required tools for adjustments professionally and properly.

Participants are able to adjust modern lighting systems with the required setting devices and

are able to assess the quality of a room for headlight setting.

The participants get an outline of the basic function and the practical work on tire pressure

monitoring systems (TPMS).

Contents

How to adjust camera systems and radar systems

How to evaluate measured values in camera systems and radar systems

Driving axle, vehicle longitudinal axis and axle geometry

How to adjust the chassis

Innovations in LED systems and laser light systems

How to equip a modern location for headlight alignment

How to adjust headlights with modern equipment

Outline of TPMS (tire pressure monitoring system)

Duration: 2 days