ZF TRAINING

CAR & COMMERCIAL VEHICLE

MODULES
CAR TRUCK

Car Transmission 6 Speed page 6 Commercial Vehicle Steering

and Suspension page 16
Car Clutch page 8
Vehicle ZF Servocom
Car DMF page 10 Steering Systems page 18

Car Steering and Suspension page 12 CV Clutch / Dual Mass &

Concentric Actuation Systems page 20

AS Tronic Transmission page 22

ZF Training Schedule Car page 24

ZF Training Schedule CV page 26

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WELCOME TO THE TECHNICAL TRAINING
MODULES DELIVERED BY ZF SERVICES
UK LTD, AND YOUR [pro]Tech TRAINING
TEAM. Our training courses are fully IMI
accredited and designed to give you both
theory and hands on experience to enhance
your product knowledge and develop your
existing technical skills. After completing
your chosen course module you will
receive an official ZF and IMI certificate.
Browse through the brochure to see the
extensive courses on offer, an overview
can be found on pages 24 - 27.

We look forward to welcoming you.

Your ZF Services UK Technical Training Team.

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CAR
Car Transmission
6 Speed
This course is aimed at garage technicians / mechanics
for Car and Light Commercial Vehicles (LCV) applications.

What is it about? Course Overview

This two day course considers the key
aspects of the transmissions operation and
servicing requirements and covers basic
diagnostic skills.
Transmission design and operation
Lubrication requirements
Correct oil change processes
Basic diagnostic skills
The use of the ZF Test Man
diagnostic system

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 CAR

What will you get out of it?

An understanding of:
How the 6 speed automatic transmission operates
The lubrication requirements of the transmission
The effect of using the incorrect lubricants
The correct processes for oil changes
How to correctly identify transmission faults in order to ensure correct diagnosis
(A separate course operates covering detailed transmission diagnostics, including
information on the mechatronic unit.)

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Car Clutch

This course is aimed at garage technicians / mechanics

for Car and Light Commercial Vehicles (LCV) applications.

What is it about? Course Overview

This one day course considers the key
aspects of clutch system awareness,
illustrating the clutch functions,
components and types through
presentation, discussion and hands on
tutorial.
Components and clutch operation
Clutch release systems - CSC fitting
awareness and installation
Vibration damping - damper design,
functions and features
XTend self-adjusting clutch - features and
fitting awareness
Fitting awareness theory
Practical fitting awareness (workshop)

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 CAR

What will you get out of it?

Skills to undertake a correct clutch and release system installation
Recognition of the a clutch components
Knowledge of vibration reduction
Skills to undertake a practical clutch damage assessment
Guidance from experienced tutor; with extensive practical knowledge of SACHS clutches
Potential workshop costs reduction (reducing chances of repeat vehicle failure)

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Car DMF

This course is aimed at garage technicians / mechanics

for Car and Light Commercial Vehicles (LCV) applications.

What is it about? Course Overview

This one day course considers the key
aspects of vehicle system awareness,
illustrating the DMFs superiority
above conventional dampers through
presentation, discussion and hands on
tutorial.
Conventional driven plate dampers
functions and failures
DMF why install it?, why need it?,
how does it work?
DMF components and types
DMF wear and damage assessment
Vehicle system faults and investigation
DMF practical asssessment of damage
(workshop)

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 CAR

What will you get out of it?

Skills to undertake a practical DMF damage assessment
Recognition of the principle differences between conventional damper and DMF
Fault finding skills for root cause of DMF failures
Guidance from experienced tutor; with extensive practical knowledge of SACHS DMF
Potential workshop costs reduction (reducing chances of repeat vehicle failure)

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Car Steering and Suspension

This course is aimed at garage technicians / mechanics

for Car and Light Commercial Vehicles (LCV) applications.

What is it about? Course Overview

This one day course considers the key
aspects of modern steering systems and
gives an insight into the developments
currently taking place in both steering and
suspension systems. This is done by both
classroom and hands on tutorials.
Steering System Integration.
Shock Absorber development including
continuous damping control
Suspension developments and the use of
composite materials
Active Steering Systems
Vehicle system faults and investigation
Steering Geometry set up and
complexity using VW/Audi multilink
system as an example

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 CAR

What will you get out of it?

An understanding of:
Steering and suspension systems as integrated parts
Modern developments in steering and suspension systems
The principles of active steering systems
The importance and complexity of steering geometry
Potential workshop costs reduction (reducing chances of repeat vehicle failure)

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COMMERCIAL
VEHICLE
Commercial Vehicle
Steering and Suspension
This course is aimed at garage technicians / mechanics
for Commercial Vehicles (LCV & PSV) applications.

What is it about? Course Overview

This one day course considers the key
aspects of modern steering systems and
gives an insight into the developments
currently taking place in both steering and
suspension systems. This is done by both
classroom and hands on tutorials.
Steering System Integration and Safety
The correct handling and installation
of parts
Shock Absorber development including
continuous damping control systems
Cab Dampers
Suspension developments and the use of
composite materials
Pneumatic Dampers
Vehicle system faults and investigation
The requirements for improved accuracy
with regards to steering geometry on
commercial vehicles

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 CV

What will you get out of it?

An understanding of:
Steering and suspension systems as integrated parts
Modern developments in steering and suspension systems
The principles of active steering systems
The importance and complexity of steering geometry
Potential workshop costs reduction (reducing chances of repeat vehicle failure)

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Vehicle ZF ServoCom
Steering Systems
This course is aimed at garage technicians / mechanics
for Commercial Vehicles (LCV & PSV) applications.

What is it about? Course Overview

This one day course considers the key
aspects of this steering system and gives
an insight into the developments currently
taking place in steering systems including
the introduction of electrical systems into
commercial vehicles. This is done by both
classroom and hands on tutorials.
Steering System Integration and Safety
The correct handling and installation of
ZF Servocom parts.
Oil, fluids and lubricants and maintenance
procedures
Developments in Commercial Vehicle
electrical steering systems
Design and system overview of ZF
Servocom components
Test points, Test Parameters and Results
(Workshop) Test Systems and Equipment
Vehicle system faults and investigation

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 CV

What will you get out of it?

An understanding of:
The ZF Servocom system and components
Modern developments in CV steering systems
The principles of the ZF Servocom System
The location of test points and parameters of the system
An awareness of the servicing requirements of the system
An awareness of the correct oils and lubricants permitted on the ZF Servocom system
Potential workshop costs reduction (reducing the chances of repeat vehicle failure)

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CV Clutch / Dual Mass &
Concentric Actuation Systems
This course is aimed at garage technicians / mechanics
for Commercial Vehicles (LCV) applications.
What is it about?
This one day course considers the key
aspects of clutch and Dual Mass Flywheel
system awareness, illustrating the clutch
and DMF functions, components and types
through presentation, discussion and hands
on tutorial. Concentric Actuation Systems
and programming requirements are also
discussed.
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Course Overview
Components involved in both Clutch
and DMF operation
Clutch release systems - CSC fitting
awareness and installation
Concentric Actuation System designs
Vibration damping - damper design,
functions and features
XTend self-adjusting clutch - features
and fitting awareness
Fitting awareness theory
Practical fitting awareness (workshop)
Clutch testing and demonstration
(workshop)
 CV

What will you get out of it?

Skills to undertake a correct clutch and release system installation
Recognition of the clutch components
Knowledge of vibration reduction as affected by Dual Mass Flywheel Systems
Skills to undertake a practical clutch damage assessment and understand root
cause failures
Awareness of Concentric Actuation Systems, programming requirements and
damage assessment.
Guidance from experienced tutor; with extensive practical knowledge of SACHS
clutches and Dual Mass Flywheel Systems
Potential workshop costs reduction (reducing chances of repeat vehicle failure)

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AS Tronic Transmission
This course is aimed at garage technicians / mechanics
for Commercial Vehicles (LCV) applications.
What is it about?
This two day course considers the key
aspects of the transmissions design
and operation, including associated
components, the interpretation of errors,
field experiences and basic programming
requirements.
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Course Overview
The design and operation of the
AS Tronic Transmission
An overview of associated components
(clutch) and its effect on the transmission
Lubrication requirements and servicing
needs
An overview of common problems and
rectifications
The basic interpretation of fault codes
and signals
 CV

What will you get out of it?

Skills to be able to correctly service the transmission
Recognition of the key components, and how and to install them
Knowledge of the effect of associated components on transmission operation
Skills to quickly identify common faults and rectify them
Awareness of fault codes and their interpretation
A basic understanding of signals and data available from the transmission
Guidance from experienced tutor; with extensive practical knowledge on the
AS Tronic Transmission
Potential workshop cost reductions (reducing chances of repeat vehicle failure)

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Course costs Contact [pro]Tech
Car: 150 per person Email: protech.zf-services-uk@zf.com
Tel: 0333 240 1123

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 CAR COURSE SCHEDULE

* Courses are subject to availability and may change.

* Contact the [pro]Tech team to request a multi booking quote.

Car Courses Places Date

Clutch 10 29/01/2015
DMF 10 11/02/2015
Hybrid 10 25/02/2015
Steering & Suspension 10 26/02/2015
DMF 10 18/03/2015
DMF 10 25/03/2015
DMF 10 14/04/2015
Steering & Suspension 10 30/04/2015
6 HP Transmission 8 12 & 13/05/2015
Bumper to Bumper 10 25 & 26/05/2015
Steering & Suspension 10 05/05/2015
Clutch 10 20/05/2015
Steering & Suspension 10 21/05/2015
Hybrid 10 03 & 04/06/2015
6HP Transmission 10 17 & 18/06/2015
Steering & Suspension 10 24/06/2015
Steering & Suspension 10 31/07/2015
6HP Transmission 10 19 & 20/08/2015
Hybrid 8 12 & 13/08/2015
Bumper to Bumper 10 20 & 21/08/2015
Steering & Suspension 10 02/09/2015
Clutch 10 16/09/2015
6HP Transmission 8 07 & 08/10/2015
Hybrid 10 20 & 21/10/2015
Steering & Suspension 10 12/11/2015
Steering & Suspension 10 25/11/2015
Bumper to Bumper 10 25 & 26/11/2015
6HP Transmission 8 26 & 27/11/2015

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Course costs Contact [pro]Tech
CV: 170 per person Email: protech.zf-services-uk@zf.com
Tel: 0333 240 1123

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 CV COURSE SCHEDULE

* Courses are subject to availability and may change.

* Contact the pro[Tech] team to request a multi booking quote.

CV Courses Places Date

Clutch/DMF 10 04/02/2015
AS Lite 10 19/02/2015
AS Range 8 18 & 19/03/2015
Steering & Suspension 10 09/04/2015
Clutch/DMF 10 15/04/2015
AS Range 10 04/05/2015
AS Range 8 27 & 28/05/2015
Servocom 8 01/07/2015
AS Lite 10 07 & 08/07/2015
Steering & Suspension 10 09/09/2015
Clutch/DMF 10 10/09/2015
Steering & Suspension 10 24/09/2015
AS Range 8 22 & 23/10/2015
Servocom 10 27 & 28/10/2015
LCV E Tronic 10 18 & 19/11/2015
AS Range 8 18 & 19/11/2015

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ZF Services UK (Nottingham Office)
Abbeyfield Road,
Lenton, Nottingham
NG7 2SX

ZF Services UK (Crick Office)

Eldon Way, Crick,
Northamptonshire
NN6 7SL

Tel: + 44 (0) 333 240 1123

Fax: + 44 (0) 844 257 0666
Email: protech.zf-services-uk@zf.com

www.zf.com/uk/protech