SDLG VRT200 Transmission Training Material 10642

VRT200 Transmission Training Material
Trainer : Peng Jiyang

Department: Service Department
Date : Apr, 2020
1. Target Group:
Service Technicians
2. Learning Objectives ：
• After the course, the student should be able to:

• Describe the structure and working principle of SDLG VRT transmission.
• Identify the components in the transmission.
• Troubleshoot the transmission when mounted in the machine.
• Replace parts and/or components.
• Disassemble and assemble the transmission and its components.
3. Duration（h）：
24 H
山东临工工程机械有限公司
What causes VRT200 have no first forward gear?
Try to introduce the transmission route of each gear of VRT200 according to the schematic diagram.
Content
Chapter Ⅰ Overview
Chapter Ⅱ Torque convertor
Chapter Ⅲ Gearbox
Chapter Ⅳ Transfer gear case
Chapter Ⅴ Electrical control valve
Content
Chapter Ⅵ Lubricating oil valve
Chapter Ⅶ Transmission pump
Chapter Ⅷ Oil supply system
Chapter Ⅸ Common failure and troubleshooting
Chapter Ⅹ VRT200 maintenance
Chapter Ⅺ Electrical system
Content
Chapter Ⅲ Gearbox
1. Overview L958F L968F
1.Features of VRT200 gearbox
1. Overview L958F L968F
2.Overview 7
4 5 6
3 2 1
1.Hydraulic torque converter 2.Gearbox 3.Drop box 4.Parking brake caliper
5.Control valve 6.Filter 7.PTO

Content
Chapter Ⅲ Gearbox
2. Torque converter L958F L968F
1.Components of torque converter
2
6
2.Structue of torque converter
Impeller
Stator
seat
Shaft
Elastic Stator
plate
Turbine
Wheel
cover
2.Structure of torque converter

7
8
1
1.Elastic plate 9
2
2.Turbine
3.Guide wheel 3
4.Cover
5.Turbine hub 4
6.Shaft 10
7.Impeller
8.PTO 5
11
9.Gear 6
10.Stator seat
11.Transfer gear
12.Torque converter 12
3.Transmit line of torque converter
4.Oil supply of torque converter
Torque
converter
Lubricatin
g valve
Guide
wheel seat
Test point of oil outlet Relief

torque converter(PC) valve
Content
Chapter Ⅲ Gearbox
3. Gearbox L958F L968F
1.Strructure of gearbox
4
Shaft of
5 KFR clutch
3
Torque
convert Shaft of K34
1 2 er clutch
Transit gear of
rear shift Intermedi
ate shaft
Shaft of K12
clutch
1.K12 clutch 2.K34 clutch 3.Intermediate shaft assembly 4.KFR clutch
2.1 Structure of clutch

Section of clutch
Gear Shaft of Piston

assembly clutch
Bearing Friction Separator Spring

plate
group

Disassembly of clutch

Assembly of clutch
3. F/V clutch
KFR clutch
3.1 Oil supply of gearbox

KFR clutch
R clutch
F clutch
Lubricating
hose
KFR oil
distributor
Hose for
forward shift
Hose for
reverse shift
3.2 Main components of clutch
KFR clutch
Gear Clutch Piston

assembly shaft
Friction
plate Separat
Bearing Spring
group or
3.3 Separator
Separator
3.3 Separator
Throttle
KFR clutch
3.4 Clutch KFR clutch
3.5 Drive and driven friction plates
9 drive 9driven friction plates
Clearance 2.65—3.35mm
3.6 Hub of clutch and spring
3.6 Hub of clutch and spring
L958F L968F
3. Gearbox
2.8 Pressure disc and retaining ring
KFR clutch
4. 1,2 clutch
K12 clutch
Friction
Gear plate group
assembly
Shaft
4.1 Oil supply of clutch
Stator
seat K1 clutch
Separator
K12 oil of K12
distributor clutch
K2 clutch
K34 oil
distributor
K12 oil
distributor
4.2 Main components of clutch
Gear group of shift 2 Friction plate group
Bearing
Bearing
Gear group
of shift 1
Shaft
4.3 Separator
Separator
Gear
Spring
Shaft Friction plate

group
4.3 Separator
Throttle
Pinhole
Piston
The oil cavity is divided into two space

Friction plate group of separator, oil through a small hole
into the second chamber, have the
effect of moderate shift shock.
4.4 Separator
4.5 Drive and driven friction plates
K1 clutch 10 drive friction plates and 10 driven friction plates( 8 thickness is 1.9mm,2 is 2.1mm）.
K2 clutch 6 drive friction plates and 6 driven friction plates （2 thickness is 1.9mm,4 is 2.1mm）.
K1 friction plate clearance from 2.85mm to 3.35mm； K2 friction plate clearance from 1.75mm to 2.25mm.
L958F L968F
3. Gearbox
4.6 Piston and piston ring
5. Clutch of shift 3 and 4

K34 Clutch
5.1 Oil supply of clutch

Oil distributor(K3,k4)
Oil distributor(K3)
Oil distributor(K4)
6. Intermediate shaft
Straight gear Intermediate shaft Angular gear
7.PTO
The function of orifice plug
1. Orifice plug
2. Plug
3. Shaft
4. Gear
8.1 Transmission line of gearbox

F1

F2

F3

F4

R1

R3
Content
Chapter Ⅲ Gearbox
4. Transfer gear case L958F L968F
1.1 Transfer case

Air breather
Oil filler
Parking brake
Oil level gauge
Brake disk
4. Transfer gear case L958F L968F
1.2 Transfer case
1.Output gear 3
2.Intermediate gear
3.K12 output gear 2
4.K34 output gear
5.Brake disk 5
1
6.Oil level gauge
7.Drain plug
7 6
Content
Chapter Ⅲ Gearbox
5. Electronic control gear selector valve L958F L968F
1.1 Control valve
Aerial
linker
Content
6. Lubricating valve L958F L968F
2. Lubricating valve
Oil outlet from To lubricating Adjust valve for oil

torque Oil to radiator system outlet of torque
converter converter
Lubricating valve
Overflow valve Oil return from radiator
Content
7. Variable speed pump L958F L968F
3. Variable pump
Layout outside Layout inside
Content
8. Oil supply system L958F L968F
2.1 Variant pump

Variant pump
2.2 Control valve
2.3 Solenoid valve

The condition of solenoid valve under different shift
Solenoid valve
Shift
S1 S2 S3 S4 S5 Clutch
S4
Neutral
S3 position
F1 ● ● ● KF、K1
F2 ● ● KF、K2
S1
F3 ● KF、K3
F4 ● ● KF、K4
S2
R1 ● ● ● ● KR、K1
R2 ● ● ● KR、K2
S5
R3 ● ● KR、K3
R4 ● ● ● KR、K4
S1 S2 S3 S4 S5
M1 M2 M6 M7 M5
Remark ：new and old material the solenoid valve correspond relationship like
this
2.4 Trimmer valve
2.5 Oil filter
Old filter New structure filter
2.6 Lubricating valve
Oil return Oil outlet

port port
To forward and
reverse clutch
Oil from radiator to this port
To radiator
2.7 Oil distributor
Idler pulley seat
Pressure test point，the K1,k2 oil distributor

shift 1、2、3、4 and
lubricating point from up
to low K3,k4 oil distributor
2.8 Oil distributor
Reverse clutch
Forward clutch
Oil distributor for forward

and reverse clutch(KFR)
Oil hose for

forward clutch
Oil hose for

reverse clutch
3.1 Oil supply principle
Oil pan
Filter
Variable
pump
Filter
Control
valve
Torque
Clutch converter
Radiator
Lubricati
Red line– Pressure oil for clutch ng valve
Blue line–Pressure oil for torque Component
convertor s
Yellow line– oil for lubricating
Green line– Air
8. Oil supply system
3.1 Forward 1（KF1）
3.5 Reverse 4 （R4）
4.2 Pressure test port
No Description Pressure range

T1 Torque converter outlet oil pressure and temperature measuring port 0.6～0.75MPa
T2 Transmission system main pressure measuring port 1.9～2.3MPa
T3 Torque converter inlet oil pressure and temperature measuring port 0.8～1.0MPa
T4 KR pressure measuring port 1.8～2.2MPa
T5 KF pressure measuring port 1.8～2.2MPa
T6 I, II, III, IV gear pressure measuring port (from top to bottom) 1.8～2.2MPa
T7 Lubricating oil pressure measuring port 0.12～0.35MPa
4.3 PTO lubricating

Oil lubricating different positions through
lubricating valve after cooling.
Lubricating oil for
KF and KR oil
distributor
Lubricating oil to
PTO
4.3 Lubricating
Lubricating line inside of

torque converter。
Oil return tube
Lubricating oil
pressure test port
Lubricating oil for

K1 K2 and K3 K4
oil distributor
9. Common failure and troubleshooting L958F L968F
No Description Analysis Solution

1）Variable speed pump wear and leakage, oil
Replace the variable speed pump
supply capacity is insufficient
Low shift oil pressure, 2）Variable valve rod wear or jammed Change the variable valve assembly
1
alarm 3）Pressure sensor with the variable valve Adjust the pressure sensor and variable
connection bad, valve connection, or replace the pressure
Or the pressure sensor failure sensor
1）Variable speed controller failure, leading to
variable speed solenoid valve on the valve gear Change of variable speed controller
without power
Machine can’t move on
2 each shift, oil shift To check the transfer case if the oil
2）Transfer case oil quantity too little, a serious
pressure is normal. contains a large number of metal debris,
shortage of gear lubrication, produce high
the gear for lack of oil lubrication, produce
temperature wear and intermediate shaft gear tooth
high temperature and wearing, replace
of a smooth, power can’t transfer to output shaft
the transfer case
Variable pressure is The generator output voltage is too high, when the
3 normal, sometimes no voltage is greater than 33.6 V, variable speed Replace the alternator
gear controller automatic protection, no output
Variable pressure is
4 normal, but no reverse Virtual connect reverse control power Use an external power supply cord
gear
Disordered transmission Variable speed controller failure Change of variable speed controller
pressure is normal, gear
in disorder, such as Harness wrong connection of speed controller Adjust the wiring
5 gearbox respectively 2,
Variable speed solenoid valve malfunction Replace the electromagnetic valve
3, with 3 walking
Virtual connect reverse Variable valve stem oil holes by foreign bodies Clean the variable valve stem or change
control power blocked the variable valve assembly
9. Common failure and troubleshooting L958F L968F
No Description Analysis Solution
A gear clutch separate shelf oil discharge Open the oil pan drain plug, if out of the oil
holes blocked, the gear switch to the other contains a large number of black powder
Transmission oil temperature
6 gear, the gear friction plate cannot be particles, and the smell of burnt food that
is high
separated in time, lead to friction plate skid, has burned clutch fault, overhauling the
high temperature gearbox, replace the fault of the clutch
Replace the turbine set, change the

1）Torque converter of turbine blade
transmission oil radiator at the same time,
The whole machine gears deciduous or roller blade is damaged
7 wash the gearbox
work less power
2）Torque converter of the turbine wheels Replace the turbine set, clean up the
spline serious wear and tear gearbox
Unable to forward or backward The forward or reverse clutch friction plate
8 Replace forward reverse clutch assembly
gears burning, or gear assembly fracture
The gear clutch friction plate burning, or

9 One gear no power Replace defective clutch assembly
broken gear assembly
Transfer case amount is insufficient or Transfer case overhaul and maintenance,
10 Transfer case noise inside forget refueling, gear wear, cutting, caused to ensure that the transfer case amount to
noise inside conform to the requirements
Transmission of oil in the Transfer case 1/2 gear blocking the o-ring
11 transfer case caused by the oil on the damage, transmission oil flow in the Replace the o-ring
into the transfer case transfer case
Variable valve with gear case
12 Seal failure, resulting in leakage Replace the seal
joint surface spills
Content
L958F L968F
10. Maintenance
Transmission Oil：
CH 15W-40 and Upper
Interval：
First 100H， Time interval 1000H
Capacity：
Transmission 17.1
Drop box 4.7L
Content
Overview
1. Component
Gear selector
Instrument
Speed sensor
Solenoid valve
Back-up
buzzer
TECU
Power cut off switch
Starter
Electrical system component
1.TECU
Spring
TECU End cover Stitch Pin
sheet
Shock Bracket
pad
1.TECU
5
1
1.TECU
TECU have two parts ：
① Input connector：
② Output connector：
1.TECU
1 Control box
2
2 Transmission ECU
3 3 Connector
4
4 Harness
ECU position differs with different machines
2. Gear selector
2
3
5 4
1 Location Pin 2 KD button 3 Lock switch 4 Harness 5 Connector
2. Gear selector
KD output
KD function
Speed output
1-4 gear select
Forward output
Neutral
Power output Direction select
Rear gear output
Gear selector schematic diagram
2. Gear selector
Gear selector schematic diagram
Selector （F）（R）（N) KD

Pin Conn Selector
Color 1 2 3 4 1 2 3 4 1 2 3 4
ector
Blue
270 7 AD1 B1 ● ● ● ● ● ●
280 Green 8 AD2 B2 ● ● ● ● ● ●
290 Black 9 AD3 B3 ● ● ● ● ● ● ● ● ● ● ● ●
240 Yellow 4 AD4 V ● ● ● ●
58 Pink 6 AD5 R ● ● ● ●
59 Glue 5 AD6 AS ● ● ● ●
210 Purple 10 AD7 ●
220 Red/black 2 ED1 (+)
2. Gear selector
Gear selector
2. Harness
（1）Split type harness

Solenoid valve
Connect with machine harness
Speed sensor
Gear selector
TECU
2. Harness
（1）Split type harness
Solenoid valve
Pin No. Line No.
Pin No. Line No.
A 170
1 170
B 130
2 130
C 140
Connect with 3 140
D 150
transmission
E 160 4 150
harness
F 0 5 160
6 0
L968F E5 model
2. Harness L958F E2 model
Integrated type harness
To TECU
Pin Wire Pin Wire

No. No. No. No.
1 48 24 210
5 58 25 290
To Instrument harness
8 280 26 270
13 150 27 310
15 140 29 59 Instrument harness

17 320 30 160
19 220 31 170
22 57 33 130
23 240 35 0
Use integrated wire only have one connector
L968F E5 model
2. Harness L958F E2 model
Integrated type harness
CN011
CN011
Pin No. Line No. Pin No. Line No. Pin No. Line No.
S4 160/Ground line
S3 150/Ground line
S1 130/Ground line
140/Ground line
S2
S5 170/Ground line
Rear frame harness
2. Harness
① Connector and terminal type
Post
② Connector pin sequence
③ Connector pins and line number correspond to the table

Pin No. Wire No. Function Pin No. Wire No. Function
1 48 Power line 24 210 KD output line
5 58 Reverse gear signal line 25 290 Power line
8 280 Speed control line AD2 26 270 Speed control line AD1
13 150 Connect with S3 27 310 Speed sensor signal line
15 140 Connect with S2 29 59 ignition interlock line
17 320 Sensor 2 ground line 30 160 Connect with S4
19 220 Power output line 31 170 Connect with S5
22 57 Power cut off signal line 33 130 Connect with S1
23 240 Forward gear output line 35 0 Ground line
2. Harness
Gears selector harness

② Pins sequence
Harness side
connector
Control lever side Harness side
Control lever Pins Wire Function Wire color

connector 2 220 Power output line Red/black
4 240 Forward gear output line Yellow
5 59 Ignition interlock signal line Glue
6 58 Reverse gear signal line Pink
7 270 Speed control line AD1 Blue

① Connector and terminal type
8 280 Speed control line AD2 Green
9 290 Power line Black

Post 10 210 KD output line Purple
2. Harness
solenoid valve connector
1. Connector and terminal type
2. Connector pins sequence
3. Connector pins and line No. correspond to the table
Pins Wire Function

A 170 Connect with S5
B 130 Connect with S1
C 140 Connect with S2
D 150 Connect with S3
E 160 Connect with S4
F 0 Ground line
2. Harness
1. Connectors for variable speed control
harness and machine harness
1. Connector and terminal type
Post
2. Connector pins sequence
3. Connector pins and line No. correspond to the table

Pins Wire Function
2 59 Ignition interlock signal line
3 58 Reverse gear signal line
6 57 Power cut off signal line
9 48 TECU power line
10 48 TECU power line
12 52 TECU indicator line
14 0 Ground line
15 0 Ground line
Solenoid valve
S4
S3
S1
S2
S5
TECU logic and clutch relationship likes in the following table
Solenoid
Direction Gear Clutch
S1 S2 S3 S4 S5 S4
1 KF/K1 ● ● ●
S3
2 KF/K2 ● ●
F
3 KF/K3 ●
S1
4 KF/K4 ● ●
N
S2
1 KR/K1 ● ● ● ●
2 KR/K2 ● ● ●
R S5
3 KR/K3 ● ●
4 KR/K4 ● ● ●
Electrical system function
1. Main function
1. Gear function Strat Start

protect interlock Gear
selector
2. Start interlock function Neutral
indicator
3.Reverse gear signal output
function
T-ECU
4. KD function
Engine hood
5. Power cut off function open Ignition
switch
6. Anti - interference and anti -
clutter file function
7. Gear interlock function
Start
motor
Electrical system function
1. Main function
Power cut off relay

Power cut off
1. Gear function indicator Power cut off
signal from
Ground transmission
2. Start interlock function
3.Reverse gear signal output Parking Parking brake indicator switch

brake
function indicator
Power
4. KD function Brake tail light switch

Brake Solenoid Power cut off
signal from
5. Power cut off function transmission
Parking brake switch Tail
lights
6. Anti - interference and anti -

The round button in the
clutter file function control panel
Emergency brake switch
7. Gear interlock function

Brake pressure
low alarm switch
Brake pressure low
alarm indicator
Power
Transmission electrical system theory
Gear
selector
S4
S5 Solenoid
S1
TECU
S2 valve
S3
Speed sensor
Ground line
Power line
Power cut off signal input line
Reverse signal output line
Start interlock line
Simulation test of variable speed control system
A. Control lever B. multimeter C. TECU D. connector E. 24V power F. connect harness

G. Variable speed control system and connector of the machine H. the connector of
control lever J. connect with solenoid valve K. solenoid valve
Fault diagnose
1. Measure the solenoid
The resistance of old solenoid is 26Ω， new solenoid valve resistance is 32.5±5%Ω
Fault diagnose
2. Power cut off switch detect
Fault diagnose
3. Gear selector detect
Red/black glue Yellow blue purple
1 4 7 10
2 11
55 8
3 6 9 12
pink Green Black
Fault diagnose
4. TECU detect
Whether Whether
Whether the main
the gear each Cable plug
circuit is normal,
shift solenoid connection and
whether the power
handle is valve is circuit is normal
supply is normal
normal normal
Use exclusion method to judge
第七节常见故障排除
Ite Fault
Cause Troubleshooting
m phenomenon
1. The starting circuit (such as power

supply voltage, electric lock, starting relay,
starting motor, etc.) is faulty
1. Check the host circuit
2. The handle is not in the neutral position
2. The handle is in neutral
Engine can’t 3. The fuse blown for Power supply of the
1 3. Change the fuse
start transmission control system
4. Plug the connector again or replace the control lever
4. Poor contact of handle plug or
malfunction of handle 5. Plug the connector again or replace the TECU
5. Poor contact of electrical control box
plug or malfunction of electrical control box
1. Check the oil level according to the correct method and add oil
1. Insufficient oil level
2. Replace the elastic plate or replace the corresponding damaged
2. The elastic plate connecting the engine
component
and the torque converter is torn or the
power connection between the torque 3. Check whether the power supply voltage is normal, whether the harness
converter and the transmission input gear is worn, and whether the harness plug is loose
Machine can’t is faulty (rarely occurs) 4. Oil path problem
2
move 3. Vehicle circuit failure 5. Check the resistance of the solenoid valve should be the specified value,
4. Variable speed pressure is too low if it is 0 or ∞, it indicates damage and needs to be replaced.
5. The solenoid valve is broken 6. Check according to the logic diagram of the handle, if it does not meet the
instructions, it needs to be replaced if it is damaged.
6. The control lever is broken
7. Check according to the logic diagram of the electric control box. If it does
7. Failure of the electric control box
not meet the description, it needs to be replaced.
1. If the emergency brake pressure switch or the parking brake switch is

First and 1. The emergency brake pressure or
disconnected from the circuit, the vehicle will restore the 1st and 2nd gears,
3 second gear parking brake pressure switch is broken
indicating that the switch is broken and needs to be replaced
can’t move 2. Solenoid valve failure S3 failure
2. Replace the solenoid valve S3

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VRT200 Transmission Training Material

Trainer : Peng Jiyang

• After the course, the student should be able to:

Chapter Ⅱ Torque convertor

Chapter Ⅳ Transfer gear case

Chapter Ⅴ Electrical control valve

Chapter Ⅶ Transmission pump

Chapter Ⅷ Oil supply system

Chapter Ⅸ Common failure and troubleshooting

Chapter Ⅹ VRT200 maintenance

Chapter Ⅺ Electrical system

Chapter Ⅱ Torque convertor

Chapter Ⅳ Transfer gear case

Chapter Ⅴ Electrical control valve

1.Features of VRT200 gearbox

5.Control valve 6.Filter 7.PTO

Chapter Ⅱ Torque convertor

Chapter Ⅳ Transfer gear case

Chapter Ⅴ Electrical control valve

1.Components of torque converter

2.Structue of torque converter

2.Structure of torque converter

3.Transmit line of torque converter

4.Oil supply of torque converter

Test point of oil outlet Relief

Chapter Ⅱ Torque convertor

Chapter Ⅳ Transfer gear case

Chapter Ⅴ Electrical control valve

1.K12 clutch 2.K34 clutch 3.Intermediate shaft assembly 4.KFR clutch

2.1 Structure of clutch

Gear Shaft of Piston

Bearing Friction Separator Spring

2.2 Structure of clutch

2.3 Structure of clutch

3.1 Oil supply of gearbox

3.2 Main components of clutch

Gear Clutch Piston

3.4 Clutch KFR clutch

3.5 Drive and driven friction plates

9 drive 9driven friction plates

3.6 Hub of clutch and spring

3.6 Hub of clutch and spring

2.8 Pressure disc and retaining ring

4.1 Oil supply of clutch

4.2 Main components of clutch

Gear group of shift 2 Friction plate group

Shaft Friction plate

The oil cavity is divided into two space

4.5 Drive and driven friction plates

4.6 Piston and piston ring

5. Clutch of shift 3 and 4

5.1 Oil supply of clutch

Straight gear Intermediate shaft Angular gear

8.1 Transmission line of gearbox

8.2 Transmission line of gearbox

8.3 Transmission line of gearbox

8.4 Transmission line of gearbox

8.4 Transmission line of gearbox

8.7 Transmission line of gearbox

Chapter Ⅱ Torque convertor

Chapter Ⅳ Transfer gear case

Chapter Ⅴ Electrical control valve

1.1 Transfer case

Selector （F）（R）（N) KD