Hyster D4N User manual

PARTS BOOK
AND,
· INSTRUCTION MANUAL
- for
HYSTER®
D4N ,TOWING ,WINCH
: -,' ·+ ;

INSTRUCTIONS FOR ORDERING
HYSTER
REPAIR PARTS
I. Always give the serial number of machine, which is found
on name plate.
2. Always specify name, number and letter of part required.
3. Always specify shipping destination and definite shipping
instructions such as Parcel Post, Express, Air Express.. Auto
Freight or Rail Freight.
Note: The oil for the transmission shall be a straight mineral type,
stable. properly refined. free from fatty acids, resins. abrasives or
other non-petroleum material and shall meet the following re-
quirements.
1. Viscosity at 210° F•........................................ 80 - 90 Seconds
Saybolt Universal
2. Viscosity Index, Minimum ............................ 85
3. Pour Point. Maximum .................................... Minus IO° F.
4. B. S. &W., Maximum .......................................05 %
5. Color, Maximum .............................................. 8
Black oils or residuum materials will NOT be considered as satis-
factory for. this specification.

PARTS BOOK
AND
INSTRUCTION MANUAL
for
HYSTER
D4N TOWING WINCH
For "Caterpillar" D4 and R4 Tractors
TRACTOR MODEL SERIAL NUMBERS SG-2076 and up
7J-9215 and up
LITHO IN U.S.A.
Including
Installation, Lubrication and
Servicing Instructions
HYSTER COMPANY
PORTLAND 8, OREGON • PEORIA I. ILLINOIS • DANVILLE, ILLINOIS
U.S.A.

2
TRACTOR OPERATOR PRECAUTIONS
1. While the tractor is in motion, extreme care should be taken
to prevent accidents and personal injuries.
2. Before stopping the engine and dismounting from the tractor
A. Stop the motion of the tractor.
B. Disengage the tractor master clutch.
C. Place the tractor transmission gearshift lever in neutral.
D. Set and lock the tractor brakes. (When parking on a hill,
the tractor should be chocked.)
3. At the start of the shift, check to be sure that all steps under
Instruction 2 have been carried out. If these instructions are
not followed, there is danger of the tractor moving when the
operator is starting the engine, and he may be dragged under
the tractor or otherwise seriously injured.
Peoria, Illinois
PORTLAND. OREGON
HYSTER COMPANY
Danville, Illino\s

Attaching Ferrules ..
SECTION A
Operating Instructions
SECTION B
Lubrication Instructions
Service Instructions ......
SECTION C
Installation Instructions
Tractor Fender Alterations
SECTION D
3
INDEX
93
4-9
12-13
.10-11
14-15
16
List of Parts and Illustrations .
Bevel Gear Shaft and Power Take-off Shaft Group
Brake Arrangement ............................
Brake Shaft and Drum Idler Gear Group .........
Drum and Drum Shaft Group ......
..17-33
22
32
23
30
General Arrangement
Intermediate Shaft and Reverse Idler Gear Group ...................................................................
Power Take-off. Transmission. Brake Assembly ....
Shifter Parts ............................
Side Frame Group ............................................
SECTION E
Parts and Instructions for D4N Towing Winch mounted on a tractor equipped with
18
24
17
20
28
Fender-mounted Fuel Tank ....... .................. ....................... ...........34-47
Bracket Attachment Group ..... ............................... ............................... 44
Brake Arrangement ........................ ....................... 42
Handling Gear . ................. .................... ................... 38
Operating Instructions .......................... .................. 34
Installation Instructions ..................... .......35-36-37
Top Cover and Gear Shifter Group-Transmission ........ 40
SECTION F
Optional Parts:
Adapter Group to mount D4N Towing Winch on the DS. RDS. Diesel 40. Gas 40,
Diesel 35, and Gas 35 ............ ......................
Adapter Group to mount D4N Auxiliary Drum Unit
Athey Mobilloader Adapter Group ..........................
64
63
6Q
Auxiliary Drum Unit ...... .....................
Conversion-Fender-tank Type Winch to Seat-tank Type Tractor
Conversion-Fender-tank Type Winch to Seat-tank Type Tractor with Athey
... 68-92
63
Mobilloader ................... .............................................
Conversion-Fender-tank Type Winch with Auxiliary Drum Unit, to mount on Seat-
tank Type Tractor .................
Conversion-Fender-tank Type Winch to Seat-tank Type Tractor with HT4 or IT4
Traxcavator ..........
Conversion-Seat-tank Type Winch to Fender-tank Type Tractor
Conversion-Seat-tank Type Winch with Auxiliary Drum Unit, to mount on Fender-
tank Type Tractor ...................
Conversion-Seat-tank Type Winch for use with old D4 and R4 Tractors .
Conversion-Seat-tank Type Winch to Fender-tank Type Tractor with HT4 or IT4
Traxcavator ..........
D4S Dozer Handling Gear Alteration ............
Earlier Type Shifting Mechanism ..... .........................
64
64
64
63
64
63
63
62
47
Pump Drive Adapter Group Mounting Instructions .. . ........ 50-51
Pump Drive Adapter Group for LaPlant Choate Pump ....
Pump Drive Adapter Group for Kay-Brunner Pump ....
Pump Drive Adapter Group for Isaacson Pump ..............................
Tie Plate Attachment Group
Traxcavator Adapter Group for D4 Seat-tank Type Tractor ..........
Traxcavator Adapter Group for D4 Fender-tank Type Tractor .
Numerical Index .....
Specifications ···-·· .
Peoria. Illinois
-- -~--
HYSTER COMPANY
PORTLAND. OREGON
52
52
54
48
56
58
94
.Inside Rear Cover
Danville, Illinois

4
Section A
OPERATION
This section, in addition to instructions for operating, contains illustra-
tions pertaining to certain simple adjustments and replacements which can
readily be made.
Lubrication instructions are provided on pages 12 and 13 and should be
carefully studied. The lubricant recommended should be used.
Keep all bolts and nuts tight, and check all other connections.
DO NOT OPERATE WINCH A.ND
TRACTOR AT THE SAME TIME
BE SURE WINCH GEAR SHIFT LEVER IS IN NEUTRAL POSITION
BEFORE MOVING THE TRACTOR
THE TRACTOR MASTER CLUTCH MUST BE DISENGAGED
BEFORE CHANGING GEARS IN THE WINCH.
The following instructions are taken from the TRACTOR parts book
and are especially applicable to tractors equipped with winches, as the
transmission shaft bearings receive oil only when transmission gears a•
revolving. When winch-equipped tractors remain stationary for a period
of three hours or more, it is necessary to take the following steps to insure
lubrication of the tractor upper transmission shaft bearings:
A. Disengage main clutch and shift gears into high.
B. Release both steering clutches and engage the main clutch for a
minute or two, to allow oil to be well splashed about in case.
C. Disengage main clutch, let go of steering clutch levers, and shift
the tractor gears to neutral.
D. WARNING: DO NOT let go of steering clutch levers until main
clutch has been disengaged.
Brake
The brake lever is located on the right-hand side of the operator. A
pawl and ratchet are provided to hold the brake in the applied position.
CAUTION-The brake should always be released before attempting to
operate the winch, otherwise serious damage will result.
Right and Left-hand Side of Towing Winch
The part of the towing winch on the right-hand side of the tractor,
when the driver is sitting in the tractor seat, is known as the right-hand si~
Peoria. Illinois
HYSTER COMPANY
PORTLAND, OREGON
Danville, lllinois

5
CUTAWAY VIEW OF HYSTER D4N TOWING WINCH
Working Principles
When the tractor engine is running with the master clutch engaged,
the engine turns the take-off shaft (clockwise) with bevel pinion (1) which
. in turn rotates the bevel gear (2) assembled to pinion and shaft (3). This
shaft, revolving on ball bearing (4) has a 13-tooth pinion integral with the
shaft, which meshes with driving gear (5) mounted on the intermediate
shaft (6). The intermediate shaft rotating on Timken roller bearings (7)
has two 15-tooth pinions integral with shaft, one of which meshes with the
reverse idler gear (8). The reverse idler gear runs on needle bearings (9).
With the shifter lever in the neutral position the drum would be sta-
wnary while the above mentioned gears and shafts would be constantly
revolving when the engine is running with the master clutch engaged.
Peoria, Illinois
HYSTER COMPANY
PORTLAND. OREGON
Danville, lllinois

6
To operate UNDERWINDING and pull in cable (explanation given o,
page 7) the HYSTER winch brake must be released and the tractor clutcL
be disengaged while shifting gears.
Depress HYSTER shifter lever stem and push shifter lever forward
into the locked position. This causes the shifter mechanism to move the
sliding gear (10) to the left-hand side and mesh with the 15-tooth pinion
on the intermediate shaft. This sliding gear slides on a splined shaft ( 11),
which revolves on bearings (12). Assembled on one end of this shaft is the
brake drum (13), on the other end the 12-tooth drum pinion (14).
Idler gear (15), when ordered as optional, is also located on shaft (11).
It runs on bronze bushings and is in constant mesh with the driving gear (5).
This idler gear is the power take-off for the auxiliary drum on "Power
Control Unit," or pump, on those winches so equipped.
The 12-tooth drum pinion (14) does not mesh directly with the drum
gear (16) but rather with a 15-tooth intermediate idler gear (17) that runs
on bearings (18). The drum gear is assembled to the drum (19) which re-
volves on roller bearings (20).
After shifting gears as above, with shifter lever in the lower locked
position, engage tractor master clutch, causing the drum to rotate in an
underwinding direction and spool in cable. To stop drum rotation, dis-
engage master clutch and apply winch brake.
To reverse drum rotation and pay out cable (underwinding), tractor
master clutch still being disengaged, depress shifter lever stem and push
shifter lever through neutral until lever locks in rear position. Release
brake and engage tractor master clutch, allowing drum to rotate and pay
out line.
To operate OVERWINDING and pull in cable, the winch brake must
be released and the tractor master clutch be disengaged while shifting gears.
With shifter lever in the backwards locked position, "A," the shifter
mechanism has moved the sliding gear (10) to the right-hand side and in
mesh with the reverse idler gear (8), thereby connecting to the cable drum
through the same train of gears as described previously. Engage the master
clutch, which will cause the drum to rotate in an overwinding direction
and spool in the cable over the top of drum. To stop drum rotation, disen-
gage tractor clutch and apply winch brake.
To reverse drum rotation and pay out cable (overwinding) tractor clutch
still being disengaged, depress winch shifter lever stem, push lever through
neutral and lock in the foreward position. Release brake and engage tractor
master clutch allowing drum to rotate and pay out line.
Peoria, Illinois
HYSTER COMPANY
P()R'fU\NO, OREGON
Danville, Illinois

7
NOTE: If not otherwise specified, all winches are shipped with the
,rake set for drum to be pulling cable in OVERWINDING (over the top
of the drum barrel).
Figure 1
Overwinding
When the cable leads from the top of the drum, the drum is overwinding.
To pull in the cable, release the winch brake, disengage the tractor
master clutch, depress shifter lever stem and pull the shifter lever back
into position "A." Then engage the tractor master clutch, which will cause
the drum to rotate. To stop the drum rotation, disengage the tractor clutch
and apply the winch brake.
To pay out line leave the tractor master clutch disengaged, depress the
lifter lever stem, push the lever through neutral "B'~-- and into forward
,..,osition "C." Release the winch brake and engage the tractor master clutch.
Peoria, lllinoia
HYSTER COMPANY
PORTLAND. OREGON
Danville. Illinois

8
Underwinding
When the cable leads from the bottom of the drum, the drum is under-
winding.
To pull in the cable release the winch brake, disengage the tractor
master clutch, depress the shifter lever stem and push the shifter lever
forward into position "C." Then engage the tractor master clutch which
will cause the drum to rotate. To, stop the drum rotation, disengage the
tractor clutch and apply the winch brake.
To pay out line leave the tractor master clutch disengaged, depress
the shifter lever stem, pull the lever through neutral position "B" and
into rear position "A." Release the winch brake and engage the tractor
master clutch.
Peoria. Illinois
HYSTER COMPANY
PORTLAND. OREGON
Danville, Illinois

9
METHOD OF ATTACHING CABLE
In the right hand drum flange there is a recess which holds the cable
ferrule. To fasten the cable to the drum, place the cable ferrule in the recess
and apply tension to the cable to pull the ferrule into the flange which
ke.eps it from coming out of the recess. If cable tension will not pull it into
place, tap the end of the ferrule. When removing the ferrule, it may be
necessary to pry or tap it free. There are no loose parts nec;ssary.
The illustration shows the cable in an underwind position. To change
to overwind, unwind the cable from the drum and reverse the position of
the f't::!rrule so the cable will lead from the opposite side of the recess.
Peoria. Illinois
HYSTER COMPANY
PORTLAND. OREGON
Danville, lllinois

10
Section B
SERVICING INSTRUCTIONS
This section, in addition to instruction for service, contains illustrations
and instructions pertaining to certain simple adjustments and replacements
which can readily be made.
Lubrication instructions are provided and should be carefully studied.
The lubricant recommended should be used.
Keep all bolts and nuts tight and check all other connections.
Brake Linkage-Overwinding
1. The brake link "A" should be connected to the UPPER HOLE in the
handlever at "C," Fig. 2, when the DRUM IS OVERWINDING.
2. Before connecting the horizontal link "A" make the following adjust-
ments. First, shove the handlever all the way forward against the
solid stop (which is the fully released position).
3. Shove the brake slack adjuster "H" all the way forward, then reverse
the slack adjuster "H" all the way backward. Note that it snaps to a
position midway of the two positions just tried.
4. With the horizontal link "A" connected to the hole "C" in the hand-
lever bring the slack adjuster "H" in line with the rear hole in the
fixed link "A" by resetting the slack adjuster. This is done by turning
the adjustment "J" on the slack adjuster with a wrench, until the
desired position of the handlever is attained.
5. Insert pin and cotter. This will give the maximum clearance of brake
band to drum and keep the brake from dragging and overheating.
Peoria. Illinois
HYSTER COMPANY
'P()RTT ANn. O'RF:r:ON
C
Figure 2 (Overwinding)
Danville, Illinois

11
13rake Linkage-Underwinding
1. The brake link ''A" should be connected to the LOWER HOLE in the
handlever at "B," Figure 3, when the DRUM IS UNDERWINDING.
2. R€maining instructions for connecting link "A," same as instructions
for overwinding.
H
Figure 3 (Underwinding)
Brake Adjustment
/~-)
";:/,;;;-/
Care should be taken to have the brake band lining about 1/32" free
from the brake drum when the handlever is pushed all the way forward.
As the brake band wears, it will be necessary to reset the slack adjuster
(H). This can be done by turning the adjustment CJ) on the slack adjuster,
with a wrench until the desired position of the handlever is attained.
Brake band wear can be taken up exactly the same way with the brake
link in either the overwinding or underwinding position as explained above.
No pins or connections need be disturbed, just reset the slack~adjuster.
CAUTION: Release the brake handlev-e.:r after_ each flcl}ustment and
check to see if brake band is sufficiently free to keep th€Dr'1µf;e from "drag-
ging" and burning up the lining.
Peoria, Illinois
HYSTER COMPANY
PORTLAND, OREGON
Danville. Il:inois

Peoria, Illinois
12
LUBRICATION CHART
A
HYSTER COMPANY
PORTLAND. OREGON
Danville. Illinois

13
LUBRICATION INSTRUCTIONS
Ref er to chart shown.
The lubrication chart shows the location of the filler, drain, and oil level
plugs on the transmission case.
NOTE: When checking oil level, if the tractor motor is running, throw
out the master clutch so that hoist gears are stationary; otherwise, a false
reading will result.
On a new winch the oil should be drained from transmission case at the
end of about 10 days, flushed out and refilled with fresh oil.
All transmission gears, bearings and drum bearings are lubricated by
a splash system from the winch transmission housing. The oil level should
be checked daily by removing the 3/4 pipe plug (B) located just above the
"Caterpillar" final drive filler plug (C) in the left-hand side frame. If the
oil level drops below this plug, the upper transmission gears and drum
bearings will not receive proper lubrication. Oil may be added through
the oil filler hole by removing plug (A) in the top cover of transmission
case.
On a new winch, after 30 days of operation drain the oil, flush out and
T"efill case up to the proper level with clean oil. The oil level in the trans-
nission case should be checked weekly, keeping the case filled up to oil
level plug.
Under normal operating conditions, drain the oil and flush through drain
plug every 30 to 90 days, depending on operating conditions. Refill until
oil comes up to level plug. In general, for refilling, use SAE 90 or the same
gravity oil as is required in "Caterpillar" tractor transmission.
Approximately four gallons of oil are required. Periodic inspection
should be made for condensation, particularly after long periods of idle-
ness. Loosen drain plug and allow water to drain off. When oil begins to
appear, tighten drain plug and check oil level.
Slack adjuster brake shaft (7, page 33) rotates in a hardened steel bush-
ing and needs lubrication every two weeks. Oil brake handlever fulcrums
and pins occasionally to keep them moving freely. A few drops of oil from
an ordinary oil can once a day should be sufficient.
Grease the fitting on the shifter crank every 100 hours with a high grade
pressure grease (see page 20, Ref. 4).
Peoria, Illinois
HYSTER COMPANY
PORTLAND. OREGON
Danville, Illinois

14
Section C
INSTALLATION INSTRUCTIONS
For installing HYSTER D4N Towing Winch on "Caterpillar" D4
tractors with seat-mounted fuel tanks.
1. Block up rear end of tractor six or eight inches high. This prevents
the oil from running out of the transmission case when covers are
removed, and makes installation easier.
2. Remove tractor seat, transmission gear and brake inspection covers,
drawbar guide plates and brackets. Also remove the final drive filler
cups.
3. Burn clearance openings in both R. H. and L. H. fenders, and under
seat, as indicated on pages 15 and 16.
4. Remove studs from lower face of drawbar brackets for installation
later in pads on bottom of winch frames.
5. Place gasket 14, page 28, in position on rear face of tractor transmis-
sion.
6. Swing the winch into place on the rear face of the tractor. Make sure
the splines on the power take-off shaft enter those of the coupling
on the tractor. ·
7. When the winch is in place, place nuts and lockwashers on the six
lower studs. Tighten all nuts so that winch is securely fastened to
tractor.
8. Before mounting brackets (B and C, page 15) on top of tractor trans-
mission cover, insert capscrews (A) in ends of brackets. Fasten brack-
ets securely with dowel pins (D) and capscrews, % l'?C x 1%, to tractor
transmission cover.
9. Fasten the winch securely to brackets (B and C) with capscrews (A)
[installed under instruction 8 above]. Fasten tractor drawbar to winch,
using the studs and nuts which were removed from tractor drawbar
brackets.
(See page 18.)
10. Install lever bracket (18). Fasten securely to R.H. tractor fender with
canscrews. % NF x 1~. (See pag-e 16 for location of lever bracket.)
11 Install brake handlever (25) and ratchet (21).
For brake iink instaliation and brake adjustment, see instructions on
page 10.
12. Install quadrant (22) on bracket (18) using capscrew, % NF x 1. Install
shifter lever (11) with end of shifter stem engaged in center notch of
quadrant (22). Move crank (5, page 20) to the farthest point to the
right and mark, then to the farthest point to the left and mark. Half-
way between will be neutral position. Connect the adjustable end of link
(5, page 18) to cranli; (5, page 20) using one rod end pin (8, page 18).
Adjust rod end (6) and connect to crank which is part of the shifter
lever (11) using the remaining rod end pin (8). Tighten jam nut (7) on
link (5). .
Peoria, Illinois
HYSTER COMPANY
PORTLAND. OREGON
Danville. Illinois

15
13. Check all bolts and connections making sure that all bolts, nuts and
other connections are in place and securely tightened.
14. The final drive filler plug provided in the HYSTER unit to fill the
"Caterpillar" housing is at the proper level for the required "Cater-
pillar" oil level. (See 15, page 29.)
15. Place bars (F ,below) in place on tractor fenders, and tractor seat on
top of bars. Fasten seat securely with capscrews (E), through angle
on bottom of seat, bars (F) and tractor fender.
16. Remove drain cock and short nipple from bottom of fuel tank. Add
Yz"-90° street elbow between nipple and tank so that outlet of drain
cock is toward rear.
TRACTOR SEAT ALTERATION
For Tractors with Seat-mounted Fuel Tank
Note: To mount winch Serial No. 90204 and up on tractors prior to Tractor
Serial No. 6U-10066 or 7U-27984, four "Caterpillar" studs No. lA-4953 with
nuts and lockwashers are required to replace drawbar studs.
To mount winches prior to winch Serial No. 90204 on tractors Serial No.
6U-10066 or 7U-27984 and up, four "Caterpillar" studs No. 3B-1656 with
nuts and lockwashers are required to replace drawbar studs.
Peoria, Illinois
HYSTER COMPANY
PORTLAND, OREGON
Danville. Illinois

1()100
16
TRACTOR FENDER ALTERATIONS
For Tractors with Seat-mounted Fuel Tank
LEFT HAND FENDER ALTERATION
I
J
!t~-------1
RIGHT HAND FENDER ALTERATION
NOTE: BURN OUT CROSS HATCHED AREAS OF
FENDERS FOR WINCH CLEARANCE
Peoria. Illinois
HYSTER COMPANY
PORTLAND. OREGON
Danville, Illinois

17
Section D
List of Parts and Illustrations
The information consolidated into this Parts List Section includes unit
assemblies and exploded views showing the part name and number.
The numerical index in the back of the book lists all parts in numerical
sequence and shows the page number, on which they are illustrated.
Note: Unnumbered parts in the illustrations are the same as correspond-
ing parts shown with number. Particular attention should be given to the
location of bolts, capscrews, washers, etc., so that they are replaced in the
holes from which they were removed.
POWER TAKE-OFF - TRANSMISSION - BRAKE ASSEMBLY
Page
A
Gear Shift Assembly
20-40
B Brake Assembly
33-42
C
Brake Shaft Assembly
26
D
Drum Pinion
26
(For Drum Gear and Drum Assembly)
30
E
Drum Idler Assembly
26
F
Bevel Gear Shaft Assembly
22
G
Reverse Idler Gear Assembly
24
H Intermediate Sha£t Assembly
24
J
Power Take-Off Shaft Assembly
22
Peoria, lllinois
HYSTER COMPANY
Danville, Illinois
PORTLAND, OREGON

18
GENERAL ARRANGEMENT AND HANDLING GEAR .
Peoria. Illinois
For Tractors with Seat-mounted Fuel Tank
HYSTER COMPANY
PORTLAND, OREGON
27
0
D
0
27
28
29
30
31
Danville, Illinois