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