Trailparts Ltd, Cnr Jervois & Tuna Sts, Dargaville, 0372 |PO Box 74, Dargaville, 0310
+64 9 439 5508 | sales@trailparts.co.nz |www.trailparts.co.nz
BRAKE CABLE INSTALLATION - CONT.
Manufacturers may wish to route cables pulling forward. This is an
acceptable solution, but in order to comply with the requirements in the
Hygo3 certification, these three features following must be fitted;
1. Tension Spring:
• A tension spring (supplied) is fitted to the cable in front of the
Bowden cable at each brake. This ensures that the handbrake
always has the correct tension throughout its life. It must be
within the first loop described in the following;
2. Equalizing Left/Right:
• Each brake cable must have equal cable tension on it. This can
be achieved by routing the cable in a loop between the left and
right drum on each axle, then adding a pulley as an equalizer to
the loop, which can then be pulled forward.
Note: Each cable loop must be formed with two cable clamps.
3. Equalizing Front/Back:
• The front and back axles are then equalised. Run a cable from
each axle equalizing pulley going in a loop around a third pulley
again at the coupling.
Note: Each cable loop must be formed with two cable clamps.
Adjusting the Hygo3 Drum Brake cable system
Cables should be relaxed without being slack. When the system is
complete and the handbrake is applied (see image on right), an indication
of correct cable tension is that the tension springs at each wheel should
have elongated by 10mm over the closed length.
Note: Brake cables may require support brackets or additional spring
supports if their weight is causing brakes to engage when slack.
☑Check coupling mount bolts are torqued to specifications.
☑Ensure brake lines are free of kinks or chafing points, and are securely mounted.
☑Check cables will pull freely, and that the handbrake applies firmly and with the tension
spring elongated by 10mm. (When engaging handbrake, lever should be pulled to its full
limit in a horizontal position)
FINAL CHECKS
8
10mm when engaged
