TRAILPARTS hygo3 User manual

Installation Guide
3.5T Hydraulic Braking System
Keeping Local trailer manufactures
competitive with EU trailer imports.

Trailparts Ltd, Cnr Jervois & Tuna Sts, Dargaville, 0372 |PO Box 74, Dargaville, 0310
[phone] | [e-mail] |www.trailparts.co.nz
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Trailparts Ltd, Cnr Jervois & Tuna Sts, Dargaville, 0372 |PO Box 74, Dargaville, 0310
[phone] | [e-mail] |www.trailparts.co.nz
CONTENTS
Brake Cable Installation
Hydraulic Drum Brake
Brake Cable Installation
Patriot Disc Brake
Page 7 - 8
Page 9 - 10
Brake Bleeding
Coupling Operation
Page 6
Page 11
Hydraulic Line Installation
Page 5
Page 3
Page 4
Coupling Mount
Handbrake Mount
The Trailparts Hygo3 is a cost eective, multi-vehicle capable,
trailer brake system that is suitable for trailers up to 3500kg in
New Zealand when installed according to this guide.
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Trailparts Ltd, Cnr Jervois & Tuna Sts, Dargaville, 0372 |PO Box 74, Dargaville, 0310
[phone] | [e-mail] |www.trailparts.co.nz
COUPLING/HANDBRAKE MOUNT
⚠ The coupling and handbrake lever are critical safety items, the mounting
instructions below must be followed completely.
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Installing a coupling to a trailer can seem like a simple task. Trailparts have a few tips and recommendations
to ensure you and your load reach your destination safely. The Hygo3 coupling has the same hole mount
pattern as standard 2500kg override couplings - 54mm x 184mm.
Positioning the coupling is important to the trailers structural integrity and connection strength. The
coupling body must be positioned so that the likelihood of inadvertent damage to any component while in
use is minimized. To meet compliance the positioning of the handbrake / breakaway lever in relation to the
coupling is important (see page 4)
Greasing / Lubrication
Properly greased couplings are the key to long life and safe use!
• Tow ball connections should be greased because metal on metal causes screeching noises and
premature wear. If the towball or inner coupling surface (tongue) wear becomes extreme the coupling
can dislodge itself from the tow vehicle while in travel.
• The coupling should be greased on the actuator load bearing surfaces using the grease nipples
located on the coupling body regularly, depending on use.
Coupling mount torques;
• Grade 8.8 M12 zinc plated bolts and locknuts. 75ft/lb 100Nm
• Grade 10.9 M12 zinc plated bolts and locknuts. 90ft/lb 120Nm
ITEM DISCRIPTION
1 Reversible Hygo 3 hand brake mount
2 Hydraulic back-frame & 1” master cylinder assembly
3 Coupling mounting plate
4 Hygo 3 Handbrake lever assembly
5 Breakaway cable
6 Nylon insert hex nut - M8
7 35mm U-bolt for breakaway cable

Trailparts Ltd, Cnr Jervois & Tuna Sts, Dargaville, 0372 |PO Box 74, Dargaville, 0310
[phone] | [e-mail] |www.trailparts.co.nz
COUPLING/HANDBRAKE MOUNT CONT.
HANDBRAKE MOUNT LOCATION
IMPORTANT FOR CERTIFICATION
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Lever Mount Plate
Trailparts have designed a reversible mounting bracket
to suit the new Hygo 3 handbrake lever. This design can
be customised or built in to your trailer plans.
Note: The hole positions are important for handbrake
lever position and will ensure correct operation.
The cable guide, is only to be used if the minimum 12 degree angle can be maintained for correct hand
brake operation. Failure to mount these parts correctly will void the warranty and violate the braking system
certification as the break away cable may not function correctly when used.
The break away cable guide can be positioned either side of the coupling or mounted to the trailer drawbar
to acheive the 12 degree angle. See the above diagram for the Trailparts reccomended mount position
dimensions.
ITEM DISCRIPTION
1 Reversible Hygo 3 hand brake mount
2 35mm U-bolt for breakaway cable
3 Coupling mounting plate

Trailparts Ltd, Cnr Jervois & Tuna Sts, Dargaville, 0372 |PO Box 74, Dargaville, 0310
[phone] | [e-mail] |www.trailparts.co.nz
HYDRAULIC LINES INSTALLATION
1. Trailparts recommend the line routing as shown in diagram below
• Avoid unnecessary loops of line. Standard lines are stocked in increments of 1m lengths, but custom hoses are
available to assist in optimizing brake line design.
• Routing lines can be done in other ways, using T-pieces or similar line splitters. This can be at the discretion of
the installer, but the rule of thumb is that less line and fewer bleed points in one line is better.
On Trailparts axles, drum brakes will be pre-adjusted and ready for installation of brakelines.
The Hygo3 brake system is designed to use Banjo Banjo stainless steel braided lines throughout,
although other fixed lines such as steel and cupro-nickel are acceptable alternatives. Banjo Banjo
braided lines are resistant to damage, and are fast and easy to install.
Lines can be run inside chassis members if desired. If mounted externally, always fix the lines firmly
to the trailer chassis using sleeved stainless or nylon P-clips.
Trailparts recommend fitting a hose
to each side of the trailer directly
from the master cylinder using a
double banjo bolt.
Note: Run lines into the bottom port in the caliper, leaving the bleed screw at the top.
Run the brake line from the master
cylinder into the front caliper along
with the next hose to the rear
caliper/brake using a double banjo
bolt.
Run the line from the front brake to
the rear one, and close the circuit
using a single banjo bolt.
MOUNTING BRAKE LINES
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Trailparts Ltd, Cnr Jervois & Tuna Sts, Dargaville, 0372 |PO Box 74, Dargaville, 0310
[phone] | [e-mail] |www.trailparts.co.nz
BRAKE BLEEDING
If available, we recommend bleeding the brakes with an automotive style vacuum bleeder. If not,
use the master cylinder handbrake to distribute fluid throughout the system. Please remember to
remove the master cylinder handbrake after bleeding the system.
The process of bleeding brakes will vary according to how the brakelines are installed. As a
guide, follow this process;
1. Fill the system with Dot 3 or 4 brake fluid.
2. Before bleeding begins, begin with the reversing solenoid, and release any air from that internal
circuit by activating it 3-4 times.
3. Pump or pull fluid through each bleed point, eliminating air bubbles before moving to the next.
• TIP: tapping the caliper or brake with a hammer can assist with the movement of air
bubbles significantly.
• TIP: elevating the brakes above the level of the master cylinder will help the flow of air
bubbles to the bleeding point.
4. Close each bleed port securely as it is finished
TIP: Trailparts stock a range of accessories to assist in the running of brake lines.
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Trailparts Ltd, Cnr Jervois & Tuna Sts, Dargaville, 0372 |PO Box 74, Dargaville, 0310
[phone] | [e-mail] |www.trailparts.co.nz
BRAKE CABLE INSTALLATION
The Hygo MkII system requires a mechanical parking brake. This can be used to securely park
the trailer, but importantly, it doubles as the emergency brake function which will apply the trailer
brakes if the trailer separates from the towing vehicle.
Hygo3 drum braked axles are supplied fitted with a Bowden cable fitted to facilitate installation.
While cables from these to the coupling-mounted brake lever can be run in dierent ways
successfully, Trailparts recommends the centre pull routing and setup as shown in diagram above.
HYGO3 - HYDRAULIC DRUM BRAKES
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Trailparts Ltd, Cnr Jervois & Tuna Sts, Dargaville, 0372 |PO Box 74, Dargaville, 0310
[phone] | [e-mail] |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
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10mm when engaged

Trailparts Ltd, Cnr Jervois & Tuna Sts, Dargaville, 0372 |PO Box 74, Dargaville, 0310
[phone] | [e-mail] |www.trailparts.co.nz
BRAKE CABLE INSTALLATION
The Hygo3 system requires a mechanical parking brake. This can be used to securely park the
trailer, but importantly, it doubles as the emergency brake function which will apply the trailer
brakes if the trailer separates from the towing vehicle.
Note: Wheel chocks are reccommended to be used at all times in addition to the handbrake.
Patriot disc braked axles require a forward or centre pull cable configuration, as shown in the
diagram following. On axles built by Trailparts, the caliper is mounted at about the 10 o’clock / 2
o’clock position so that the handbrake lever is angling up and towards the chassis for easier routing.
HYGO3 - PATRIOT DISC BRAKES
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Trailparts Ltd, Cnr Jervois & Tuna Sts, Dargaville, 0372 |PO Box 74, Dargaville, 0310
[phone] | [e-mail] |www.trailparts.co.nz
BRAKE CABLE INSTALLATION - CONT.
Each braked wheel must be equalized to the others, as follows;
1. Tension Spring:
• A tension spring (supplied) is fitted to the cable from each brake,
and we recommend fixing this directly to the brake lever. This
ensures that the handbrake always has the correct tension
throughout its life.
2. Equalizing Front/Back:
• Each brake lever must have equal cable tension on it, which can
be achieved by routing the cable in a loop between the front and
rear axle, then adding a pulley as an equalizer to the loop, which
can then be pulled forward. One for the left hubs and one for the
right.
Note: Each cable loop must be formed with two cable clamps.
3. Equalizing Left/Right:
• The whole cable brake system is equalized together by running a
loop from each side’s equalizing pulley forward and through the
adjuster pulley located at the coupling.
Note: Each cable loop must be formed with two cable clamps.
Adjusting the Hygo3 Patriot Disc Brake cable system
Cables need to be relaxed enough so that suspension movement when
loaded does not cause them to engage. 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
10
10mm when engaged

Freephone 0800 487 245
E [e-mail]
www.trailparts.co.nz
HYGO MKII COUPLING OPERATION
Trailparts Hygo3 is using an over center handbrake lever.
• When manually engaging the hand brake. Ensure the lever
arm is pulled forward untill it reaches its limit. The arm
should be in a horizontal.
A stand-alone cable brake system provides a parkbrake function that
doubles as an emergency brake that activates in the event of a tow
vehicle seperation.
• Always insure the lanyard is attached to the tow vehicle in
place of or in addiotion to the safety chains.
As part of the Hygo3 exemption compliance the handbrake lever on
the master cylinder backframe must be removed from the system
after the brakes have been successfully bled.
Please keep the handle for future brake bleeding.
PARK BRAKE
BREAKAWAY LANYARD
MASTER CYLINDER
HANDBRAKE