Hopkins InSIGHT, FLEX-DISPLAY, FLEX-CONTROL, FLEX-MOUNT Installation Manual
INST
ALLATION PRECAUTIONS
• Braking capacity is for 2, 4, 6 or 8 trailer brake applications.
• Thi
s brake control will apply the trailer brakes while in reverse.
• Thi
s brake control is inertia activated. When the vehicle is not
mov
ing, the brake control will not automatically apply the trailer
brakes. In this event, the manual brake must be depressed to
actuate the brakes.
• Thi
s brake control is not reverse polarity protected. Reversing
the c
onnection to the vehicle battery or the breakaway battery
on the trailer will damage the brake control.
• Thi
s brake control is designed to operate trailers with electric or
ele
ctric/hydraulic brakes.
• For b
est results when installing components with double sided
tap
e, make sure to prep the area by cleaning it with rubbing
alcohol first.
INST
ALLATION GUIDE
• Sma
rt-Box
™
Mou
nting:
Locate an area under the vehicle dash on center console
or kick panel to mount the Smar t-Box, making sure it is not in
a position that interferes with the emergency brake or pedal
operation. Orientation of the Smart-Box Mount should be where
[SIDE A] of the Smar t-Box mounts against the kick panel or
center console. Allow enough room to plug in the brake control
harness and peripheral devices easily. Mount with foam tape,
cable ties or self-tapping screws (provided).
• Fle
x-Control
™
and F
lex-Display
™
Mou
nting:
1. Sit i
n the driver’s seat and decide where you want to install
the F
lex-Display™ and Flex-Control™. Make sure that the
Flex
-Display is within sight lines that will allow you
to lo
cate it easily while driving. The Flex-Control should be
mou
nted in a position that it is within easy reach while
dri
ving.
2. Onc
e the installation locations are determined, bring the
Flex
-Display™ to the area it will be mounted and begin to
run t
he wire either behind vehicle panels or behind weather
str
ipping down to the Smart-Box™. Use double sided tape
to secure the Flex- Display™ to desired mounting location.
App
ly tape to the bottom of the display bracket, or remove
the d
isplay bracket and attach the tape directly to the back
of th
e display.
3. Wit
h the Flex-Control™ in the desired location, run the wire to
the Smart-Box
™
usi
ng the vehicle’s dash seams and panels to
conceal the wire. Use double-sided tape to secure the FlexControl
™
to desired mounting location.
[Op
tional: Use Control Bracket and attach to dash with screws
or do
uble sided tape. Optional mounting bracket flexes to allow
easy mounting to curved sur faces.]
4. Wit
h all wires routed down to the Smar t-Box™ location, plug all
peripheral wires into the Smart-Box
™
.
HOW T
O ATTACH TO
VEHICL
E FACTORY TOW PACKAGE
If your vehicle came equipped with a factory tow package, brake
control func tion wires may exist under the vehicle dash. Consult
vehicle manual or call for location. Purchase a vehicle specific
Plug-in Simple!
®
brake control connector and simply plug into
the factory tow package plug, or splice the wires to the function
wires under the dash.
Black wire – positive terminal (+) on battery
Red wire – cold side of stop lamp switch or brake light
White wire – ground/negative terminal (-) on bat tery
Blue wire – trailer electric brakes
VEH
ICLE MANUFACTURER
WIR
ING CODES
For i
nstallations on vehicles
WITHO
UT a factory
tow pac
kage use the following procedure:
1. Be sure to use proper wire gauge when installing your control
(12 g
auge for electric brakes and positive power, 16 gauge for
the stop lamp switch and ground ).
2. Con
nect the white wire directly to the negative pos t on the
veh
icle batter y. Grounding to any other location may cause
intermittent brake control operation or failure.
3. Att
ach 20-amp circuit breaker (for 6 or 8 brake use 30-amp)
or in
-line fuse to the positive terminal on the vehicle’s battery.
Route black wire from the brake control to the fuse or breaker.
4. Spl
ice the red wire into the cold side of the vehicle’s stop lamp
swi
tch located by the brake pedal. Find the wire by using a
circuit tester and probing for the wire that powers the vehicle
stop lamps when the brake pedal is pressed.
5. Rou
te the blue wire from the brake control to the vehicle side
tow
ing connector at the rear of the tow vehicle.
NOTE
S
• Som
e late model Ford/Mercury trucks and sport utility vehicles
hav
e 2 or more stop lamp switch wires. For proper operation,
use the light green wire. The other wire is red with a green
stripe. This wire goes directly to ground when not in use.
Splicing into this wire will short circuit your brake control and
possibly damage the unit.
• For C
hevrolet vehicles 1999-0 6, if your vehicle does not have
a tow
ing package, only t he ground and stop lamp switch will be
active in the function wires under the dash. The electric brake
wire and 12-volt power lead will be terminated outside the
firewall. These will have to be routed to the trailer connector and
battery on the vehicle.
• For C
hevrolet vehicles 2007 New B ody Style-13, only the
gro
und and stop lamp switch will be active in the function wires
under the dash. T he electric brake wire and 12-volt power lead
will be terminated outside the firewall. These will have to be
routed to the fuse block on the vehicle. 20-amp fuses will need
to be installed to power these functions.
• For D
odge 2005-06, to find the cold
sid
e of the stop lamp
switch, you must have the key in the “on” position.
• For
d and Dodge tow packages come
wit
h a 20-amp battery
feed wire system that will accommodate 2 and 4 brake trailer
magnets. An upgrade to a 30-amp (12 gauge) battery wire
system will be needed for 6 brake systems.
OPE
RATING AND SETTING
YOUR CONTROLLER
1. RED D
OT
A red d
ot on bottom-right hand cor ner of the
dig
ital display indicates trailer is connected.
2. BLA
NK
A blank display (no dot) indicates trailer is not
conn
ected.
3. POW
ER
Pow
er adjustment buttons (+/-) on top of the
con
trol adjust power sent to the trailer brakes.
Pressing the (-) button decreases power.
Pressing (+) increases power. Power will be
displayed as a percentage on the digital display
from 5 to 99 in increments of 5%.
4. S
ENSITIVITY
Thi
s feature makes your trailer braking
res
ponse more or less sensitive. A setting of 1
indicates least sensitive. A setting of 7 indic ates
most sensitive. Adjust the sensitivity by pressing
the button labeled “S” on the side of the unit.
5. SHO
RT CIRCUIT
SC indicates that a short circuit has occurred
TESTI
NG / ADJUSTING
THE BRAKING RESPONSE:
Connect to your trailer and test drive on a dry open area at low
spe
ed (20 to 25 mph). Apply vehicle brakes aggressively.
1. If trailer brakes lock-up, adjust down the power setting to just
bel
ow brake lock-up by pressing the (-) power button.
2. If th
e braking per formance from the trailer feels as if it is
push
ing the tow vehicle, adjust the power setting higher by
pressing the (+) power button. Repeat proces s until smooth
braking is obtained.
BRAKE CONTROL
WIRE COLOR
BLACK RED WHITE BLUE
MAKE
MODEL
& YEAR
VEHICLE WIRE COLOR
CHEVY
& GMC
2007
(New
Style)
- 2013
RED
LIGHT
BLUE &
WHITE
WHITE
DARK
BLUE
CHEVY
& GMC
1999 - 2007
(Classic Style)
RED
LIGHT
BLUE
BLACK
DARK
BLUE
DODGE 2009-2012
RED &
YELLOW
WHITE &
VIOLET
BLACK &
DRK GREEN
DARK
GREEN
DODGE 2003-2008
RED &
WHITE
BLUE &
WHITE
BLACK &
GREEN
BLUE
DODGE 1997-2002
RED WHITE BLACK BLUE
FORD F-250 / 350
2009-2013
RED &
BROWN
BLUE
ORANGE
BLACK &
GRAY
BLUE
FORD F-150 2009-
2013
RED OR
RED &
GRAY
GREEN
OR YEL
GRN
WHITE &
BROWN
BLUE
FORD F-150
1994-2008
RED
LIGHT
GREEN
WHITE
DARK
BLUE
TOYOTA
&
LEXUS
2003-2012
BLACK
GREEN &
YELLOW
BLACK &
WHITE
BLUE &
RED
InSIG
HT
FLEX-
MOUNT
™
TRAILER BRAKE CONTROL
™
I
MPORTANT
Read the following instructions carefully before in
stalling
and/or operating the brake control.
(blank)
FLE
X-DISPLAY
™
FLEX
-CONTROL
™
SMART
-BOX
™
CAUT
ION
DO NOT
MOUNT ON DASH
ONLY MOU NT ON KICK PAN EL OR CENTE R CONSOLE
CONTROL BRACKET
(opti
onal)
KICK P
ANEL
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