Ford F-Series 5.4L, 6.4L, 6.8L 2008-2010

An ISO 9001:2000 Registered Company
GatewayBMAI (GTWY820-B1 with BrakeMax)) - Installation
Instructions
Ford Econoline (with Tow Haul only) 2007-2010
Ford F-Series 5.4L, 6.4L, 6.8L 2008-2010
It is not necessary to cut any OEM wires during the installation of the wire harnesses. Always disconnect the
battery before installing any electrical devices.
It is imperative that each harness be installed into the correct module connector, or damage to the module will
result. The connections are color coded to assist with proper installation.
Gateway module installation
•
Ensure that the ignition is in the OFF position.
•
Determine if the ambient temperature in the area of the module is at or above 150 ºF during system operation.
If so, determine the external heat source. This will typically be caused by engine heat if the module is
mounted near the engine cover or hot air being supplied by the heater ducts. Locate the module in an area
away from the external heat sources.
•
Identify each harness connector before installation into the Gateway module.
•
Do not simply match up the number of pins in a harness connector with the number of pins in a module
connector receptacle. There are several 6-pin connections on the harness and module that, if swapped, may
cause permanent module damage.
•
The harness will have a colored tape on the module connector end that will identify which module receptacle
to plug it into. The color of the tape on the harness should be matched up to the color of the lettering that
identifies the connector receptacles on the module.
986 So. Canyon Way
Colfax, CA 95713
www.intermotive.net
Page 1 of 3
Phone: (530) 346-1801
Fax: (530) 346-1812
Rev. C 03/03/2010
Gateway Module Suggested Mounting – 2009 Ford Econoline
•
•
•
•
Mount the Gateway module above the foam knee bolster
which is attached to the lower dash panel.
Secure the control module using 2-sided foam tape.
Verify that the harnesses are routed such that the tilt
steering column will not contact them in the full down
position.
When installing the harnesses, leave several inches of take
out such that the lower dash panel can be removed if
necessary.
Gateway Module Suggested Mounting – 2007-2008 Ford Econoline
•
•
•
Mount the Gateway module above the foam knee bolster which is
attached to the lower dash panel.
Secure the control module using 2-sided foam tape.
Verify that the harnesses are routed such that the tilt steering
column will not contact them in the full down position.
Module Suggested Mounting – 2005-2006 Ford Econoline
•
•
Mount the Gateway module on the left side of driver knee bolster bracket.
Secure the control module behind the lower dash panel using 2-sided foam tape, self tapping screws, or wire
ties.
GM/Chevy Applications Suggested Mounting
•
•
There are several mounting options, however, the module must not be installed in the direct flow of heater
ducts, or too close to the engine compartment, as excessive heat can cause the module to reset.
Secure the control module in its mounting location using 2-sided foam tape or screws.
986 So. Canyon Way
Colfax, CA 95713
www.intermotive.net
Page 2 of 3
Phone: (530) 346-1801
Fax: (530) 346-1812
Rev. C 03/03/2010
DATA LINK HARNESS (6-Pin Connector - Red)
•
•
•
•
•
•
•
Locate the vehicle Data Link Connector.
It will be mounted below the lower dash
panel on the driver’s side. (See photo).
Ensure the connection is fully seated and secure with the
supplied nylon wire tie.
Check to see that the mounting for the black connector from
the GatewayBMAI Data Link Harness is where the vehicle
OEM Data Link Connector originally was.
Secure the Data Link Harness such that it does not hang
below the lower dash panel.
Plug the 6 pin connector from the Data Link Harness (red
tape) into the connector labeled in red, “Data Link” on the
Control Module.
Attach the ground eyelet from the Data Link Harness to a known good ground.
The white two pin connector in this harness is only used when installing lift interlock kit ILIS501-H5 for 2009
Ford Econoline.
CONTROL/LED DISPLAY PANEL (6-Pin Connector - Blue)
•
•
•
•
•
•
Locate a suitable position on the dashboard, within view of the driver for the mounting of the Control/LED
Display Panel. The length of the display harness is 40”.
This is the maximum distance the display can be from the Control Module.
Drill a ¾” hole in the dashboard where you wish the center of the display to be.
Attach the blue taped end of the LED harness to the Control Module in the connector labeled in blue, “AFIS
LED. Run the other end of the harness under the dash and out through the ¾” hole.
Attach the end of the display harness to the Control/LED Display Panel.
Ensure panel is level, and secure using the supplied screws.
BrakeMax Harness–
• Locate the Ford connector C2135 (Tow Haul Mode Switch).
• Separate the connector and install the InterMotive (3-pin with
green wire) T-harness.
• Route the wire harness and insert into the Gateway connector
labeled “AUX I/O”.
Reconnect vehicle battery.
Check system for proper operation (see Post-Installation Instructions).
Technical inquiries – InterMotive Technical Support (530) 346-1801
986 So. Canyon Way
Colfax, CA 95713
www.intermotive.net
Page 3 of 3
Phone: (530) 346-1801
Fax: (530) 346-1812
Rev. C 03/03/2010
An ISO 9001:2000 Registered Company
Gateway – OEM Input / Output Plug
The GatewayAI has an optional I/O Port. This port is available to send or receive data with
the vehicle body. Provided is a four pin connector (green) and 5 terminals (1 extra). The
available Input/Outputs can be specified by Bus OEM’s. If a custom configuration is not
specified, the GatewayAI comes with a standard configuration. The actual Input/Outputs
will be denoted on a label on the side of the module. The standard configuration is as
follows:
P1: 2.2Hz/mph - Connector Pin #1. This output is the vehicle speed reported in the same
format as Ford’s OEM vehicle speed signal. (2.2 Hz Per/MPH).
P2: VSS<2 – Connector Pin #2. This output will provide a ground whenever vehicle
speed is less than 2 mph.
P3: Vbat<12 – Connector Pin #3. This output will provide a ground whenever battery
voltage is less than 12Volts.
P4: F/I input – Connector Pin #4. This will allow fast idle activation from a location other
than the standard AFIS LED Panel. This is accomplished by providing an external ground
signal to this Pin.
To install, crimp the OEM circuits to the provided terminals and install them into the
correct Pin location. The largest allowable wire that can be used with these terminals is
16GA. The pin #’s are located on the back of the 4 pin connector. Finally, snap the
connector into the port labeled in green, “I/O Port”. It is imperative that this harness be
installed into the correct module connector, or damage to the module will result. Check
for proper operation.
Note: These circuits are designed for low current usage. The outputs can drive one
standard automotive relay coil, but any current draw above 500 milliamps will result
in damage to the GatewayAI module.
986 So. Canyon Way
Colfax, CA 95713
www.intermotive.net
Phone: (530) 346-1801
Fax: (530) 346-1812
7/27/07
Revision B
An ISO 9001:2000 Registered Company
GatewayBMAI (GTWY820-B1) – Post Installation Testing
THE FOLLOWING PROCEDURE MUST BE PERFORMED TO VERIFY PROPER INSTALLATION:
1. Place transmission in the “Park” position and start engine.
2. Verify LED prove-out on AFIS LED Status Panel. Both upper LEDs should illuminate for approximately two
(2) seconds upon initial power on and then automatically turn off. (Check vehicle voltage if the Red “LOW
VOLTAGE” LED remains illuminated. Vehicle voltage is being read as less than the minimum voltage.) This
voltage varies based on the requested configuration of each bus manufacturer. Contact the bus manufacturer to
determine your minimum voltage setting. Vehicle voltage must remain above the minimum setting for the
remaining steps.
3. Manually engage fast idle by pressing the Engage button on the LED display panel. If currently in automatic
fast idle mode, press on service brake pedal while simultaneously pressing the manual engage switch. This will
end the automatic fast idle. Then shift vehicle out of park and back into park and press the Engage button to
enter manual fast idle mode.
4. Engine speed should increase and the Green LED should automatically illuminate. If this does not occur,
check for loose connections at the GatewayBMAI Control Module or the vehicle Data Link Connector.
5. Depress the service brake for 1 second. Fast idle will temporarily stop anytime the brake pedal is depressed,
but will automatically reengage after approximately 2 seconds once the brake pedal is released. Exit fast idle
by depressing the service brake pedal while simultaneously pressing the manual engage switch. Fast idle
should cancel and the Green LED should turn off.
6. Place wheel chocks at front and rear of one tire and set the Park Brake. Place transmission shift lever in the
“Neutral” position. Attempt to manually engage fast idle. The system should not activate.
7. Place transmission shift lever in the “Park” position and turn off the engine.
8. Verify that all active LED’s turn off after several minutes.
9. The AFIS option of GatewayBMAI is properly installed only if it passes all of the above steps.
10. BrakeMax option: Test drive vehicle and ensure the correct operation of BrakeMax.
a. When the vehicle is started, tow-haul mode is automatically engaged and the tow-haul light will be on.
b. To deactivate tow-haul mode, press the tow-haul mode button.
c. When vehicle is restarted, tow-haul mode will again be automatically reengaged
11. Fill out online warranty registration card at www.intermotive.net and return to InterMotive Vehicle Controls.
If any irregular operational issues persist, contact InterMotive Vehicle Controls at 530-346-1801 for technical
assistance.
986 So. Canyon Way
Colfax, CA 95713
www.intermotive.net
Phone: (530) 346-1801
Fax: (530) 346-1812
9/29/2008
An ISO 9001:2000 Registered Company
GatewayBMAI (GTWY820-B1) – Operating Instructions
GATEWAYBMAI
The GatewayBMAI is a sophisticated module designed to obtain real-time data from the onboard vehicle data port
and use the received information for intelligent control applications. Ford/GM specific chassis data is obtained by
communicating across the Ford/GM onboard Controller Area Network (CAN) data network.
The Gateway BMAI is designed for both fixed and custom control applications. The fixed control applications
included in all Gateway BMAI modules are options for an Advanced Fast Idle System (AFIS) and an Intelligent Lift
Interlock System (ILIS). Customization is available by way of an external 4-pin Input/Output port that is
configured to meet each user’s requirements.
Gateway Operation:
The Gateway BMAI initializes when the vehicle ignition is on. On 2009 Model Year vehicles, the Gateway will also
initialize with the vehicle ignition off, if the wheelchair lift door is open and the vehicle is equipped with an
optional InterMotive Intelligent Lift Interlock System. During initialization, LED display panels connected to the
Gateway BMAI perform prove-out for 2 seconds. After the initialization, the Gateway BMAI requests various vehicle
data by sending data request messages across the OEM CAN diagnostic data network and all control logic is
performed. When the Gateway BMAI module has been running and the vehicle ignition is turned to the off or
accessory positions and the wheelchair lift door is closed, the connected LED panels may remain illuminated for
up to several minutes before the Gateway BMAI module goes into a low current consumption “sleep” mode. Note: If
installed on 2009 Model Year vehicles and equipped with an InterMotive Intelligent Lift Interlock System,
the wheelchair lift doors must be closed in order for the Gateway to return to sleep mode.
The Gateway BMAI module obtains data from the onboard vehicle data port. In order to not interfere with a possible
scan tool communication, the Gateway BMAI will refrain from transmitting CAN messages for 10 seconds if a scan
tool CAN communication is detected. If during these 10 seconds another scan tool message is received, an
additional 10 seconds will be added to the end of the first 10 second timeout. When no scan tool messages have
been received for at least 10 seconds, the Gateway BMAI module will restart communication.
The Gateway BMAI retransmits obtained vehicle data across the SAE J1939-based InterMotive proprietary Merlin
Multiplex Network. In this way, vehicle data may be shared with other InterMotive modules attached to the
communication network.
ADVANCED FAST IDLE OPTION
The Advanced Fast-Idle System (AFIS) option of the Gateway BMAI includes Charge-Protect as well as FullyAutomatic and Manual engage modes. Charge-Protect is a feature that maintains vehicle charging system voltage
by increasing and controlling vehicle idle speed when necessary. Whenever charging system voltage falls below a
minimum voltage (determined by each bus manufacturer) for 2 seconds, this AFIS feature will increase idle speed
and maintain fast idle until one of the safety conditions is no longer met or the voltage is raised above the
minimum level.. The Fully-Automatic and Manual engage modes also require that all safety conditions are met.
986 South Canyon Way
Colfax, CA 95713
www.intermotive.net
Phone: (530) 346-1801
Fax: (530) 346-1812
9/29/2008
Safety conditions that must be met to engage or maintain Fast Idle operation
ƒ Vehicle NOT moving (speed = 0 MPH).
ƒ Service Brake NOT pressed.
ƒ Vehicle Transmission Range in Park
ƒ RPM inside of safe operating range.
ƒ Transmission Fluid Temperature below 250° F.
ƒ Engine Coolant Temperature below 230° F.
Control/Display Panel:
The AFIS Control/Display Panel consists of two LED’s and a Manual Engage Switch. The red LED will illuminate
whenever charging system voltage is less than minimum level. The green LED will illuminate when Fast Idle is in
progress. When the vehicle’s ignition switch is first turned on, both LED’s will illuminate for 2 seconds as a
proveout of proper LED operation. The LED’s are also used for diagnostic code retrieval by an authorized service
technician. The Manual Engage Switch can be used to engage Fast Idle operation if the voltage is above the
minimum level and all safety conditions are met.
Fast Idle Operation:
Fast Idle may be initiated by either a manual or automatic Fast Idle trigger. The AFIS strategy can only command
elevated idle when certain safety conditions are met (see section above). Fast Idle operation can be terminated by a
safety condition violation, a Merlin Multiplex Network Command, or an automatic Fast Idle disengagement
trigger. An automatic Fast Idle disengagement trigger will only act if the vehicle is in the particular type of
automatic Fast Idle corresponding with the disengagement trigger. If an automatic Fast Idle is in progress and an
automatic Fast Idle disengagement trigger occurs that would cause the Fast Idle to cease, yet there is a different
pending automatic Fast Idle trigger, Fast Idle operation will NOT cease. In this case, automatic Fast Idle will
continue under the new automatic Fast Idle triggering condition. If a Fast Idle Operation terminates due to an
automatic Fast Idle disengagement trigger, automatic Fast Idle is available pending another automatic trigger. If a
Fast Idle operation terminates due to a safety condition violation, automatic Fast Idle is unavailable until Park is
de-asserted and re-asserted. (Shift out of Park and back into Park). If manual Fast Idle is triggered while Fast Idle
operation is in progress due to an automatic Fast Idle trigger, the firmware will switch to a manual Fast Idle mode
of operation.
The base Fast Idle RPM level is determined by the type of engine (Gas or Diesel) in the vehicle. For Gas engine
vehicles, the idle speed is 1500 RPM and may be increased in increments of 100 RPM by subsequent presses of the
manual engage button up to a maximum of 2000 RPM. Diesel applications remain fixed at 1200 RPM.
Manual Fast Idle Start Triggers:
ƒ Manual Engage Switch.
ƒ Merlin Multiplex Network Command.
ƒ Fast Idle Input – ground applied to I/O Pin 4 of the GatewayAI Module, such as an input from Coach AC
(OPTIONAL)
Automatic Fast Idle Start Triggers:
ƒ Charge Protection - Battery voltage stays below minimum voltage for 2 seconds and engine running for 5
seconds.
ƒ Chassis A/C Boost - OEM A/C commanded on with ambient temperature above 70° F and engine running for
at least 5 seconds.
ƒ Heater Boost – Ambient air temperature below 70° F and Engine Coolant Temperature below 170° F.
986 South Canyon Way
Colfax, CA 95713
www.intermotive.net
Phone: (530) 346-1801
Fax: (530) 346-1812
9/29/2008
ƒ
ƒ
ƒ
ƒ
ƒ
ƒ
ƒ
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Fast Idle Disengagement Triggers:
Safety Condition Violation.
Merlin Multiplex Network Command.
Battery Voltage > 0.5 volts above minimum voltage setting. (Automatic Fast Idle Disengagement Trigger –
Active only in Charge Protect mode).
Cab A/C Commanded Off (Automatic Fast Idle Disengagement Trigger – Active only in Cab A/C Boost
mode).
Coach A/C Commanded Off (Automatic Fast Idle Disengagement Trigger – Active only in Coach A/C Boost
mode).
Engine Coolant Temperature > 190° F (Automatic Fast Idle Disengagement Trigger – Active only in Heater
Boost mode).
Open or battery voltage on I/O pin 4 while in Fast Idle caused by I/O Pin 4 fast idle input. (OPTIONAL)
Transmission Fluid Temperature above 250° F.
Note: Fast idle will temporarily stop anytime the brake pedal is depressed, but will automatically reengage
after approximately 2 seconds once the brake pedal is released. Fast idle may be manually cancelled by
depressing the service brake pedal while simultaneously pressing the manual engage switch.
Manual Operation:
To manually engage Fast Idle, the manual engagement switch must be pressed for at least a quarter second and
released. The Fast Idle operation will begin when the button is released, not when first pressed. Holding the switch
for more than five seconds will initiate a diagnostic routine that displays stored status codes from previous
operations. If the driver accidentally enters this routine, it can be exited by cycling the vehicle’s ignition off and
then back on. To exit Fast Idle operation, the driver can simply depress the service brake pedal while
simultaneously pressing the manual engage switch.
Note: When additional electrical or A/C loads are in use, engine RPM may drop. The AFIS Dynamic Load
Response feature will then raise the RPM back up to the fast idle speed. When the load is removed, engine
RPM will increase. AFIS will then lower the RPM back to the fast idle speed. This may be more noticeable on
cold engine startup.
BrakeMax Operation Instructions:
•
When the vehicle is started, tow-haul mode is automatically engaged and the tow-haul light will be on.
•
To deactivate tow-haul mode, press the tow-haul mode button.
•
When vehicle is restarted, tow-haul mode will again be automatically reengaged.
•
See OEM owner's manual for features and benefits of tow-haul mode.
986 South Canyon Way
Colfax, CA 95713
www.intermotive.net
Phone: (530) 346-1801
Fax: (530) 346-1812
9/29/2008
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
REVISIONS
1
DATE :
CHANGE :
2
BMAI
3
Gateway
AFIS LED
4
Merlin
I/O
Port
Aux/ I/O AFIS LED
10
11
2
GREEN
1
2
3
4
Calibrated Output 1
Calibrated Output 2
Calibrated Output 3
Calibrated Output 4
2
1
3
4
5
6
BLACK (External Ground)
RED
(Battery Voltage)
YELLOW (Ford CAN High)
GRAY
(Ground)
OPEN
(No Connection)
BROWN (Ford CAN Low)
ILIS LED
AUX
I/O
ILIS
I/O Port
Data Link
9
GATEWAYBMAI
8
TOW/HAUL CONTROLLER,HIGH IDLER,LIFT INTERLOCK
7
YELLOW (LED Power)
WHITE (Low Voltage LED)
BLACK (BACKLIGHT GROUND)
BROWN (Switch)
(Fast Idle LED)
BLUE
RED
(12 V)
B
6
1
2
3
4
5
6
ENGAGE
5
Install Between The OEM
TOW / HAUL Switch
Connector
ADVANCED FAST IDLE SYSTEM
AFIS
LED
Data
Link
12
Data
Link
13
14
ONLY USED WITH
INTERLOCK KIT ILIS501-H5
(2009 ECONOLINE)
15
DRAWN BY:
PRODUCT :
GATEWAY BMAI
BRUCE
HODGE
DATE DRAWN : CHECK BY :
10/1/08
PART
NO:
K Thomas
GTWY820-B1
DATE CHECKED :
10/1/08
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