eqss JLG RT 69 Series User manual

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
JLG RTxx69 Series
Installation Manual
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30/11/2023
Model6253 OverWatch™Installation Manual
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EQSS Model6253 –OverWatch™
JLG RTxx69 Series
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** Failure to follow this installation manual will void warranty **

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
JLG RTxx69 Series
Installation Manual
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Model6253 OverWatch™Installation Manual
Document # DO001359
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AUTHORS:
Kieren Grogan
AUTHORISED BY:
Kieren Grogan
CHECKED BY:
Andrew Donegan
DOCUMENT ABSTRACT:
This Installation Manual details the manufacturer’s installation instructions for installing the Model6253 OverWatch™on a JLG
RTxx69 scissor lift.
PRODUCT NAME:
Model6253 OverWatch Operator Detection System
REFERENCE DOCUMENTS:
DO001195 Model6253 OverWatch User Manual
CURRENT DOCUMENT REVISION:
1.2
REVISION INFORMATION:
•1.1 Initial Document Creation for installation on a JLG RTxx69 Series
•1.2 Inclusion of harness schematics and new sensor mounting bracket
•1.3 Update of model configuration instructions

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
JLG RTxx69 Series
Installation Manual
REV 1.3
30/11/2023
Model6253 OverWatch™Installation Manual
Document # DO001359
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Important Information
Information contained in this publication regarding this device’s applications and the like, is provided only for your
convenience and may be superseded by updates. It is your responsibility to ensure that the application or our
equipment meets with your specifications.
EQUIPMENT SAFETY SYSTEMS MAKE NO REPRESENTATIONS OR WARRANTIES OF ANY KIND, WHETHER EXPRESSED OR
IMPLIED, WRITTEN OR ORAL, STATUTORY OR OTHERWISE, RELATED TO THE INFORMATION, INCLUDING, BUT NOT
LIMITED TO, IT’S CONDITION, QUALITY, PERFORMANCE, MERCHANTABILITY OR FITNESS FOR PURPOSE.
Equipment Safety Systems disclaims all liability arising from this information and its use. Use of Equipment Safety
Systems’ products as critical components in life support systems is not authorised except with express written
approval by Equipment Safety Systems. No licenses are conveyed, implicitly or otherwise, under any Equipment Safety
Systems intellectual property rights.
This is a class A product certified to AS/NZS CISPR 22:2006. In a domestic environment this product may
cause radio interference in which case the user may be required to take adequate measures.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
JLG RTxx69 Series
Installation Manual
REV 1.3
30/11/2023
Model6253 OverWatch™Installation Manual
Document # DO001359
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Table of Contents
Preparation.........................................................................................................................................................................5
Required Tools ...............................................................................................................................................................5
Installation Time ............................................................................................................................................................ 5
Operator Sensor............................................................................................................................................................. 6
Control Module..............................................................................................................................................................9
Post Installation Configuration .........................................................................................................................................15
Overview...................................................................................................................................................................... 15
Minimum system requirements .................................................................................................................................. 15
Wi-Fi Connection & Web Page Access .........................................................................................................................15
Machine Model Selection ............................................................................................................................................16
Installation Test............................................................................................................................................................ 17
Change Model Configuration.......................................................................................................................................18
System Settings.................................................................................................................................................................19
Default Parameters...................................................................................................................................................... 19
Polarity and Input Style................................................................................................................................................ 20
Harness Drawing AS002075..............................................................................................................................................21
Replacement Parts............................................................................................................................................................ 22

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
JLG RTxx69 Series
Installation Manual
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Model6253 OverWatch™Installation Manual
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Preparation
Required Tools
The OverWatch has been designed to be fitted using basic workshop tools. Shown below is a list of tools required
to complete the installation
Item
Tool / Description
1
Electric Drill
2
Centre punch
3
Hammer
4
Side Cutters
5
Drill 3.2mm
6
Drill 5.0mm
7
Metric sockets or spanners
8
Needle nose pliers
9
Screw drivers
Installation Time
The suggested time required to install the OverWatch is as detailed below
Task
Estimated Time (Minutes)
Open the operator control box
1
Drilling of all mounting holes for the various components
13
Mechanical assembly
10
Electrical assembly
10
Post installation system tests
10
Close the operator control box
1
Total
45

EQUIPMENT SAFETY SYSTEMS
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Model6253 OverWatch™Installation Manual
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Installation Instructions
Operator Sensor
Step
Description
Diagram
1.
Remove all the bolts on the
side of the control box to get
access to the side plate and
the bottom control box
wiring.
2.
Mount the operator sensor
bracket to the LEFT side of the
control box as shown in the
image.
Use the sensor mounting
bracket as a drilling template
and drill the first hole at the
location shown in the image.
Position the sensor backet so
it is 30 degrees from the
vertical line shown.
Drill the remaining holes and
mount the bracket.

EQUIPMENT SAFETY SYSTEMS
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3.
Sensor Mounting Guard V1
(ME001794)
Mount the Operator sensor to
the bracket, using M4 security
screws and washers.
Use the following hardware
from the kit.
1 x AS001910 Operator
Sensor
1 x ME001794 Sensor
Mounting Guard V1
2 x FA001417 M4 X 12mm
Security Screw
2 x FA001235 Plain Washer
4.
Sensor Mounting Guard V2
(AS002326)
This guard (AS002326)
supersedes the original V1
design. Mount the operator
sensor in on the mounting
bracket using the supplied M5
washers and nuts. Make sure
that the sensor is on the 0.0-
degree angle, such that it is
not twisted away from the
joystick.
The 0.0-degree angle is
achieved by using the bolt
hole as show in the image.

EQUIPMENT SAFETY SYSTEMS
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5.
Drill one M20 hole and install
the operator sensor cable
gland.

EQUIPMENT SAFETY SYSTEMS
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Control Module
Step
Description
Diagram
1.
Wiring connections are
made with the AS002075
harness.
2.
Joystick and Power
Connection:
Disconnect the 9-pin
connector from the
joystick and install the
OverWatch harness in
series.
Note: It is highly
recommended to
unscrew the Joystick
during the installation
process.

EQUIPMENT SAFETY SYSTEMS
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3.
Horn Connection:
At the back of the horn
switch, disconnect the
white wire on the SW19-2
and install the OverWatch
white wires with the
spade and lug connectors.
Note: Check that the
connectors are tight, use
needle nose pliers to
squeeze the connection if
necessary
4.
Drive Select:
At the back of the drive
switch, disconnect the
white wire labelled as
SW18-2 and install the
OverWatch purple wires
with the spade and lug
connectors.
Note: Check that the
connectors are tight, use
needle nose pliers to
squeeze the connection if
necessary

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
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JLG RTxx69 Series
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5.
Elevate Select:
At the back of the elevate
switch, disconnect the
white wire labelled as
SW16-2 and install the
OverWatch orange wires
with the spade and lug
connectors.
Note: Check that the
connectors are tight, use
needle nose pliers to
squeeze the connection if
necessary
6.
Stabiliser Select:
At the back of the
stabiliser switch,
disconnect the white wire
labelled as SW17-2 and
install the OverWatch
yellow/green wires with
the spade and lug
connectors.
Note: Check that the
connectors are tight, use
needle nose pliers to
squeeze the connection if
necessary

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
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JLG RTxx69 Series
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7.
Placing the Joystick back:
Position the joystick
harness connectors at the
back of the E-stop while
placing the joystick back
in.
Note: Make sure the
cables are secure and in
position as not to be
pinched or damaged
during the closure.

EQUIPMENT SAFETY SYSTEMS
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8.
Position the Overwatch
ECU and Horn relay:
Position the Overwatch
ECU and horn relay at the
back of the horn push
button as shown in the
image.
Connect the 12-pin
connector from the
Overwatch harness to the
Overwatch ECU.
9.
Connect the 8-pin
connector from the sensor
to the ECU and place back
the bottom plate of the
control box to its original
position.

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10.
Reattach the two plates of
the control box.
Make sure the operator
sensor cable runs clear to
the joystick enclosure and
tighten the M20 gland to
seal the cable entry point.
Use cable ties to secure
the operator sensor cable
as shown in the image.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
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JLG RTxx69 Series
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Model6253 OverWatch™Installation Manual
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Post Installation Configuration
Overview
After the system has been installed it must be configured with the parameters to suit the machine. Follow the
instructions below to configure the OverWatch.
Minimum system requirements
Any smart phone, tablet or laptop that meets the following requirements:
•The device can connect to a Wi-Fi access point
•The device has an up to date web browser installed. Firefox, Chrome or Safari are recommended.
Wi-Fi Connection & Web Page Access
To enable the Wi-Fi connection on the OverWatch to complete the configuration follow the steps below.
1. Power down the platform control box with the ESTOP
2. Wait 5 seconds
3. Power up the platform control box with the ESTOP
4. While standing in front of the operator sensor, switch on the OverWatch
5. As the welcome chime starts to play, cover the sensor. The LED will flash white then black to acknowledge.
6. Remove your hand from the sensor. The LED will flash white then black to acknowledge.
7. After covering then uncovering the sensor this way 2 more times, "Wi-Fi On" will be announced
8. On your Wi-Fi enabled device (laptop, tablet, smartphone, etc), show the available wireless networks
9. Select the wireless network (starts with “overwatch”) to connect to the OverWatch
10. When prompted, enter the password 12345678
11. Open your preferred web browser (Chrome, Firefox, Safari)
12. Enter the following into the address bar http://192.168.4.1 to open the OverWatch main page

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
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JLG RTxx69 Series
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Machine Model Selection
Follow the instructions below to configure the OverWatch.
1. Select the Setup option
2. If there is a password field at the bottom of the page, follow the instructions in Change Model Configuration
to obtain the password and enter the password field
3. Select the EWP Model from the drop-down list and click Set
4. Click on Proceed to test to begin the installation test

EQUIPMENT SAFETY SYSTEMS
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Installation Test
After the model configuration has been set or updated an Installation Test must be performed. This will ensure the
installation has been correctly performed and the OverWatch is functioning correctly. Follow the instructions on
the web page to complete the Installation Test.

EQUIPMENT SAFETY SYSTEMS
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Change Model Configuration
To reconfigure the OverWatch for a different model requires an authorisation password. The authorisation
password is generated from the EQSS website. The EQSS website requires a login username and password, contact
EQSS for these details.
Follow the instructions below to obtain an authorisation password. It is important to note that each ECU has a
unique serial number and a unique password.
1. Open your web browser and enter the following into the address bar http://www.eqss.com.au/overwatch to
open the Login page
2. Enter your username and password
3. Enter the EUC serial number which is shown on the setup page or on the ECU serial number sticker, also
enter the owner and model details of the EWP and then click Generate Hash
4. The generated Hash code or password can be used to change the model configuration.

EQUIPMENT SAFETY SYSTEMS
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System Settings
Default Parameters
The OverWatch is configured with the following default parameters.
Setting Name
Description
Default
max_safe_velocity
This is the velocity threshold for the cutout in cm/s for drive
mode.
95
max_safe_displacement
This is the maximum permitted distance in cm the operator
may be away from the calibration position in drive mode.
50
max_safe_velocity_elevate
This is the velocity threshold for the cutout in cm/s for
elevate mode.
75
max_safe_displacement_elevate
This is the maximum permitted distance in cm the operator
may be away from the calibration position in elevate mode.
50
fwddispadj
The proportion of the calibration distance toward the
sensor permitted to the operator.
0.7
fwdveloadj
The coefficient to apply to the maximum allowable velocity
when the movement of the operator is toward the sensor.
1.0
zone_obstruction
If the lidar sensor reading is below this, the lidar is
considered to be obstructed (with paint or thick coat of
dust) and the system is cutout until the obstruction is
cleared.
5
zone_minimum
The minimum calibration distance. If the operator is closer
to the sensor than this “operator zone” will be announced.
17
zone_maximum
The maximum calibration distance. If the operator is further
from the sensor than this “operator zone” will be
announced.
120
adc_elevate_threshold
Threshold value for the elevate ADC input.
1000
adc_drive_threshold
Threshold value for the drive ADC input.
1000
adc_trigger_threshold
Threshold value for the trigger ADC input.
1000
adc_joystick_fwd_threshold
Forward threshold value for the joystick ADC input.
1300
adc_joystick_bwd_threshold
Backward threshold value for the joystick ADC input.
1400
throttle_time
Period after the trigger is pressed (ms) during which initial
velocity reading is computed.
500
driving_state_timeout
Mode selection switch timeout (ms)
7000

EQUIPMENT SAFETY SYSTEMS
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Polarity and Input Style
The table below describes each setting
Setting Name
Description
Default
joystick_drive_forward
Direction of joystick to move machine forward
forward
joystick_elevate_upward
Direction of joystick to move machine upwards
backward
elevate_polarity
Direction of signal logic
high
drive_polarity
Direction of signal logic
high
trigger_polarity
Direction of signal logic
high
joystick_polarity
Direction of signal logic
Low
driving_state_input
Direct or timer based
direct