eqss OverWatch JLG 94RT Series Manual

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
JLG xx94RT Series
Installation Manual
REV 1.1
15/09/2023
Model6253 OverWatch™Installation Manual
Document # DO001627
EQSS Model6253 –OverWatch™
JLG xx94RT 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 xx94RT Series
Installation Manual
REV 1.1
15/09/2023
Model6253 OverWatch™Installation Manual
Document # DO001627
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AUTHORS:
Kieren Grogan, Bhavani Kacharapu
AUTHORISED BY:
Kieren Grogan
CHECKED BY:
Kieren Grogan
DOCUMENT ABSTRACT:
This Installation Manual details the manufacturer’s installation instructions for installing the Model6253 OverWatch™on a JLG
xx94RT Series Rough Terrain Scissor Lift.
PRODUCT NAME:
Model6253 OverWatch™Operator Detection System
REFERENCE DOCUMENTS:
DO001195 Model6253 OverWatch - User Manual
CURRENT DOCUMENT REVISION:
1.1
REVISION INFORMATION:
•1.0 Initial Document Creation for installation on a JLG xx94RT Series.
•1.1 Update of installation manual and instructions for harness installation.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
JLG xx94RT Series
Installation Manual
REV 1.1
15/09/2023
Model6253 OverWatch™Installation Manual
Document # DO001627
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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convenience and may be superseded by updates.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 xx94RT Series
Installation Manual
REV 1.1
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Model6253 OverWatch™Installation Manual
Document # DO001627
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Table of Contents
Preparation.........................................................................................................................................................................5
Required Tools ...............................................................................................................................................................5
Installation Time ............................................................................................................................................................ 5
Installation Instructions......................................................................................................................................................6
Operator Sensor............................................................................................................................................................. 6
Control Module............................................................................................................................................................10
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 Settings............................................................................................................................................................19
Polarity and Input Style................................................................................................................................................ 20
AS002320 Harness ............................................................................................................................................................ 21

EQUIPMENT SAFETY SYSTEMS
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JLG xx94RT Series
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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
10
Soldering Iron
Installation Time
The suggested time required to install the OverWatch™is as detailed below
Task
Estimated Time (Minutes)
Open the operator control box
2
Drilling of all mounting holes for the various components
15
Mechanical assembly
10
Electrical assembly
15
Post installation system tests
10
Close the operator control box
3
Total
55

EQUIPMENT SAFETY SYSTEMS
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Installation Instructions
Operator Sensor
Step
Description
Diagram
1.
Remove the front panel from
the outer metal enclosure.
2.
Drill two 5mm holes to install
the operator sensor mounting
bracket as shown in the
image. The distance between
the two holes is 30mm.

EQUIPMENT SAFETY SYSTEMS
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3.
Drill one 5mm hole to install
the P-clip as shown in the
image.
4.
Drill two 5mm holes which
are 65mm apart to install the
OverWatch ECU as shown in
the image.
Drill one 5mm hole to install
another P-clip.

EQUIPMENT SAFETY SYSTEMS
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5.
Drill a 20mm hole to install
the operator sensor cable
gland as shown in the image.
6.
Mount the bracket in the
located position by using M5
washers, nuts, and socket-
head bolts.

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7.
Mount the operator sensor to
the bracket by using M4
washers and security bolts.
Secure the operator sensor
cable by using a P-clip.
Note: Use highlighted holes
to position the Operator
Sensor.
8.
Install the operator sensor
cable gland and run the cable
from the operator sensor into
the enclosure.
Use the P-clip provided to
secure the cable.

EQUIPMENT SAFETY SYSTEMS
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Control Module
Step
Description
Diagram
1.
Mount the ECU inside the
enclosure by using M4
screws and washers.
2.
Wiring connections are
made by the Overwatch
harness AS002320.

EQUIPMENT SAFETY SYSTEMS
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3.
Joystick and power:
Disconnect the 9-pin
connectors from the
joystick and install the
OverWatch joystick
connectors in between as
shown in the image.
4. 5
.
Horn:
At the back of the horn
push button, disconnect
the existing horn
connectors and install the
OverWatch harness horn
connectors in between as
shown in the image.

EQUIPMENT SAFETY SYSTEMS
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5. 7
.
Drive Select:
At the back the LED circuit
panel solder the purple
drive select wire to the
location as shown in the
image.
Note: Please use a P-clip
to secure both drive and
elevate signal wires before
soldering.
Refer to the schematic
drawing which shows a
general overview of the
connection into the
circuit.

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6. 8
.
Elevate Select:
At the back the LED circuit
panel solder the orange
elevate select wire to the
location as shown in the
image.
Refer to the schematic
drawing which shows a
general overview of the
connection into the
circuit.
7. 1
0
.
Secure all the soldering
joints with hot glue to
avoid any damages to the
LED circuit panel.
The P-clip must be used to
secure the wires such that
there are no potential
forces placed on the
solder joints.

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8. 1
1
.
Connect the 8-pin
connector from the
Operator Sensor and the
12-pin connector from the
OverWatch harness, into
the ECU module.
9.
Re-assemble the joystick
panel back into the
control box enclosure.

EQUIPMENT SAFETY SYSTEMS
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Post Installation Configuration
Overview
After the OverWatch™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 (2019 onwards). Firefox or Chrome 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 10 seconds
3. Power up the platform control box with the ESTOP
4. While standing in the operator position, 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, Edge)
12. Enter the following into the address bar http://192.168.4.1 to open the OverWatch™main page

EQUIPMENT SAFETY SYSTEMS
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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
JLG xx94RT Series
JLG xx94RT Series
JLG xx94RT Series

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 to be supplied by a
service manager. The authorisation password is generated from the EQSS website. The EQSS website requires a
login username and password. If you are a service manager and don’t have a username and password, contact
EQSS to register. Follow the instructions below to obtain an authorisation password.
1. Open your preferred web and enter the following into the address bar http://www.eqss.com.au/overwatch
to open the Login page
2. Select Customer
3. Enter your username and password
4. Ask the service technician for the serial number shown on the Setup page or on the ECU module along with
the owner details of the EWP and complete the details form then click Generate Hash
5. Provide the 5-digit hash password to the service technician

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System Settings
Default Settings
See the sections below for details on each of the JLGxx94RT OverWatch™system default settings.
Setting Name
Description
Default
deltaseek
This specifies which of the previous lidar reading to
compare against the current one to calculate the
speed.
20
max_safe_velocity
This is the velocity threshold for the cutout in cm/s.
for drive mode.
100
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. in
elevate mode.
80
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 coefficient to apply to the displacement when the
displacement is toward the sensor.
0.75
fwdveloadj
The coefficient to apply to the velocity when the
displacement is toward the sensor.
1
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
Any lidar reading below this will trigger a cutout with
the message: “Operator Zone”
15
zone_maximum
Any lidar reading above this will trigger a cutout with
the message: “Operator Zone”
120
adc_elevate_threshold
For the elevate ADC input, a reading above this
indicates the EWP is in elevate mode.
500
adc_drive_threshold
For the drive ADC input, a reading above this indicates
the EWP is in drive mode.
500
adc_trigger_threshold
For the trigger ADC input, a reading above this
indicates the trigger is pressed.
1000
adc_joystick_fwd_threshold
For the joystick ADC input, a reading above this
indicates the joystick has been pushed forward.
1100
adc_joystick_bwd_threshold
For the joystick ADC input, a reading below this
indicates the joystick has been pulled backward.
1400

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Setting Name
Description
Default
throttle_time
Period after the trigger is pressed, the system does
not track velocity.
500
Polarity and Input Style
The table below describes each setting
Setting Name
Description
Default
joystick_drive_forward
Direction of joystick to move EWP forward
forward
joystick_elevate_upward
Direction of joystick to move EWP upward
forward
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
neutral_safe
Monitor when no drive mode set
no
ewp_joystick_needs_trigger
Whether trigger needs to be pressed before joystick
signal is present
false
ewp_drivable_during_test
Whether the EWP should remain drivable during the
install test
true
ewp_has_testchannel
Whether the test channel input is used
false
ewp_neutral_cutout
Whether standard cutout in effect when the drive mode
is neither drive nor elevate
false