eqss Overwatch JLG ES Series User manual

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
JLG xxxxES Series
Installation Manual
REV 1.9
06/12/2023
Model6253 OverWatch™Installation Manual
Document # DO001203
EEQSS Model6253 –Overwatch™
JLG xxxxES 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 xxxxES Series
Installation Manual
REV 1.9
06/12/2023
Model6253 OverWatch™Installation Manual
Document # DO001203
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AUTHORS:
Kieren Grogan, Bhavani Kacharapu
AUTHORISED BY:
Kieren Grogan
CHECKED BY:
Andrew Donegan
DOCUMENT ABSTRACT:
This Installation manual details the instructions for installing the Model6253 OverWatch™on a JLG xxxxES Series Scissor Lift.
PRODUCT NAME:
Model6253 OverWatch™Operator Detection System
REFERENCE DOCUMENTS:
DO0001195 Model6253 OverWatch™User Manual
CURRENT DOCUMENT REVISION:
1.9
REVISION INFORMATION:
•1.0 Initial Document Creation for system installation on a JLG xxxxES Series
•1.1 Update of wire connection and sensor mounting instructions
•1.2 Update of schematic
•1.3 Update to be suitable with quick connect harness installation
•1.4 Update on installation procedures to use Plug and Play loom
•1.5 Update on installation procedures to suit newer model of ES Boxes
•1.6 Update of title page image and mounting instructions to reflect new bracket
•1.7 Update of installation images
•1.8 Update on config name and system settings
•1.9 Inclusion of mounting guard V2 and update of configuration procedures

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
JLG xxxxES Series
Installation Manual
REV 1.9
06/12/2023
Model6253 OverWatch™Installation Manual
Document # DO001203
|3 of 27|
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convenience and may be superseded by updates.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 xxxxES Series
Installation Manual
REV 1.9
06/12/2023
Model6253 OverWatch™Installation Manual
Document # DO001203
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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 .........................................................................................................................................20
Overview...................................................................................................................................................................... 20
Minimum system requirements ..................................................................................................................................20
Wi-Fi Connection & Web Page Access .........................................................................................................................20
Machine Model Selection ............................................................................................................................................21
Installation Test............................................................................................................................................................ 22
Change Model Configuration....................................................................................................................................... 23
System Settings.................................................................................................................................................................24
Default Parameters...................................................................................................................................................... 24
Polarity and Input Style................................................................................................................................................ 25
Harness Drawing AS001937.............................................................................................................................................26
Replacement Parts............................................................................................................................................................ 27

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
P: [phone] E: [e-mail]
JLG xxxxES Series
Installation Manual
REV 1.9
06/12/2023
Model6253 OverWatch™Installation Manual
Document # DO001203
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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
Drill 10.5mm
8
Metric sockets or spanners
9
Needle nose pliers
10
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
5
Drilling of all mounting holes for the various components
15
Mechanical assembly
20
Electrical assembly
10
Post installation system tests
10
Close the operator control box
15
Total
75

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
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JLG xxxxES Series
Installation Manual
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Model6253 OverWatch™Installation Manual
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Installation Instructions
Operator Sensor
Step
Description
Diagram
1.
Remove top and bottom
modules from the plastic
housing.
2.
Open the top module
and drill a 12mm hole on
the back panel of the
enclosure to install the
M12 cable gland.
The position of the hole
is detailed in the image,
being 30mm from the
top edge and 40mm
from the right edge.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
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JLG xxxxES Series
Installation Manual
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Step
Description
Diagram
3.
Open the bottom
module and prepare to
drill two holes, make
sure that all internal
cables are clear before
drilling holes on the back
panel of the control box
enclosure as shown in
the image.
4.
Operator Sensor Gland:
Drill a 20mm hole to
install the sensor cable
gland in the location
shown in top left of the
image.
28mm from the top
edge to the centre
55mm from the left edge
to the centre

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
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JLG xxxxES Series
Installation Manual
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Step
Description
Diagram
5.
Drive/Elevate Gland:
Drill a 12mm hole to
install M12 cable gland
in the location shown in
the image.
Horizontal and vertical
distance measured as
11mm as shown in the
image.
Note: Install cable gland
at the exact location
shown in image
Feed the two-core cable
from the Overwatch
harness through the
gland.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
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Step
Description
Diagram
6.
Run the two-core cable
from the bottom unit to
the top unit, through the
two M12 cable glands.
Route the cables using
cable ties, as shown in
the image.
Refer to the adjacent
image for feeding
direction of the two-core
cable.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
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JLG xxxxES Series
Installation Manual
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Control Module
Step
Description
Diagram
1.
Wiring connections are
made with the AS001937
harness.
2.
The following connections
will be done in the bottom
module.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
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JLG xxxxES Series
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Step
Description
Diagram
3.
Joystick and power:
Disconnect the 9-pin
connector from the JLG
joystick and install the
Overwatch harness in series.
4.
Buzzer:
At the back of the buzzer on
the Negative side, install the
Overwatch buzzer
connection (white wire).

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
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JLG xxxxES Series
Installation Manual
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Step
Description
Diagram
5.
Place the Overwatch ECU
module at an angle and in
the location as shown in the
image.
Neatly manage the cables,
making sure the joystick
connectors are positioned
as shown.
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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Step
Description
Diagram
6.
The following connections
will need to be done in the
top module.
7.
Drive and Elevate Select:
At the back of the
drive/elevate switch
disconnect the existing 3 pin
connector and install the
drive/elevate cable from the
OverWatch harness in
series.

EQUIPMENT SAFETY SYSTEMS
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Step
Description
Diagram
8.
Sensor Mounting Guard V1
(ME001794)
Mount the operator sensor
to the mounting bracket
ME001819 by using the
wedges, sensor guard, bolts,
and washers.
The orientation of the
wedge blocks is critical for
the correct positioning of
the operator sensor. Make
sure that the sensor is
angled, such that it is
twisted inwards from the
joystick controller. Make
sure to place the narrow
face side wedge in between
the sensor guard and
mounting bracket. Place the
wider face outside the
mounting bracket as shown
in the image.
Mount the sensor in
position using the
positioning wedges, sensor
guard, M4 washers, and
bolts.

EQUIPMENT SAFETY SYSTEMS
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9.
Sensor Mounting Guard V2
(AS002326)
This guard (AS002326)
supersedes the original V1
design. Mount the operator
sensor to the mounting
bracket ME001819 by using
the wedges, sensor guard,
bolts, and washers.
The orientation of the
wedge blocks is critical for
the correct positioning of
the operator sensor. Make
sure that the sensor is
angled, such that it is
twisted inwards from the
joystick controller. Make
sure to place the narrow
face side wedge in between
the sensor guard and
mounting bracket. Place the
wider face outside the
mounting bracket as shown
in the image.
Make sure that the sensor is
on the 0.0-degree position
inside sensor guard.
The 0.0-degree angle is
achieved by using the bolt
hole as show in the image.

EQUIPMENT SAFETY SYSTEMS
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Step
Description
Diagram
10.
Drill two 5mm holes using
the sensor backing plate
(ME001820) as a drilling
template, as shown in the
image.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
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Step
Description
Diagram
11.
Drill one 5mm hole to route
the operator sensor cable by
using a cable tie as shown in
the image.

EQUIPMENT SAFETY SYSTEMS
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Step
Description
Diagram
12.
Mount the operator sensor
assembly in position using
the backing plate, M4
washers, nuts, and security
bolts.
Use the following hardware
from the kit.
3 x M4 x 25mm bolts
3 x M4 Lock Nuts
6 x M4 Washers
The backing plate and
sensor mount should align
with the existing pattern in
the control box plastic
enclosure.

EQUIPMENT SAFETY SYSTEMS
75 Naxos Way, Keysborough 3173 Victoria Australia
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JLG xxxxES Series
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Step
Description
Diagram
13.
Re-assemble the bottom
module and top module and
mount to the plastic
housing.
Make sure the operator
sensor cable runs clear to
the joystick enclosure and
tighten the M20 gland to
seal the cable entry point.
Care must be taken when
closing the boxes, make
sure all internal wires are
clear of the box edges and
bolt inserts, do not pinch or
crush any internal wires
when closing the boxes.

EQUIPMENT SAFETY SYSTEMS
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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