OverWatch - Installation - JLG ERT (OLD Pre 2022 Harness) - Installation Instructions

OverWatch - Installation - JLG ERT (OLD Pre 2022 Harness) - Installation Instructions

Notes
This Tech Doc was written to help customers with very old JLG ERT installations
Operator Sensor
Installation Steps:
1. Undo the bolt 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 photo below).
3. Drill the first hole at the location shown.
4. Position the sensor bracket so it is 30 degrees from the vertical line shown.
5. Drill the remaining holes and mount the bracket.


6. Using security bolt provided, mount the Overwatch Lidar to the bracket. 


7. Drill M20 hole and install the supplied cable gland in the location shown in the image.


Control Module
Installation Steps:
1. Wiring connections are made by the Plug and Play loom AS002041.


Joystick and power piggyback:
2. Disconnect the 9-Pin connector from the joystick and install the Harness Joystick connectors in between (as shown on photo below).
Note: There is very little space to navigate the harness and the final routing must be carefully considered.
It is highly recommended to unscrew the Joystick (whilst doing the install) and then reinstalling the joystick when completed.

Horn piggyback:
3. Disconnect the White cable at the back of the horn push button (SW19-2 HORN)
4. Install the Harness Horn connector in between (as shown below).


Drive Select piggyback:
5. Disconnect the White cable at the back of the Drive Select Push Button, labelled SW18-2 DRIVE Mode
6. Install the Harness Drive Select connector in between (as shown below). 


Elevate Select piggyback:
7. Disconnect the White cable at the back of the Elevate Select Push Button, labelled SW16-2 LIFT Mode
8. Install the Harness Elevate Select connector in between as shown.


Stabilise Select piggyback:
9. Disconnect the White cable at the back of the Stabilizer Select Push Button, labelled SW17-2 LIFT Mode.
10. Install the Harness Stabilise Select connector in between as shown.


Putting the Joystick back:
11. Position the joystick harness connectors at the back of the E-stop while screwing the joystick back in.
Note: Space is very limited so take care not to get any wire disconnected or crushed during the closing process. 


Position the Overwatch ECU and Horn relay:
12. Position the Overwatch ECU and Horn relay at the back of the Horn Push button (as shown in photo).
13. Connect the 12-Pin connector from the Overwatch Harness to the Overwatch ECU.


Closing the control box:
14. Connect the 8-Pin Lidar connector to the Overwatch ECU
15. Return the bottom plate of the control box to its original position.


Closing the control box:
16. Reattached the 2 side plates of the control box.
17. Get rid of any slack on the Lidar cable, by pushing them back into the control box.
18. Cable tie the Lidar cable to the side of the control box.
19. Return the control box to the Machine and complete the Post Installation Configuration. 
This will test all connected control lines between the Control box electronics and the Overwatch



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 below for 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

 
 

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.

 
Change Model Configuration
To reconfigure the Overwatch for a different model requires an authorisation password. The authorisation password is generated via a web page from the EQSS website (link provided below). 

Go to the Reconfiguration page and follow the instructions to create an authorisation password.
Then enter the hash password when prompted by the Overwatch. Proceed to test and make sure that all of the control lines pass. If all of the tests don't pass, then check the harness connections and make sure that they have been connected to the correct locations. Then proceed to test again. The Overwatch will not be enabled for operation until all of the Installation tests have passed.
Troubleshooting:-  If the tests continue to fail
- Make sure that you have selected the correct configuration for your machine
- Make sure that all connectors have been firmly plugged into the appropriate sockets
- Make sure that the harness hasn't been pinched by the case during reassembly


Settings
The OEM Settings page defines preset OEM parameters
See the sections below for details on each parameter:

Polarity and Input Style
The table below describes each setting: 


Bypass

Date and Time


Connection Schematics