MachineSense System Installation Guide for a Hydrema
1. Overview
As a general rule, all 12T Hydremas are fitted in a similar manner. While there may be slight variations in how the cable is secured and routed—such as the path to the battery compartment or the fuse board for the signal cable—the overall process remains consistent.
The primary requirement is that the MachineSense device (Blue box) is mounted on the roof, and the Universal Power Adaptor (Grey box) is affixed externally to the rear screen of the cab within one metre of the MachineSense unit or ziptied to the protective cage. When these conditions are met, the fitting process is generally straightforward.
This guide outlines the necessary steps to ensure correct installation of the system. It covers component placement, cable routing, and power connections.
2. Required Components
MachineSense Device (The Blue)
(Mounted externally on the roof)Metal Ovals to adhere to roof surface. (Click below for product link)
Grey Universal Power Adaptor (UPA)
(Mounted externally on the rear screen of the cab)Wiring Loom
(3-core cable. Red and Black direct to battery. Green to Ignition live fuse or relay) - Pre-fittedCable Ties and Mounting Adhesive Pads
(For securing cables)Fuse holder and fuse tap
(For connecting inline fuse to positive battery terminal and signal cable to fuse board)
3. Pre-Installation Checks
Ensure the machine is powered down with battery isolated
Inspect and clean mounting surfaces such as rear screen for UPA fitment
Verify all parts are present and undamaged.
Ensure podium steps are supplied for roof access
4. Component Placement
4.1. Plastic Roof Applications
Component List:
Qty | Product | Image/URL |
2 | Oval Plates |
|
1 | CTec - Grab and Bond |
Process Steps.
Step 1:
Connect plates across the adjacent magnets (shown below):
WARNING: THE MAGNETS ARE STRONG SO AVOID TRAPPING FINGERS BETWEEN THE OVAL PLATES AND THE MAGNETIC FEET WHEN CONNECTING
Step 2:
Apply adhesive across the width of each oval plate:
4.2. Attach the MachineSense
Step 1:
Ensure the roof surface is completely dry and free from any contaminants.
Step 2:
Turn the MachineSense device over and carefully place it on the designated area of the roof.
Step 3:
Press down firmly, then move the device from side to side to achieve maximum adhesion.
BE MINDFUL NOT TO TRAP ANY SECURITY OR POWER CABLES WHEN GLUING THE UNIT INTO PLACE. THE POWER CABLE MUST RUN TOWARDS THE FITTED UNIVERSAL POWER ADAPTOR (1M).
5. Universal Power Adaptor (UPA)
Location: External rear of cab, affixed top left on rear window (within 1 metre of the MachineSense unit)
Mounting Method: Adhesive pad.
Ensure the UPA is level and stable.
Mount 'PLINX Ready' Sticker beneath.
5.1 . Scan the QR code on the UPA:
Using a smart phone, scan the QR code on the UPA . This will direct you to the UPA registration screen, where you must enter some machine details before proceeding with the installation:
After scanning the QR code, the 8-digit UPA ID number will be pre-populated. Enter the Fleet number such as DT12T###, followed by a brief description of the machine (e.g., its model number, class and owner such as 912G, Hydrema, OWNER NAME).
Next, select the machine type from the drop-down list:
Select SUBMIT before proceeding.
5.2 Clean the glass:
Using glass cleaner or a similar appropriate solution, clean an area in the top left corner of the rear windscreen to ensure strong adhesion for the UPA. The UPA comes with a strong double-sided tape—remove the backing and firmly press the UPA onto the cleaned surface.
IN TEMPERATURES BELOW 5 DEGREES THE ADHESIVE WILL NOT BE EFFECTIVE. MAKE SURE THE FITTING ENVIRONMENT IS SUITABLE BEFORE CONTINUING.
Next to the UPA, apply the 'Plinx Ready' sticker, indicating that the machine is prepared for MachineSense fitting once all connections have been completed.
5.3 Cable routing options (Battery):
The UPA connection requires direct access to the battery on all machines. With a Hydrema, the battery is located within its own compartment behind the cab on the left side of the machine. Access direct into this compartment is through the same rubber seals the battery cables run through from the engine.
1  | 2  | 3  |
4  | 5  | 6  |
7  | 8  | 9  |
Cable passes through body of machine
Cable is secured along existing cable route
Connection direct to battery via fuse block (Only 2 cores required here)
Signal cable routed up away from engine bay (Green core is split and extended)
Signal cable routed over protective cage behind cab
Signal cable routed across rear screen of cab and behind protective cage
Signal cable routed down through wheel hub
Signal cable routed through cab access
Signal cable attached to Ignition Fuse via fuse tap (10A)
6. Driver Interface Bracket
Location: External front left of cab, affixed to top of grab rail (Amalgamating tape may be required)
Mounting Method: Truss clamps
Ensure the LED screen is visible to the operator.
Secure and tidy cables (Avoid looping)
7. Cable Routing and Connection
7.1 MachineSense to UPA
Use the pre-fitted 1m cable to connect the MachineSense unit to the UPA.
Tighten waterproof nut, secure with cable ties; avoid sharp bends or pinch points.
7.2 Driver Interface to MachineSense
Use 2m cable to connect the Driver Interface to the MachineSense unit (PORT 1)
Tighten waterproof nut, secure with cable ties; avoid sharp bends or pinch points.
7.3 Power Cable UPA to Battery
Route: From UPA to the machine’s battery compartment. Tidy all cables.
Connection:
Red to Positive (+) via Inline fuse connector
Black to Ground (–)
Secure all cables to avoid loose ends or contact with moving parts.
7.4 Signal Cable (Green) to Fuse Board
Route the signal cable to the fuse board. Use extension core where required.
Use a fuse tap or connect inline via a spare accessory fuse slot (e.g., ignition).
Confirm fuse rating matches system specs (typically 2A–5A).
8. Final Checks and Power-On
Double-check:
All cable connections are tight and insulated.
Mounts are secure and weather-sealed (for roof device).
UPA and MachineSense are within 1 metre of each other.
Driver display is fixed and visible
Turn on the machine and verify:
LEDs are lit on the Driver Display (Green)
9. Troubleshooting Tips
Issue | Likely Cause | Solution |
No power to UPA | Loose battery connection | Check terminals, ensure polarity is correct |
Signal not registering | Signal wire not fused or connected | Check fuse board tap and continuity |
GPS not locking | Obstructed roof device | Move MachineSense to clearer location |