MachineSense System Installation Guide for a Telehandler 6m to 17m
1. Overview
As a general rule, all Telehandlers are fitted in a similar manner, whether they be a 6m or a 17m machine. 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 or ignition relay for the signal cable—the overall process remains consistent.
The primary requirement is that the MachineSense device (Blue box) is mounted on the roof where possible, and the Universal Power Adaptor (Grey box) is affixed externally to the rear screen of the cab within one metre of the MachineSense unit. When these conditions are met, the fitting process is generally straightforward and 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 Oval plates
(For adhesion to the plastic roof)
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 Tap and Fuse Holder
(For connecting signal cable to fuse board and for adding inline fuse to positive cable)
3. Pre-Installation Checks
Ensure the machine is powered down.
Inspect, clean and dry mounting surfaces.
Verify all parts are present and undamaged.
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.
Scan the QR code on the UPA:
UPA Registration Instructions
Step 1: Scan the QR Code:
Use a smartphone camera to scan the QR code located on the UPA device. This will automatically direct you to the UPA registration screen.
Step 2: Enter Machine Details:
On the registration screen:
The 8-digit UPA ID number will be pre-populated. (Check this is correct)
Enter the Machine Fleet Number (e.g.,
EX25T###).Provide a brief description of the machine, including:
Model number (e.g.,
308)Machine class (e.g.,
Excavator)Owner name (e.g.,
OWNER NAME)
Example: 308, Excavator, OWNER NAME
Step 3: Select the Machine Type:
From the drop-down list scroll to the correct machine type and select
Step 4: Select SUBMIT before proceeding.
Step 5: Proceed with Installation:
Once the registration is complete, you may proceed with the physical installation of the UPA and subsequent MachineSense setup.
6. Clean the glass:
Mounting the UPA
Step 1: Clean the Mounting Surface
Use glass cleaner or a similar appropriate solution to thoroughly clean a section of the top left or right corner of the machine’s rear windscreen.
Ensure the surface is dry and free of dust, grease, or debris to guarantee strong adhesion.
Step 2:Attach the UPA
Peel off the backing from the double-sided adhesive tape on the UPA.
Firmly press the UPA onto the cleaned area of the rear windscreen.
Hold in place for a few seconds to ensure secure bonding.
Tip: Choose a spot that allows easy cable routing from the MachineSense unit mounted on the roof.
IN TEMPERATURES BELOW 5 DEGREES THE ADHESIVE WILL NOT BE EFFECTIVE. MAKE SURE THE FITTING ENVIRONMENT IS SUITABLE BEFORE CONTINUING.
Step 3: Apply the 'Plinx Ready' Sticker
After securely mounting the UPA:
Place the ‘Plinx Ready’ sticker next to the UPA on the rear windscreen.
This sticker indicates that the machine is fully prepared for MachineSense installation, pending completion of all necessary power and data connections.
Note: Ensure the sticker is clearly visible and adheres well to the glass surface.
7. UPA cable routing options (Battery):
The UPA connection requires direct access to the battery on all machines. With a Telehandler (TEH), the battery is located within its own compartment underneath the driver cab on the ingress side of the machine. Access directly into this compartment is from underneath the cab from the back in between the machine body and the cab frame.
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. Driver Interface Bracket
Location: External front left of cab, affixed to external safety screen bars. (The bars are 10mm dia. so there is a need to secure using cable ties through the truss clamps)
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.
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 |