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5. Final Verification

The final step of installation confirms the whole system works together: the Head Unit recognises each grease point, records grease delivery, and passes that activity through the Gateway to GreaseCloud, where it appears against the right points.

This is step 5 of installing the GreaseBoss Manual Greasing System. For the full sequence, see Solution Installation Process and Requirements Overview.

In this article:

  • Before Starting
  • Carrying Out a Test Run
  • Checking the Results in GreaseCloud
  • If Something Isn't Right
  • When Installation Is Complete
  • Next Step

 

Before Starting

Steps 2 to 4 must be complete:

 

Carrying Out a Test Run

The test run uses the system exactly as operators will use it day to day.

  1. Take the synced Head Unit off its charger, on its grease gun.
  2. Carry out some greasing or a full grease run across the mapped points. The amount is up to the site.
  3. At each point, connect the coupler and read the screen and LED before pumping. The Head Unit should show the point name. Grease only when it shows a task is due, and stop when the target is reached.
  4. Note anything unexpected, such as a QR code, "No task found" on a point that should be due, or "Wrong grease", with the point name.
  5. Return the Head Unit to its charger at the end of the run. Connecting the charge plug starts a sync, which uploads the test run activity to GreaseCloud.

The Head Unit responds at each point as follows:

SITUATION NOZZLE LED SCREEN ACTION
Tag read, lubrication due Blue Task found, with the point name and target volume Grease toward the target volume
Target volume reached Green Target reached Stop greasing and move to the next point
Tag read, no lubrication currently due Red No task found Don't grease. Note the point if it should be due
Delivered volume over the threshold Red Over-delivery warning Stop greasing and move on
Grease assigned to the Head Unit doesn't match the point Red Wrong grease Stop. Note the point
Tag read but point not mapped Red QR code Note the point for mapping

The Head Unit warns the operator but does not stop grease being delivered, so the screen must be read before pumping.

Hold the coupler by its handle and keep hands clear of the metal parts while connecting. A hand over the coupler blocks the antenna, and grease delivered without a tag read is recorded as untracked.

 

 

Checking the Results in GreaseCloud

Allow 10 to 20 minutes after the Head Unit syncs for the activity to appear in GreaseCloud. Then review the test run in the GreaseCloud Dashboard and check that:

  • Every point greased in the test run has an event, recorded against the correct point name, asset and location.
  • The grease type, volume and time of each event match what was done at the point.
  • There are no untracked events. Grease delivered without a tag read shows as untracked greasing or against an unknown point.
  • The tasks due in GreaseCloud match the tasks the Head Unit showed. What the system expects and what the Head Unit prompts operators to do should be identical.

Make any configuration changes needed (for example a schedule, volume or grease type), let the Head Unit sync again, and recheck the affected points.

 

 

If Something Isn't Right

WHAT'S SEEN LIKELY CAUSE WHAT TO DO
QR code on the Head Unit at a point that was mapped The mapping wasn't saved or synced, or the Head Unit hasn't synced since mapping Check the point has an RFID number in GreaseCloud, sync the app and the Head Unit, then read the point again. If it's still missing, map the tag again (see 4. Install and Map Grease Tags with the GreaseBoss App)
Wrong point name shown The tag is mapped to the wrong point, or two nearby tags are cross-reading See Grease Tag Troubleshooting, Part C
"No task found" on a point that should be due No schedule applied to the point in GreaseCloud, or the task isn't due yet Check the point's schedule in GreaseCloud, then sync the Head Unit
"Wrong grease" The grease assigned to the Head Unit doesn't match the grease assigned to the point Check both in GreaseCloud and correct whichever is wrong, then sync the Head Unit
Greasing recorded as untracked or against an unknown point Grease was pumped before the tag was read, a hand blocked the antenna, or the point isn't mapped Read the point again with hands clear of the coupler and wait for the point name before pumping. See Grease Tag Troubleshooting, Part D
No test run activity in GreaseCloud The Head Unit hasn't synced with the Gateway Check the Head Unit is on its charger within range of the Gateway and the Gateway is powered. See Head Unit Troubleshooting

 

When Installation Is Complete

Installation is complete when:

  • the Gateway is powered and connected to GreaseCloud;
  • the Head Unit syncs successfully from its charger;
  • grease activity arrives in GreaseCloud against the right points; and
  • the test run results have been reviewed and any issues fixed.

GreaseBoss Customer Success will then work with the site team over the first weeks of operation to review the data and fine-tune the setup.

Two habits make the biggest difference from the first day of normal use:

  • Charge and sync after every run. A Head Unit left off its charger can't upload activity, receive schedule changes or be supported remotely.
  • Read the screen before pumping. The Head Unit confirms the point, the grease and the amount before any grease is delivered.

 

Next Step

The system is ready for daily use. For how operators and supervisors use it day to day, see the Manual Greasing System Operational Guide, starting with Operational Guide - 1. Introduction & System Overview and Operational Guide - 3. Daily Operations.

 

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