Endpoints – Not Reporting Grease Activity in GreaseCloud

Applies to: LF300, HF300, LF400, HF400, MP2 and Bulk Flow Endpoints in the Automatic Grease Monitoring Solution, with either an HME Gateway or a Fixed Plant Gateway. The steps are the same for every model; only the sync interval and the button and LED sequences differ.

Scope: This guide covers a GreaseBoss Endpoint that is connected and syncing but not reporting greasing activity into GreaseCloud. The Endpoint sits in the grease line, so a blocked or seized Endpoint is diagnosed here — note that contaminants carried in the grease are the usual cause, which makes it a grease cleanliness problem rather than a product defect. The site's automatic lubrication system — pump, reservoir, controller, injectors, divider blocks and lines — and the asset itself are outside this guide, and it routes you there once the Endpoint is cleared. An asset that is shut down, parked or in maintenance will report no greasing activity: that is expected, not a fault.

If the Endpoint is showing Offline, use Endpoints Status "Offline" in GreaseCloud instead. For how the system is put together, see Automatic System - System Design & Architecture.

DIAGNOSTIC STEPS

Step 1 — Confirm the Endpoint is syncing but not recording grease

• Open Dashboards > Assets, select the asset, select the Group, then select the Endpoint.
• Connectivity = Offline, or Last Sync far older than the expected sync interval (Step 2) → the Endpoint is not reporting at all. Go to Endpoints Status "Offline" in GreaseCloud.
• Last Grease Event recent, but with regular gaps in the record → grease is being recorded intermittently. Go to Step 4 — this guide covers it.
• Last Grease Event recent and the record is complete → greasing is being recorded. If the volumes or compliance figures look wrong rather than missing, that is a reporting question, not this guide.
• Last Sync recent, Last Grease Event much older → this is the fault this guide covers. Confirm it on the Activity tab.

On the Activity tab, set the date range wide enough to cover the last known greasing.

• Volume Dispensed stops while the Endpoint keeps syncing → it has measured no grease. Go to Step 2.
• No Volume Dispensed anywhere in the range → the Endpoint has never recorded grease. Go to Step 6.

Step 2 — Confirm a lubrication cycle has run since the last sync

• An Endpoint stores what it measures and uploads it at its next sync. Greasing delivered after the last sync has not been sent yet.
• Know the expected sync interval before judging a gap:
  • LF400, HF400, MP2 and Bulk Flow sync every hour as standard.
  • LF300 and HF300 sync times are configured with the site and vary from site to site. Confirm the interval set for your Endpoints.

• Compare Last Grease Event against Last Sync, and against when the point was last due to be greased.
• No sync since the last cycle → expected. Recheck after the next sync, or force a re-sync (Step 7).
• Asset shut down, parked or in maintenance → expected. The lubrication system is not running and there is nothing to report. No action.
• Syncs have happened since a cycle ran and Last Grease Event has not moved → Step 3.

Note: Allow 10–20 minutes after a sync for data to appear in GreaseCloud.

Step 3 — Confirm the Endpoint itself is healthy

• Open the Diagnostics tab over the same date range.
• Voltage steady, both RSSI traces continuing, temperature still reporting → the Endpoint is powered and communicating. It is recording no grease because none is passing through it. Go to Step 4.
• Voltage declining, or showing regular downward spikes that increase in frequency → the battery is depleting. Replace it using the guide for the model, then Step 7.

Note: A depleting battery usually stops an Endpoint syncing altogether before it affects recording, so it is not the first suspect for missing grease activity. It can still cause activity to be recorded incompletely, so eliminate it rather than assume it.

• RSSI traces below −80 dBm or dropping out → weak signal to the Gateway. Use Endpoints Status "Offline" in GreaseCloud.
• All diagnostic traces stop at the same point → the Endpoint has stopped reporting entirely. Use the Offline guide.

Step 4 — Narrow it to the point or the whole asset

Know what normal looks like for this asset and this point before judging a gap. Some points track pump activity closely and deliver on a very regular pattern; others are naturally erratic. Judge the record against this point's own history, not against another point's rhythm.

• On the asset's Analysis tab, compare this Endpoint against points that should behave like it: neighbouring points, the same point or bearing on the opposite side of the machine, and other points fed by the same grease system and pump.
• Comparable points still recording volume, this one flat → grease is reaching that part of the system but not this point, or not through this Endpoint. Go to Step 5.
• This Endpoint records some cycles and misses others, while comparable points record every cycle → intermittent delivery or measurement at this point. Go to Step 5.
• Every Endpoint on the same grease system flat from the same date → that system is not delivering. Confirm with the site's lubrication or maintenance team. This is outside GreaseBoss scope.

Note: An asset can carry more than one grease system and pump. Comparing across systems proves nothing — a point on a healthy system will look normal while the one you are diagnosing sits on a system that has stopped.

Then check Grease Pump activity, which is shown on every data tab where a Pump Monitor Wire Harness is installed and in use.

• Pump activity present, no Volume Dispensed against it → the pump ran and this point recorded nothing. Go to Step 5.
• No pump activity at all → the pump has not run. Confirm with the site's lubrication or maintenance team.
• No Grease Pump series on the asset → no Pump Monitor Wire Harness is installed or in use there. Confirm pump activity at the machine instead.

Note: Analysis compares Endpoints on the same asset only — Endpoints on different assets cannot be plotted together. On an asset with a single Endpoint, the pump bars are the comparison.

Note: Series on the Analysis chart can use different scales. Compare whether a series is present and when it stopped, not the height of its bars.

Step 5 — Find the blockage

This is the most common cause of an Endpoint that has stopped recording grease. Five things produce it, and only the first is at the Endpoint:

• The Endpoint is blocked — contaminants carried in the grease have seized its internal gears, so nothing passes through and nothing is measured.
• No grease is being pumped through the system.
• The injector or progressive divider block upstream of the Endpoint is not working.
• A blockage upstream of the Endpoint, so no grease reaches it.
• A major blockage downstream of the Endpoint, preventing more grease being pumped into the line.

First, the checks that cost nothing:

• Confirm the pump is running and the reservoir has grease (Step 4).
• Confirm the injector or divider block feeding this point is cycling.
• Check the inlet and outlet fittings are tight and no grease is escaping at a joint upstream — grease that finds an easier path never passes through the Endpoint.
• Check the lines either side for damage or crimping, and the Endpoint body for impact damage.

Then isolate the blockage, with the system delivering grease. Take one connection at a time and reattach it before moving to the next:

• Remove the line at the inlet of the Endpoint and confirm grease comes out of the line. Reattach.
• Remove the line at the outlet of the Endpoint and confirm grease comes through. Reattach.
• Remove the line at the grease point and confirm grease. Reattach.

Read the result:

• No grease at the inlet → nothing is reaching the Endpoint. The pump, the injector or divider block, or the line upstream. Site's lubrication system.
• Grease at the inlet, none at the outlet → the Endpoint is blocked or its gears are seized. Clear it as below.
• Grease at the outlet, none at the grease point → a blockage downstream, in the line or at the point itself.
• Grease at all three → nothing is blocked. Go to Step 6.

Note: That sequence assumes the usual install — the Endpoint downstream of the injector, progressive block or grease source, monitoring delivery to a grease point. Where the Endpoint is fitted on the pump outlet or in a trunk line upstream of an injector bank, run the downstream test where the line next terminates, and test as far through the system as you can.

Clearing a blocked Endpoint

• Use a hand-held grease gun to pump grease through the Endpoint, starting in the reverse direction. This clears the blockage and frees the gears.
• Once it clears, pump through again in multiple directions.
• Force a re-sync to the asset's Gateway (Step 7), then confirm the grease activity has uploaded and appears against the point.
• Will not clear → contact GreaseBoss Support. A blocked or seized Endpoint can be returned to GreaseBoss for inspection, and GreaseBoss will advise whether it can be cleared or repaired, or needs replacing.

Do not open or disassemble an Endpoint. Return it to GreaseBoss instead — opening it voids any warranty on the unit.

Where the Endpoint has been recording intermittently rather than not at all, clear it as above, then compare it against pump activity over the next few cycles. The pattern continues → the injector serving the point is faulty, or the Endpoint is. Replace the injector through the site's lubrication system, or contact GreaseBoss Support about the Endpoint.

Do not leave the lubrication system pumping against a seized Endpoint. Enough pressure on seized gears will bend the pins they rotate on, and the Endpoint will not free after that. Clear it by hand as above.

Warning: Grease at these pressures can inject through skin. Do not test flow against any part of the body, and relieve pressure before disconnecting a line.

Note: A seized Endpoint blocks the line it sits in, so the grease point is being starved as well as unreported. Treat it as a lubrication problem, not just a data one.

Step 6 — Confirm the Endpoint is mapped to the grease point

• Open the Group and find the grease point.
• Grease point listed with no Endpoint against it → the Endpoint is not mapped to it. Map it, then Step 7.
• Endpoint not shown anywhere on the asset → an Endpoint assigned to the account but not mapped to a point is not displayed at all. Treat it as unmapped and map it.
• Endpoint listed against a different point → remap it to the correct point.
• Endpoint recently installed, replaced, or had its top swapped → confirm the replacement was mapped. An unmapped replacement records nothing against the point. See Endpoint Swap Top Instruction Guide.
• Mapped correctly → Step 7.

Step 7 — Force a re-sync and confirm resolution

• Confirm the Gateway serving the asset is powered and online.
• Force a re-sync using the button and LED sequence for the model:
  • Bulk Flow / MP2 / LF400 / HF400 sync guide
  • LF300 sync guide
• Wait 10–20 minutes, then reopen the Endpoint.
• Fixed → Last Sync updates, Last Grease Event moves to the recent greasing, and new Volume Dispensed (cc) appears on the Activity tab.
• Still nothing recorded after a confirmed greasing cycle → go to STILL NOT WORKING.

SYMPTOM / LIKELY CAUSE / SUGGESTED ACTION

STILL NOT WORKING

An Endpoint, or something else in the GreaseBoss system, can fail in ways these steps won't isolate. GreaseBoss Support will work through it with you, and can arrange the return of a blocked or seized Endpoint for inspection. Do not open the unit yourself.

Contact GreaseBoss Support with:

• Asset name and location
• Endpoint serial number and model
• The Group and grease point the Endpoint is fitted to
• When greasing was last confirmed at the point, and how it was confirmed
• What has already been checked, including the lines either side of the Endpoint
• Screenshots of the Endpoint's Activity and Diagnostics tabs
• A photo of the installed Endpoint and its fittings

Email: support@greaseboss.com.au