Visit PT Wizard for product selections and configuration settings.
Start selection by clicking on the Intelli-Lube homepage after logging in.
For new installations or a Dodge recommendation for selection and configuration, click the Select button under New and click Next.
To use an existing bearing part number, leave the default Part Number / Description option selected, and then select your part number by searching and selecting the correct part number in the Part Number / Description field. Then, click Next.
In the Application Conditions section, enter details about the operating conditions of the bearing including speed, temperature, orientation, and operating time.
Continue scrolling down and select the Environmental Factors of the bearing that best represent the application. This is subjective. If unsure, it is generally a good idea to pick worse conditions. When finished, click Next.
If desired, pick a discharge setting from the drop down list. The default Recommended selection will provide the best choice, but you can reduce this time if you want to maintain a fixed replacement schedule for multiple bearings across all plants. Click Next.
Options for equivalent cartridge sizes and dispense rates will be shown if available. Click on the option with your desired cartridge size and discharge settings.
Scroll down, and if desired, select a mounting kit. These kits are optional if the drive will be attached directly to the bearing but are good for placing cartridges in easy-to-reach positions for maintenance. Once done, click Next.
A summary page will be generated. This can be saved as a PDF and sent to a distributor for purchasing. Keep this document on file for reference when installing the Intelli-Lube components. The QR code will be used when commissioning the cartridge.
Clean the lubrication point thoroughly with a cloth or other cleaning material.
Remove the pre-existing grease fitting.
Thread on the reducer if required. Thread the support flange.
Pre-fill the lubrication point.
Insert the battery into the bottom of the drive until it clicks into place.
Attach the drive to the new grease cartridge. Press the drive down onto the cartridge, and then turn the retaining sleeve clockwise until firmly seated.
Remove the cartridge plug.
Thread the drive-cartridge combination into the support flange until tight.
Mount the beam clamp to a bar or hang the cage hanger from a nearby point (see the alternative button below). Tighten the securing bolts from below.
Attach the lube bracket to the mounts using the included screws.
Clean the lubrication point thoroughly.
Remove the grease fitting.
Add any hose reducers if required.
Cut, install, and prefill the lube line from the mounting brackets to the bearing.
Insert the battery into the bottom of the drive until it clicks into place.
Attach the drive to the new grease cartridge. Press the drive down onto the cartridge, and then turn the retaining sleeve clockwise until firmly seated.
Remove the cartridge plug.
Install the lubricator cartridge into the remote mount kit. Protect them using the provided cover.
Remove the drive-cartridge assembly from the support flange.
Turn the retaining sleeve counter-clockwise to detach the spent cartridge.
Press the battery retainer inwards and remove the battery.
Insert the new battery that was supplied with the new grease cartridge.
Press the new grease cartridge against the drive and turn the retaining sleeve clockwise until tight and the arrows are fully visible.
Reinstall the drive-cartridge combination into the support flange.
In the mobile app, select the unit you just replaced on the Assets page.
Press the Load button to load a fresh measurement
The app will automatically detect that the cartridge has been replaced. If you replaced the cartridge with a different size or grease type, press Yes. Otherwise, select No. If you select No, you are now finished.
Scan the QR code on the new lubrication cartridge.
Confirm that you wish to swap between the two cartridges.
The app will scan to ensure the Intelli-Lube is in range, and then write the new cartridge settings to the drive. Stay in range of the drive until the changes are complete.
A green confirmation pop-up will confirm that the cartridge was successfully changed.
Select the Asset to which you wish to commission your new Intelli-Lube unit. Assets are located within the PLANT tab of the OPTIFY platform.
Select the Edit button.
Scroll down on the Edit menu and select the Commission Sensors button.
Select the online gateway from the list.
The gateway will scan for available sensors. Select your Intelli-Lube from the list.
If desired, give the sensor a custom position name, then select Commission.
Select the first Scan QR Code button.
Use your computer camera to scan the QR code on the side of the grease cartridge, then click Next.
Choose the second Scan QR Code button.
Scan the QR code on the PT Wizard document, then click Next.
Confirm that the displayed settings are correct, then click Next.
Once the sensor has commissioned, select Confirm.
From the OPTIFY dashboard, navigate to the Plant tab on the left.
Select the asset containing the Intelli-Lube you wish control, and then press Edit.
Navigate to the Sensors tab of the Edit menu.
Turn on the drive by scrolling down to the Configuration section and click the Turn On button. This will start the dispensing of grease at regular intervals.
Likewise, to turn off the drive, click the Turn Off button. This will stop the regular grease dispensing until the drive is turned back on.
Once a confirmation is received, save your changes by selecting Save All.
From the OPTIFY dashboard, navigate to the Plant tab on the left.
Select the asset which contains the Intelli-Lube you wish control, and then press Edit.
Navigate to the sensor page of the Edit menu.
Scroll down to the Configuration menu and select the Purge button.
On this menu you can select how much grease to purge. Select 1, 2, or 3 dispense cycles. Each dispense cycle, discharges 2CC of grease. Once selected, click Save.
Once the purge is complete, save your changes by selecting Save All.
From the OPTIFY dashboard, navigate to the PLANT tab on the left.
Select the asset which contains the Intelli-Lube you wish control, and then press Edit.
Navigate to the sensors page of the Edit menu.
Scroll down to the Configuration menu and click the Change Settings button.
Click the drop down next to Cartridge Size to select a different cartridge. Adjusting the cartridge size should be used if the wrong size cartridge was accidentally entered during commissioning. This will affect the fill level shown on the KPI charts to accurately reflect the new cartridge size.
Click the drop down next to Discharge Period to select a different period. This will affect the Alert and Alarm levels shown on the KPI trends, as the cartridge will now be empty in a different amount of time.
When finished, select save to save your changes.
Select the Asset to which you wish to commission your new Intelli-Lube unit. Assets are located within the Assets tab of the mobile app.
Scroll down on the Assets properties page to the Sensors section. Select the Commission sensor button.
Ensure your Intelli-Lube device has the battery inserted and is on. Then, select the device from the list of available sensors, making sure that the serial number displayed on screen matches your Intelli-Lube's serial number if you are online.
Under Cartridge Size, select the Scan QR Code button and use your devices camera to scan the QR code on the side of the lubrication cartridge. This will automatically load the cartridge details.
Under Discharge Period, select the Scan QR Code button and use your devices camera to scan the QR code on the printed PT Wizard document. This will automatically load the necessary discharge settings.
Select the Yes, Commission button to finish.
If a Firmware update is required, the app will do so automatically. This can take a few minutes, so be sure to stay in range of the sensor while the update takes place.
If you are ready to install the Intelli-Lube, do so, and then press Turn On Now. Otherwise, select Turn On Later so that the unit will not dispense grease before it is installed. If you select Turn On Later, you MUST remember to turn on the unit at a later date when it is installed.
Select the Assets tab on the bottom of the OPTIFY app.
Select the asset which contains the Intelli-Lube unit you wish to control.
Navigate to the Asset Properties page by swiping from side to side. Scroll down to find the Sensors section and select the specific Intelli-Lube unit to control.
Use the toggle slider to turn the drive on and off. Note the drive will need to be in range of the mobile device.
Select the Intelli-Lube asset from the Assets Page.
Navigate to the Asset Properties page.
Scroll down and select the Intelli-Lube sensor you wish to dispense extra grease.
Select the Purge button.
Select from 2cc, 4cc, or 6cc. The grease will be released in 2cc increments. Once selected, press Start Dispense.
The app will scan for the sensor to ensure that the Intelli-Lube is in range. Once in range, press Confirm.
Please wait while the purge takes place.
When finished, a green confirmation will display.
Select the Intelli-Lube asset from the Assets Page.
Navigate to the Asset Properties page.
Scroll down and select the Intelli-Lube sensor you wish to modify.
Select Change Cartridge Size.
Scan the cartridge QR code using the device camera to automatically load in a new cartridge size (if applicable).
After scanning the QR code for cartridge size, press Save.
Select Change Discharge Period.
Select a discharge period using either a PT Wizard QR code or by manual entry.
After scanning the QR code for the discharge period, press Save.
The app will scan to ensure that the Intelli-Lube is in range. Once found, press Save again.
A green banner will appear confirming that the cartridge settings were successfully changed.
Select the Intelli-Lube asset to which you wish to replace. Assets are located within the Assets tab of the mobile app.
Swipe to the first page, which is Asset properties, then scroll down and tap the Intelli-Lube you wish to replace.
Tap the Sensor Utility to open the Sensor settings menu.
Tap Replace sensor.
Select the Intelli-Lube you wish to replace your current drive with, taking care that the serial number matches.
Tap Yes, Replace to initiate the drive replacement.
Tap Use New Cartridge or Use Existing Cartridge depending on your circumstances.
If you select Use Existing Cartridge, the app will prompt you to estimate how much grease you have left in your existing cartridge.
You can select a percentage in multiples of 10 to estimate the grease amount.
Once your grease level is selected, tap Confirm.
If you selected Use New Cartridge, the app will prompt you to scan the QR code on your new cartridge. Tap Scan QR Code.
Scan the QR code on your new cartridge.
Confirm that the cartridge information is correct, then press Yes, Confirm.
After selecting your cartridge option, the app will check the Intelli-Lube's firmware and update it if necessary.
The app will continue to set up the sensor.
Check that your new Intelli-Lube's serial number in the OPTIFY app matches the serial number of your new drive.
Select the asset that has the Intelli-Lube you wish to transfer to another asset.
Swipe to the first page, which is Asset properties, then scroll down and tap the Intelli-Lube you wish to transfer.
Tap the Sensor Utility to open the Sensor settings menu.
Tap Transfer sensor.
Select the asset group and the asset you want to transfer your Intelli-Lube to.
Tap Transfer.
Confirm that you want to transfer this sensor by tapping Yes, transfer.
You can confirm that your Intelli-Lube has been successfully transferred by navigating to the asset you transferred it to and checking for your Intelli-Lube.
The Fill Level KPI represents how much grease is remaining in a specific Intelli-Lube cartridge.
Access the Intelli-Lube Fill Level KPI on the web portal by selecting the unit from the Asset Tree on the Assets page.
The Fill Level KPI is shown over time to better represent how quickly a cartridge is being consumed.
This data will update each time the Intelli-Lube drive dispenses a new grease shot. Zoom in to see specific dispenses, and hover over a point to see the time and date.
If an Intelli-Lube unit loses connectivity for any reason, a projected fill level will appear in the KPI trends. This projected line will provide OPTIFY's best guess of the current fill level of the cartridge to ensure that notifications are still received for low and empty cartridges.
The projected fill level will continue to populate until connectivity with the drive is re-established. At this point, the projected fill level will be replaced by the actual fill level data.
If the cartridge reaches its alert or alarm levels while disconnected, the dashboard will display the asset status change, but will also notify you that this is only a prediction.
The Intelli-Lube unit will report the ambient temperature of the environment in which it is installed. This temperature display can be shown by clicking the eye icon in the rightmost panel to toggle the graph to be viewed.
This will bring up a second chart showing the Ambient Temperature over time.
The Intelli-Lube drive can broadcast a number of error states to immediately notify a user when an issue occurs:
Low Temperature:
The drive may have difficulties dispensing grease when the ambient temperature is too low. Consider turning off the drive and greasing manually.
Low Battery:
The battery of the drive has reached an unacceptable level and both the battery and canister should be replaced to ensure continuous greasing.
Overload:
A blockage has occurred and the drive is unable to push grease into the unit. Recommend inspecting the lube lines and unit, and then purging grease through the line to clear a blockage.
Once the line is clear, use the OPTIFY mobile app to turn the unit back to the ON state.
Empty:
The lubrication cartridge is completely empty and should be replaced immediately.
Fill Level:
Represents when the cartridge has reached 30 days until empty for alert (yellow) and 7 days until empty for alarm (red). When a unit reaches alert status, new cartridges should be ordered, and when a unit reaches alarm status, the cartridges should be planned for replacement.
The Cartridges tab can be accessed on the left-hand menu of OPTIFY.
The Overview page provides an at-a-glance view of the status of Intelli-Lube drives in your plant. This includes:
1. A count of action items
2. A proposal for how many cartridges should be ordered immediately
3. A percentage of cartridges in each status
4. A list of the current cartridges in your plant
Cartridge Empty:
Percentage of the existing Intelli-Lube drives that are out of grease and should be replace immediately.
Inspect Lubricator:
Can occur during very cold temperatures, blockages, no connection, and more. The drive should be inspected to ensure is operating properly.
Plan Replacement:
The cartridge is expected to be empty in 7 days or less. At this point, you should already have replacement grease cartridges on hand and should make a plan to replace them ASAP.
Verify Plant Inventory:
The percentage of drives that will be empty within 30 days. Ordering replacement cartridges is recommended to ensure that you have the proper pieces on hand before the Intelli-Lube is empty.
Good:
The Intelli-Lube is performing as expected and has over a month of grease left in the cartridge. This drive requires no action.
A maintenance report is a summary of each Intelli-Lube in the plant and its current condition. Download this report using the Maintenance Report button under the Cartridges Overview tab.
Critical Assets provides a list of each drive that will need a cartridge replacement in 7 days or less.
Assets Nearing Replacement shows a list of cartridges which have less than 30 days until the cartridge needs to be replaced.
All Assets is a list of every drive in the plant for reference for where cartridges are being used and how long each unit has until replacement.
Navigate to the Recommended Replacements tab of the Cartridges page.
Cartridges already in use in your plant will be automatically added, but if desired, add additional cartridges to the list using Add Item +.
Select which cartridges you wish to generate a replacement report for by selecting the check boxes on the left.
Choose a quantity of each selected cartridge using the + and - buttons on the right.
In the summary on the right, confirm the correct cartridges are selected and then click Generate Report.
The generated report will be available for download in the Replacement Report History tab.
Navigate to the Replacement Report History page of the Cartridges tab.
If a Replacement Report has just been generated, it will appear as New in the Status column.
To view this Replacement Report, click Download PDF.
The PDF Replacement Report will contain the cartridge and part number for each of the cartridges you selected when generating the report. This is the perfect document to send to your local distributor.
Once a PDF has been downloaded, the Replacement Report status will change from New to Viewed.
After you have ordered the cartridges, the status can be manually changed from Viewed to Ordered. To do so, click on the Viewed button.
A drop-down will appear, click Update the update the status from Viewed to Ordered
Once the ordered cartridges have been received on site, change the status from Ordered to On Site. To do so, click the Ordered status.
Click Update to update the status from Ordered to On Site
When a replacement report is marked as On Site, the Customer Inventory page is automatically updated to include these new cartridges. See Logging Cartridge Inventory for more information on cartridge inventory management.
If you are having trouble finding a local distributor, select the Find Local Distributor button.
You will be automatically redirected to Dodge PT Place to locate a local distributor servicing your location. Enter your zip code and click on Search.
A useful feature offered by OPTIFY is the ability to log your current lubrication cartridge stock. Logging your lubrication cartridge stock is an optional way to optimize the replacement reports feature. OPTIFY automatically manages the inventory as cartridges are replaced. To access this feature, navigate to the Customer Inventory page of the Cartridges tab.
Any cartridges that have been assigned to at least one Intelli-Lube will be automatically included. To add additional cartridges, click the Edit button
Click the Add Item + button.
Enter the Cartridge Type and Cartridge Size, OPTIFY will automatically load the required part number.
Click Add Item.
To log your current inventory, click the Edit button
Next to each cartridge you may add or subtract from the current value.
When you are finished editing, click Save
Install the battery into the bottom of the drive unit. Confirm that the LCD screen on the top of the unit illuminates to ensure the battery was installed correctly.
Thread the drive unit onto the top of your selected cartridge until the white indicators are clearly visible.
The Intelli-Lube drive unit will show "00" when first turned on in its unconfigured state. To configure the drive unit, the following steps must be completed quickly, one after the other. It is recommended to read all of the next steps before starting the setup.
Press and hold the SET button for 5 seconds until the three lines at the bottom of the LCD screen begin to blink slowly on and off.
Press the SET button repeatedly to cycle through the cartridge size options until the lines at the bottom of the screen are indicating the correct cartridge size. The sizes are in CC's (cubic centimeters).
Stop pressing SET and wait for the next screen to appear.
The drive will now be blinking between "m" (months) and "w" (weeks). Press the button to cycle between weeks or months to your desired interval, then stop pressing and wait.
Enter the number of weeks/months for the discharge period. Press the SET button repeatedly to count up to the desired period. Once selected, wait for the next screen to appear.
The drive is now configured and these settings will be used by default when a new battery and cartridge are installed. To turn the drive on or off, press and hold the SET button for ~1 second until the screen changes.
To purge an extra 6 CC (cubic centimeters) of grease at any time, press and hold the SET button for ~10 seconds until PU appears on the screen.