Infusion pumps · Flo-Gard family

Baxter Flo-Gard 6301: troubleshooting and error codes

The ServiceForge knowledge base holds 160 documented symptoms for the Baxter Flo-Gard 6301, with 293 ranked causes, 233 diagnostic checks with test points and expected values, and 95 error codes. Each symptom below shows its causes and the first check; the rest is one connection away. Connect ServiceForge to your AI

Symptoms

AIR alarm continuously on patient safety

AIR alarm message remains on display continuously despite troubleshooting

Ranked causes

1. Air trapped in tubing (common)
2. Incorrect or improperly loaded administration set (common)
3. Tubing scratched or deformed (occasional)
4. Air sensor out of calibration (occasional)
5. Air sensor dirty (occasional)
6. Air sensor failure (rare)
7. Occlusion sensor failure (rare)

First check

Check for air in tubing

Test point: administration set tubing
Expected: no visible air bubbles

4 more checks with pass and fail actions, 7 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Free flow occurs when door is closed patient safety

Solution flows past the pump mechanism when door is closed, indicating loss of occlusion

Ranked causes

1. Incorrect administration set type (occasional)
2. Tubing positioning or seating improper (occasional)
3. Temperature outside 60-100 F range (occasional)
4. Cracked door hinges (occasional)
5. Deformed coil springs on back plate (occasional)
6. Worn cams and pumping fingers (occasional)
7. Damaged or deformed door latch (occasional)

7 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Inaccurate infusion delivery patient safety

Actual delivered volume does not match programmed rate or volume to be infused

Ranked causes

1. Incorrect administration set type (occasional)
2. Tubing positioning or seating improper (occasional)
3. Temperature outside 60-100 F range (occasional)
4. Cracked door hinges (occasional)
5. Deformed coil springs on back plate (occasional)
6. Worn cams and pumping fingers (occasional)
7. Damaged or deformed door latch (occasional)

7 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

OCCLUSION alarm occurs with pump door closed caution

OCCLUSION or UPSTREAM OCCLUSION alarm activates when pump door is closed and START key is pressed

Ranked causes

1. Tubing positioning or seating improper (common)
2. Obstructions upstream or downstream of pump (common)
3. Incorrect administration set type (occasional)
4. Temperature below 60 degrees F (occasional)
5. Solution spills or residue on door or baseplate (occasional)
6. Damaged door latch or hinges (occasional)
7. Sensor calibration required (unknown)

First check

Verify tubing positioning and seating in sensor

Test point: pump sensor and safety clamp
Expected: tubing properly seated and straight

6 more checks with pass and fail actions, 7 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Front panel keys not accepted caution

One or more front panel keys do not respond to operator input

Ranked causes

1. Front panel locked (common)
2. Key requires reset (occasional)
3. Front panel ribbon cable disconnected or faulty (occasional)
4. Front panel film defective (rare)
5. Sensor board failure (rare)
6. Display board failure (rare)

6 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Free flow occurs when door is opened patient safety

Solution flows past pump mechanism when door is opened, when flow should stop

Ranked causes

1. Incorrect administration set type (occasional)
2. Solution spills on safety clamp (occasional)
3. Tubing positioning or seating improper (occasional)
4. Temperature outside 60-100 F range (occasional)
5. Broken safety clamp spring or clamp (occasional)

5 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

INSERT SLIDECLAMP alert or alarm constantly on caution

INSERT SLIDECLAMP alert or alarm message remains on display continuously

Ranked causes

1. Slide clamp sensor dirty or contaminated (common)
2. Connection issue with sensor (occasional)
3. Sensor calibration required (occasional)
4. Sensor board failure (rare)
5. Safety/slide clamp assembly fault (rare)

5 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

OCCLUSION or UPSTREAM OCCLUSION alarm with pump door closed patient safety

Alarm occurs when pump door closed and START key pressed

Ranked causes

1. Tubing mispositioned or pinched (common)
2. Obstruction in line upstream or downstream (common)
3. Wrong administration set type (occasional)
4. Ambient or solution temperature too low (occasional)
5. Spill or residue on door or base plate (occasional)

First check

Verify tubing positioning and check for kinks

Test point: Tubing path through pump
Expected: Tubing properly seated, no pinches or kinks

2 more checks with pass and fail actions, 5 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

AIR alarm occurs with tubing in sensor patient safety

Air alarm triggered when tubing properly seated or pump door closed and START pressed

Ranked causes

1. Tubing not fully positioned into air sensor (common)
2. Tubing scratched or flattened (occasional)
3. Wrong administration set type (occasional)
4. Air sensor contaminated with solution spill (occasional)

First check

Verify tubing positioning in air sensor

Test point: Air sensor
Expected: Tubing fully positioned

2 more checks with pass and fail actions, 4 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Air detected in administration set patient safety

Ultrasonic sensor detects air bubble; pump stops infusing, red ALARM LED illuminates, AIR message displayed, audible alarm activated

Ranked causes

1. Air bubble at sensor (common)
2. Empty fluid container (common)
3. Improper set loading (common)
4. START key pressed with no set in pump (occasional)

First check

Inspect administration set for air bubbles

Test point: Tubing at pump head
Expected: No visible air bubbles

2 more checks with pass and fail actions, 4 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Air detected in infusion set patient safety

Ultrasonic sensor detects air bubble in administration set. Pump stops infusing, red ALARM LED illuminates, AIR displayed in message display, audible alarm activated.

Ranked causes

1. Air bubble at sensor (common)
2. Empty fluid container (common)
3. Improper set loading (occasional)
4. Start key pressed with no set in pump (occasional)

4 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

PANEL LOCK switch not accepted caution

PANEL LOCK switch on rear panel does not register or activate properly

Ranked causes

1. Switch operation malfunction (common)
2. CN701 or CNI/F2 connection fault (occasional)
3. PANEL LOCK switch hardware failure (occasional)
4. Sensor board fault (rare)

4 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Power indicator not lit when plugged in

Plug icon not lit or battery icon lit when device plugged into AC outlet

Ranked causes

1. Power plug not firmly seated in outlet (common)
2. Rear power fuses failed (common)
3. AC outlet voltage too low (occasional)
4. Power cord continuity broken (occasional)

First check

Verify power plug is tightly seated

Test point: AC outlet
Expected: Power plug fully inserted into outlet

3 more checks with pass and fail actions, 4 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Pump door does not open or close smoothly caution

Door movement is difficult or restricted

Ranked causes

1. Tubing or slide clamp misaligned (common)
2. Wrong administration set type (occasional)
3. Solution spills or debris in door mechanism (occasional)
4. Door latch or hinge damage (rare)

4 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Pump door will not open or close smoothly caution

Door binding or difficult to operate

Ranked causes

1. Tubing and slide clamp mispositioned (common)
2. Wrong administration set type (occasional)
3. Door latch roller pin stiff or damaged (occasional)
4. Door hinge or latch damaged (occasional)

First check

Check tubing and slide clamp positioning

Test point: Pump door interior guides and channels
Expected: Tubing seated in guides, slide clamp in slot, safety clamp open

4 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Pump operation louder than normal caution

Pump produces noise levels exceeding normal operating volume

Ranked causes

1. Incorrect administration set type (occasional)
2. Solution spills on pumping fingers or backplate (occasional)
3. Loose motor mounting bracket screws (occasional)
4. PC board or assembly vibrating internally (occasional)

4 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Safety clamp does not latch open caution

Safety clamp fails to remain in open position or does not latch properly

Ranked causes

1. Improper positioning or seating of slide clamp (common)
2. Incompatible administration set (occasional)
3. Safety clamp arm cover not fully open (occasional)
4. Solution spills or residue (occasional)

4 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Safety clamp will not latch open

Safety clamp cannot be opened or latches improperly

Ranked causes

1. Slide clamp not fully positioned in slot (common)
2. Wrong administration set type (occasional)
3. Safety clamp arm cover not in full open position (occasional)
4. Spill or residue on safety clamp (occasional)

First check

Verify slide clamp positioned fully in slot

Test point: Slide clamp slot
Expected: Slide clamp fully seated

1 more check with pass and fail actions, 4 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Slide clamp not inserted or improperly positioned patient safety

Safety slide clamp missing or not fully seated in pump slot; blocks infusion until corrected

Ranked causes

1. Slide clamp not inserted or misaligned (common)
2. Dirty slide clamp sensor (occasional)
3. Slide clamp sensor calibration out of range (occasional)
4. Slide clamp sensor or assembly defective (rare)

First check

Slide clamp physical insertion

Test point: Slide clamp slot
Expected: Clamp fully inserted and seated
Tools: Visual inspection

2 more checks with pass and fail actions, 4 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

AIR alarm with no air present or door closed

Air detection alarm sounds without air in line or with door closed

Ranked causes

1. Tubing damaged or flattened (common)
2. Wrong administration set (occasional)
3. Air sensor contaminated (occasional)

3 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Backup buzzer does not activate during self test

Backup alert buzzer fails to sound during power-on self test

Ranked causes

1. Buzzer wiring disconnected (common)
2. Battery fuse blown (occasional)
3. Backup buzzer defective (occasional)

3 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Calibration: Main battery voltage (MB)

Verification of main battery charging circuit voltage in Automatic Test Mode 1

Ranked causes

1. Main battery voltage out of specification (unknown)
2. DC power supply requires calibration (unknown)
3. Main battery requires replacement (unknown)

First check

Check MB value in SEC RATE window

Test point: SEC RATE window on Main Display
Expected: 688 to 714 displayed counts, 688-714
Tools: Pump display

1 more check with pass and fail actions, 3 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Communication error with external device

Serial communication failure between pump and external computer; framing, overrun, or parity error detected

Ranked causes

1. Pump not in computer control mode (common)
2. Communication cable disconnected or damaged (common)
3. PC software error or mismatch (occasional)

First check

Pump in computer control mode

Test point: Pump front panel display
Expected: Computer control mode active
Tools: Visual inspection of display

3 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Device or pump unexpectedly stops with audible alarm

Pump stops running with alarm sound for no apparent cause

Ranked causes

1. ICP301 component failure (common)
2. Front panel connection failure (occasional)
3. Front panel film or Display board failure (rare)

3 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Door not fully closed caution

Pump door not fully closed or latch magnet missing. Tubing not properly loaded. Pump will not operate until door fully closed with tubing properly seated.

Ranked causes

1. Door not fully closed (common)
2. Tubing not properly loaded (common)
3. Missing magnet in door latch (rare)

3 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

DOOR OPEN alarm incorrect operation caution

DOOR OPEN alarm occurs when door is closed, or does not occur when door is opened

Ranked causes

1. Missing magnet on door latch (common)
2. CN851 or CN852 connection fault (occasional)
3. CPU board fault (rare)

3 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Downstream occlusion detected caution

Pressure buildup detected in line distal to pump; may indicate blockage or kink in delivery tubing

Ranked causes

1. Tubing damage, kink, or occlusion (common)
2. Temperature out of specification (occasional)
3. Dirty or contaminated occlusion sensor (occasional)

First check

Inspect tubing for damage or kinks

Test point: Entire downstream tubing path
Expected: Tubing smooth, no kinks, no visible blockage
Tools: Visual inspection

2 more checks with pass and fail actions, 3 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

INSERT SLIDE CLAMP alert or alarm

Alert or alarm when pump door is closed

Ranked causes

1. Slide clamp not in slide clamp slot (common)
2. Wrong administration set without slide clamp (occasional)
3. Spill or residue on slide clamp assembly (occasional)

First check

Verify slide clamp is in slot

Test point: Slide clamp slot
Expected: Slide clamp fully inserted into slot

1 more check with pass and fail actions, 3 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

INSERT SLIDECLAMP alert or alarm when door closed caution

INSERT SLIDECLAMP alert or alarm occurs when pump door is in closed position

Ranked causes

1. Slide clamp not inserted in slot (common)
2. Solution spills on slide clamp assembly (occasional)
3. Incompatible administration set (occasional)

3 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Low battery voltage detected caution

Battery voltage drops to 10.4 V or below; may indicate dead battery or charging system failure

Ranked causes

1. AC charger not connected or defective (common)
2. Power or battery fuse blown (occasional)
3. Battery internal failure or connection loose (occasional)

First check

AC power connection and voltage

Test point: AC outlet, pump AC connector
Expected: AC power connected, voltage ≥105 VAC, +20/-15 VAC
Tools: Multimeter

2 more checks with pass and fail actions, 3 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

One or both pumps cannot be turned on

Pump fails to start when power button activated

Ranked causes

1. Low or dead backup battery (common)
2. Front panel cable short circuit (occasional)
3. CPU board failure (rare)

3 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Pump does not start or stops with failure code alarm patient safety

Pump fails to operate when START key pressed or immediately stops with alarm code displayed

Ranked causes

1. Administration set not primed or improperly loaded (common)
2. Door open or improperly closed (common)
3. Failure code alarm condition detected (occasional)

First check

Verify administration set is primed and properly loaded

Test point: Tubing in pump guide channel and mechanism
Expected: Tubing clean, dry, seated properly with no slack, kinks or pinches; no resistance when door closes

3 more checks with pass and fail actions, 3 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Slide clamp not detected or INSERT SLIDECLAMP alert not clearing patient safety

After loading primed administration set with slide clamp into slide clamp slot, INSERT SLIDECLAMP message may appear on display or not clear after proper insertion.

Ranked causes

1. Slide clamp sensor contamination or misalignment (common)
2. Slide clamp sensor calibration error (occasional)
3. Slide clamp assembly or wiring failure (occasional)

First check

Verify slide clamp feature configuration is enabled (option 2 or 3)

Test point: Configuration utility SLIDE CLAMP setting
Expected: Option 2 (ON or ALERT) or 3 (ALARM)

8 more checks with pass and fail actions, 3 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Upstream occlusion detected caution

Pressure drop or vacuum detected in proximal tubing; may indicate air leak, tubing damage, or blockage on supply side

Ranked causes

1. Tubing damage, leak, or blockage (common)
2. Dirty upstream occlusion sensor (occasional)
3. Temperature out of specification (occasional)

First check

Upstream line pressure and connections

Test point: Supply tubing, connectors, catheter hub
Expected: Tight connections, no leaks, no blockage counts, +/-36 counts
Tools: Visual inspection, pump display reading

1 more check with pass and fail actions, 3 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Air bubble detected in infusion line patient safety

Air detected in tubing during pump operation in Run mode; may trigger audible alarm

Ranked causes

1. Improper tubing load or tubing damage (common)
2. Dirty or contaminated air sensor (occasional)

First check

Visual inspection of tubing

Test point: Entire infusion line path
Expected: No visible air bubbles, no flattening or scratches
Tools: Visual inspection

1 more check with pass and fail actions, 2 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Air detection not functioning or incorrect sensitivity patient safety

Pump fails to detect air bubbles or air detection sensitivity is incorrect as determined by the Air Alarm Test.

Ranked causes

1. Air bubble size configuration setting incorrect (common)
2. Air sensor requires troubleshooting and repair (occasional)

First check

Prime and load administration set with Y-site above pump

Test point: Administration set inlet
Expected: Set primed and loaded per Administration Set Preparation steps 1-6

2 more checks with pass and fail actions, 2 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Air sensor does not detect air bubbles patient safety

Pump does not alarm or display AIR message when air bubble reaches sensor

Ranked causes

1. Air bubble breaks up before reaching sensor (occasional)
2. Air sensor calibration incorrect (common)

First check

Observe air sensor response to air bubble

Test point: Air sensor in pump
Expected: AIR displayed, red ALARM LED flashes, audible alarm activated, pump stops

1 more check with pass and fail actions, 2 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

All front panel keys disabled except BACKLIGHT

Most front panel keys do not respond to presses

Ranked causes

1. Panel lock engaged (common)
2. Display board failure (rare)

2 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Audible alarm always on caution

Alarm sounds continuously without stopping

Ranked causes

1. Battery disconnect/reconnect needed (common)
2. Component connection or short circuit (occasional)

2 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Audible alarm does not sound patient safety

Alarm fails to generate sound when triggered

Ranked causes

1. Software error or connection issue (common)
2. Speaker defective (occasional)

2 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Backlight is off when running on internal battery power

Display not lit while operating on battery

Ranked causes

1. Front panel locked (common)
2. Backlight not activated (common)

First check

Verify front panel lock status

Test point: Main Display
Expected: No LOT indicator shown

1 more check with pass and fail actions, 2 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Battery not detected after AC disconnection

BATTERY message not displayed on pump when disconnected from AC power, or BATTERY message does not disappear when plugged back in

Ranked causes

1. Battery absent or not functioning (common)
2. Battery charging voltage incorrect (occasional)

First check

Verify BATTERY message displayed when AC disconnected

Test point: Main display
Expected: BATTERY message appears

2 more checks with pass and fail actions, 3 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Beep does not sound when key pressed (non-BACKLIGHT/SILENCE)

No audible beep when pressing control buttons

Ranked causes

1. Connector disconnection or short circuit (common)
2. Speaker defective (occasional)

2 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Calibration: Air sensor patient safety

Calibrate air detection sensor using fluid-filled and air-filled calibration tubing segments; required after pump head, CPU board, air sensor, door assembly, or latch replacement

Ranked causes

1. Air sensor replacement or related component replaced (common)
2. Air sensor values out of calibration range (occasional)

First check

Check for pump head door modification

Test point: Pump head door opposite air sensor
Expected: White tubing guide shim or letter 'A' present

10 more checks with pass and fail actions, 2 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Communication timeout with computer

No communication between device and controlling computer for specified time period; COMM TIMEOUT message displayed

Ranked causes

1. Disconnected communication cable (common)
2. Computer problem or malfunction (occasional)

First check

Verify communication cable connection

Test point: Communications port connector
Expected: Cable fully inserted and secure at device and computer

2 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Door open alarm does not activate when door is opened during operation patient safety

Pump continues to operate or alarm does not sound/display when pump door opened while pumping

Ranked causes

1. Door open sensor malfunction (rare)
2. Display or alarm circuits defective (occasional)

First check

Program and start pump at specified settings

Test point: Pump select key; PRI RATE, PRI VTBI, PRI START keys
Expected: Primary rate 100 mL/hr, primary VTBI 10 mL, pump running

1 more check with pass and fail actions, 2 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Electrical safety parameters out of specification high voltage

Leakage current exceeds 50 microamps or ground impedance exceeds specification; power cord shows wear, damage, or broken pins

Ranked causes

1. Leakage current or ground impedance out of specification (rare)
2. Power cord damaged or worn (occasional)

First check

Measure leakage current per UL 544

Test point: Device under test per UL 544 standard
Expected: Not to exceed 50 microamps
Tools: Leakage current tester per UL 544

2 more checks with pass and fail actions, 2 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

External communication error from computer

EXT COMM ERROR message displayed; controlling computer sending multiple queries or commands without waiting for device replies

Ranked causes

1. Computer sending multiple queries without waiting for device responses (common)
2. Computer software malfunction (occasional)

First check

Verify pump is responding to manual commands

Test point: Pump control buttons (SILENCE, PUMP 1, PUMP 2, OPTIONS)
Expected: Pump responds to button press and switches to manual mode

2 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Force Sensing Resistor (FSR) values unstable

FSR zero offset values jump more than 10 counts between power cycles

Ranked causes

1. FSR connector dirty or corroded (common)
2. FSR device defective (occasional)

First check

Note left and right FSR values with pump on

Test point: FSR display readout

2 more checks with pass and fail actions, 2 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

INSERT SLIDECLAMP message appears when clamp not fully inserted

When the clamp is only inserted approximately one-third of the way into the mechanism and the pump door is closed, the INSERT SLIDECLAMP message incorrectly displays.

Ranked causes

1. Slide clamp sensor dirty or requires calibration (common)
2. Safety/slide clamp assembly defective (occasional)

First check

Verify INSERT SLIDECLAMP message does not display with partial clamp insertion

Test point: Display
Expected: INSERT SLIDECLAMP does not appear on display

2 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

INSERT SLIDECLAMP message does not appear on display

When the clamp is inserted approximately one-third of the way into the mechanism and the pump door is closed, the INSERT SLIDECLAMP message fails to display.

Ranked causes

1. Slide clamp sensor dirty or misaligned (common)
2. Safety/slide clamp assembly or wiring defective (occasional)

First check

Verify INSERT SLIDECLAMP message displays after cleaning sensor

Test point: Display
Expected: INSERT SLIDECLAMP appears on display

2 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

LCD blank, missing segments, or irrational display

LCD display is blank, shows missing characters, or displays incorrect information

Ranked causes

1. LCD connection or mounting issue (common)
2. Sensor board failure (rare)

2 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

No communication with computer caution

No communication between pump and controlling computer for specified time period. Pump displays COM TIMEOUT alarm.

Ranked causes

1. Disconnected communication cable (common)
2. Computer communication problem (occasional)

2 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

One or more front panel keys not accepted

Individual keys fail to respond when pressed

Ranked causes

1. Key needs reboot to clear (common)
2. Front panel cable issue (occasional)

2 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Pump delivers excessively high flow or fails drive defect test caution

Pump running at 1999 mL/hr with fluid-filled tubing produces downstream occlusion alarm or F-78/F-79 failure code within 15 seconds

Ranked causes

1. Drive mechanism defect (F-78 or F-79 alarm) (rare)
2. Downstream occlusion alarm triggered by normal high-speed operation (occasional)

First check

Prepare and load fluid-filled administration set

Test point: Tubing loaded in pump head
Expected: Fluid-filled tubing properly seated, door closed, all clamps open

2 more checks with pass and fail actions, 2 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Pump does not operate long on battery power

Battery runtime significantly shorter than expected

Ranked causes

1. Battery capacity degraded (common)
2. Battery harness continuity failure (occasional)

2 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Pump does not run on AC but runs on battery

Unit operates only on internal battery; AC power not working

Ranked causes

1. AC power cord not firmly connected (common)
2. AC fuses blown (occasional)

2 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Pump fails to detect air bubble in tubing patient safety

Air bubble present in administration set but no air alarm triggered; pump continues to run without stopping

Ranked causes

1. Air sensor calibration incorrect or sensor defective (occasional)
2. Air bubble too small to trigger alarm threshold (common)

First check

Verify air sensor calibration values

Test point: Air sensor calibration per Section 5.3.2
Expected: Calibration values within specification for NORM or M/N setting

3 more checks with pass and fail actions, 3 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

RATE, VTBI, or START key not accepted by pump

Keypad input ignored or rejected

Ranked causes

1. Rate outside allowable configuration range (common)
2. VTBI outside allowable configuration range (common)

First check

Verify rate within configuration limits

Test point: Configuration option
Expected: Rate within allowable range

1 more check with pass and fail actions, 2 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Rear clamp fails to hold pump on IV pole patient safety

Rear clamp does not grip firmly enough to secure pump to intravenous pole

Ranked causes

1. Worn or missing friction pad (common)
2. Worn clamp threads or other defective parts (common)

2 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

More symptoms

Remote computer configuration cannot be set
Slide clamp insert message not displayed or not clearing
Tubing misloaded in pump mechanism
Air detected in line
ALARM and ALERT LEDs lit but pump does not operate
ALARM LED always lit
ALARM LED does not light
ALARM LED(s) always lit
ALARM LED(s) do not light
Alarm volume not adjustable
ALERT LED always lit
ALERT LED does not light
ALERT LED(s) always lit
ALERT LED(s) do not light
All front panel keys disabled except BACKLIGHT and TOT VOL/STATUS
Audible alarm tone interval too long
Audible alarm volume insufficient
Audible alarm volume too low
Backlight cannot be turned off
Backlight does not light
Backlight off while pump runs on internal battery
Battery capacity degraded
Battery does not provide backup power when AC unavailable
Battery Icon lit during AC operation
Battery icon lit while pump runs on AC
Battery Icon off during battery operation
Battery icon off while pump runs on internal battery
Battery low
Battery not charging
Battery power exhausted
Calibration: A/D Converter Reference Voltage
Calibration: Air sensor recheck after value adjustment
Calibration: Air sensor with no tubing
Calibration: Air sensor with primed tubing
Calibration: Air sensor with unprimed (air-filled) tubing
Calibration: Backup battery voltage (BB)
Calibration: Battery charging
Calibration: CPU voltage (Vcpu)
Calibration: DC Line Voltage
Calibration: DC line voltages
Calibration: Device temperature and initial state
Calibration: Force Sensing Resistor (FSR) tube misloading sensor with door closed
Calibration: Force Sensing Resistor (FSR) tube misloading sensor with door open
Calibration: FSR sensor response to tubing misloading
Calibration: Slide Shaft Sensor
CHECK SET LOADING alarm when pump door closed
CHECK SET/LOADING alarm when pump door closed
Communication timeout with external device
Computer communication error
Device fails to run on internal battery
Device runs on battery but not AC power
Door Open Alarm does not trigger
DOOR OPEN alarm incorrectly triggered or missing
Door open alarm not activating
Downstream occlusion not detected
Downstream occlusion sensor not responding
FLOW RATE or CHECK VTBI alarm when START pressed
FLOW RATE or CHECK VTBI alarm with START key pressed
Gravity flow not prevented by safety clamp
Hi or Lo displayed during Volume-Time programming
INSERT SLIDE CLAMP alert or alarm constantly on
Keypad sealant defective or missing
LCD displays blank, irrational, or missing segments
Mounting clamp screw binding or clamp components damaged
No beep on key press when pump stopped
One or both pumps cannot be turned off
One or both pumps do not power off
One or both pumps do not power on
Optional nurse call always off
Optional nurse call always on
Panel lock not functioning
Plug icon not lit when plugged into AC
Power cord insulation damaged or connectors compromised
Pump delivers different volume than programmed VTBI
Pump does not detect upstream occlusion within 3 minutes
Pump does not stop or alarm when downstream tubing is pinched
Pump exterior unclean or physically damaged
Pump fails to run on internal battery (no LCD display)
Pump flow rate accuracy out of specification
Pump malfunction detected
Pump stops with audible alarm unexpectedly
Pump stops with BATTERY LOW alarm
PUMPING LED always lit
PUMPING LED does not light
PUMPING LED(s) always lit
PUMPING LED(s) do not light
Rear clamp fails to hold device on IV pole
Safety clamp arm fails to hold position or tubing removal not properly restricted
Self-test does not complete properly
Slide clamp alert or alarm does not trigger
Slide clamp not loaded
Slide clamp not loaded in slot
START key causes BATTERY LOW alarm
Tube misloading not detected
Tubing not fully positioned in air sensor
Tubing pinched at pump head door
Tubing pinched in door
Upstream occlusion alarm response delayed
Upstream occlusion not detected
Upstream occlusion sensor not responding

100 more symptoms with ranked causes and checks are in ServiceForge. Connect ServiceForge to your AI

Error codes

Code	Meaning	Trigger	Severity
`0`	No alarms or failures		info
`1`	Air bubble detected in tubing	Air detected during infusion in run mode	warning
`10`	Misloaded tubing detected	Infusion set tubing not properly positioned in pump mechanism	warning
`12`	Upstream occlusion (Revolution Counter)	Upstream occlusion detected by revolution counter interrupt	warning
`2`	Downstream occlusion detected	Sensor output increased by specified value	error
`20`	Door open detection circuit malfunction	Door open sensor circuit remains low when it should be high	critical
`21`	Occlusion detection frequency converter fault	Frequency converter for occlusion sensor P20 remains high or low	critical
`22`	Occlusion detection converter fault (duplicate)	Same as Code 21; frequency converter circuit failure	critical
`23`	Door Open detection circuit malfunction	P54 (Pump 1) or P55 (Pump 2) remains low	error
`23`	IRQ interrupt port stuck high	P50 IRQ port pin remains at +5 VDC when it should be low	critical
`24`	UP and DOWN occlusion values agree incorrectly	Upstream and downstream occlusion readings match when they should differ	critical
`25`	Generic occlusion circuit failure	Occlusion detection circuit malfunction	critical
`25`	Frequency converter malfunction for occlusion detection	P20 of Master CPU remains low	error
`27`	Slide clamp detection circuit malfunction	Frequency converter circuit failure	error
`28`	Four air sensors outputs cannot be selected	NORM and MIN outputs of both pumps cannot be selected	error
`29`	Two occlusion sensors cannot be selected	UP and DOWN sensors cannot be selected	error
`3`	Upstream occlusion detected	Pressure drop in proximal tubing detected	warning
`30`	A/D converter malfunction for air detection	A/D conversion did not complete in 50 microseconds	error
`31`	Air MIN detection circuit malfunction	A/D converter input remains high	error
`31`	Air MIN sensor A/D input stuck high	A/D converter input for MIN air transducer remains high with no oscillation	critical
`32`	Air NORM sensor A/D input stuck high	A/D converter input for NORM air transducer remains high	critical
`32`	Air NORM detection circuit malfunction	A/D converter input remains high	error
`33`	Air MIN sensor not oscillating but A/D not zero	MIN air transducer stopped oscillating but A/D input is not 0 V	critical
`34`	Air NORM sensor not oscillating but A/D not zero	NORM air transducer stopped oscillating but A/D input is not 0 V	critical
`35`	Front panel key stuck for 40+ seconds	Any front panel key held down for more than 40 seconds	unknown
`36`	Abnormal power ON/OFF signal	Master CPU received incorrect power control signal during startup/shutdown	critical
`37`	ON-OFF/CHARGE key pressed for more than 5 seconds when pump power was off	Key pressed for more than 5 seconds while powered off	warning
`38`	Malfunction in tube misloading detection circuitry	Tube misload detector hardware failure	critical
`4`	Upstream occlusion detected	Sensor output decreased by specified value	error
`41`	Abnormal operation of master CPU	Master CPU malfunction detected	critical
`42`	Malfunction in alarm control circuit	Alarm control circuitry failure	critical
`46`	PWRON1 signal is held low	PWRON1 signal stuck low	critical
`47`	PWRON1 signal is held high	PWRON1 signal stuck high	critical
`48`	RTC does not count time correctly	Real time clock malfunction	critical
`49`	Abnormal RTC data	RTC data corruption or defect	critical
`5`	Upstream occlusion (alternate)	Alternative detection method confirms upstream occlusion	warning
`50`	Master CPU received TRAP interrupt	TRAP interrupt signal to master CPU	critical
`51`	Master CPU received CMI interrupt	CMI interrupt signal detected	critical
`52`	Master CPU received SWI interrupt	SWI interrupt signal detected	critical
`53`	Master CPU received NMI interrupt	NMI interrupt signal detected	critical
`54`	Master CPU received OCI interrupt	OCI interrupt signal detected	critical
`55`	Master CPU received IRQ2 interrupt	IRQ2 interrupt signal detected	critical
`58`	TIMER 1 interrupt does not occur	TIMER 1 interrupt signal missing	critical
`59`	Program stuck in block 1 routine	Program execution halted in block 1	critical
`6`	Low battery voltage detected	Battery voltage 10.4V or less	critical
`60`	Battery voltage detection input to A/D remains high	A/D converter input stuck high	critical
`61`	Battery voltage detection input to A/D remains low	A/D converter input stuck low	critical
`62`	Backup battery voltage detection input to A/D remains high	Backup battery voltage detection A/D stuck high	critical
`63`	Lithium backup battery voltage too low	Backup battery voltage insufficient	critical
`64`	A/D conversion channels 0-3 did not complete in 144 mS	A/D conversion timeout for channels 0-3	critical
`65`	A/D conversion channels 4-7 did not complete in 144 μS	A/D conversion timeout for channels 4-7	critical
`66`	CPU supply voltage is too high	CPU supply voltage exceeds acceptable range	critical
`67`	CPU supply voltage is too low	CPU supply voltage below acceptable range	critical
`68`	A/D conversion channels 8-9 did not complete in 72 μS	A/D conversion timeout for channels 8-9	critical
`69`	Abnormal battery recharging voltage	Battery charging voltage out of specification	critical
`7`	Communication alarm detected	Framing, overrun or parity error during communication with external computer	error
`70`	Data in duplicate memory areas does not agree	Memory check detects mismatch in duplicate storage	critical
`71`	Slave CPU received no data from Master CPU	Master CPU fails to send data to Slave	critical
`72`	Slave CPU received undefined data 4 times from Master CPU	Multiple reception of undefined data	critical
`73`	Overcurrent to motor	Motor current exceeds safe limit	critical
`74`	Motor slipped at maximum current	Motor unable to maintain engagement at max current	critical
`77`	No revolution interrupt while motor was rotating	Motor rotation not detected by encoder	critical
`78`	Drive defect - overinfusion	Motor speed exceeds expected revolution count	critical
`79`	Drive defect - underinfusion	Motor speed below expected revolution count	critical
`8`	Communication timeout alarm detected	No communication between device and external PC for given period	error
`82`	No acknowledgment from Slave CPU for three trials	Slave CPU fails to acknowledge after three attempts	critical
`83`	Undefined message type received from Slave CPU	Invalid message received from Slave CPU	critical
`86`	LVDT reading of downstream occlusion sensor too low	Downstream occlusion sensor LVDT below threshold	warning
`87`	LVDT reading of downstream occlusion sensor too high	Downstream occlusion sensor LVDT above threshold	warning
`89`	Bank switching control circuit failure	Bank switching circuit malfunction detected	critical
`9`	Slide Clamp Alarm	Slide clamp not inserted or improperly inserted (software 1.09+)	warning
`90`	Checksum error of RATE, VTBI and VI data	Data checksum verification failed	critical
`91`	Checksum error of Programmed Delivery Profile stored data	PDP stored data checksum verification failed	critical
`92`	Checksum error of Programmed Delivery Profile working data	PDP working data checksum verification failed	critical
`93`	M5M5165 write data and read data do not agree	Memory write/read verification failed	critical
`94`	Configuration option settings checksum is not 0	Configuration settings checksum verification failed	critical
`95`	Checksum error of alarm log data	Alarm log data checksum verification failed	critical
`96`	Checksum error of ROM code	ROM code checksum verification failed	critical
`99`	Undefined failure code received from Slave CPU	Invalid failure code from Slave CPU	critical
`AIR`	Air bubble detected in infusion set	Ultrasonic sensor detects air bubble	unknown
`BATTERY LOW`	Battery charge level critically low	Battery charge drops below minimum operating level	warning
`BATTERY LOW (critical)`	Battery power exhausted	Battery depleted after initial 15-minute warning	critical
`C03`	NIBP kinked tubing	Internal tubing kink detected in NIBP system	warning
`C04`	NIBP disconnected tubing or module fault	NIBP tubing disconnected or module failure detected	warning
`CHECK SET/LOADING`	Tubing pinched in pump door	Tubing detected between door and base plate	warning
`COMMON FAILURE with code number`	Device-level microprocessor malfunction detected	Dual-pump system detects fault; code number identifies specific failure	critical
`COM TIMEOUT`	No pump-computer communication	Communication timeout with computer	warning
`DOOR OPEN`	Pump door not properly closed	Door sensor detects open position or improper latch	warning
`EXT COMM ERROR`	Computer communication protocol error	Computer sends multiple commands without waiting for replies	warning
`FAILURE`	Microprocessor detected pump malfunction	Hardware or software fault detected	error
`FAILURE with code number`	Microprocessor detected pump malfunction	Device detects internal fault; code number identifies specific failure	critical
`INSERT SLIDECLAMP`	Slide clamp not detected in slide clamp slot or slide clamp sensor unable to confirm insertion	Primed administration set loaded into pump mechanism without slide clamp inserted into slide clamp slot, or slide clamp sensor contaminated or not detecting clamp presence	warning
`INSERT SLIDECLAMP`	Slide clamp not loaded	Slide clamp loading enabled but clamp not in slot	warning
`OCCLUSION`	Downstream blockage detected	Increased back-pressure sensed between patient and pump	unknown
`UPSTREAM OCCLUSION`	Upstream blockage detected	Closed clamp or blockage upstream of pump sensed	unknown

Likely causes and actions for each code are in ServiceForge. Connect ServiceForge to your AI

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0 fixes logged by technicians through their AI, with outcomes, for this model.

ServiceForge knowledge base record. Field-unverified unless technicians confirmed it. A teaching summary of the record, not a service manual. Export 2026-10-14.