Infusion pumps

Hospira LifeCare 4100 PCA PLUS: troubleshooting and error codes

The ServiceForge knowledge base holds 56 documented symptoms for the Hospira LifeCare 4100 PCA PLUS, with 106 ranked causes, 41 diagnostic checks with test points and expected values, and 24 error codes. Each symptom below shows its causes and the first check; the rest is one connection away. Connect ServiceForge to your AI

Symptoms

Alarm test failure

Alarm does not sound or indicates test failure during PVT

Ranked causes

1. Loose/defective ribbon cable at power supply (common)
2. Defective alarm volume switch (occasional)
3. Defective piezoelectric alarm (occasional)
4. Defective power supply PWA (occasional)
5. Defective CPU/display PWA (rare)

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

Keypad test failure

Touchswitch or keypad does not respond during PVT test

Ranked causes

1. Loose/damaged ribbon cable at touchswitch (common)
2. Loose/damaged ribbon cable at power supply (common)
3. Defective touchswitch (occasional)
4. Defective CPU/display PWA (occasional)

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

Low/empty syringe test failure

Syringe level sensors fail or do not detect during PVT test

Ranked causes

1. Loose connection (common)
2. Syringe low sensor switch out of adjustment or defective (common)
3. Syringe empty sensor switch out of adjustment or defective (common)
4. Defective power supply PWA (occasional)

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

Motor rotation test failure

Motor does not rotate or stalls during PVT test

Ranked causes

1. Lead screw dirty or needs lubrication (common)
2. Loose connection (common)
3. Defective power supply PWA (occasional)
4. Defective motor assembly (occasional)

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

Occlusion test failure

Occlusion detection system fails during PVT test

Ranked causes

1. Syringe not modified properly (common)
2. Set not installed or primed properly (common)
3. Occlusion pressure switch out of adjustment or defective (occasional)
4. Defective power supply PWA (occasional)

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

Syringe test failure

Syringe detection or positioning fails during PVT test

Ranked causes

1. Loose connection (common)
2. Injector sensor switch defective (common)
3. Vial sensor switch out of adjustment or defective (occasional)
4. Defective power supply PWA (occasional)

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

Battery charger test failure

Battery charging system fails during PVT test

Ranked causes

1. Loose connection (common)
2. Defective boost charger PWA (occasional)
3. Defective power supply PWA (occasional)

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

Delivery accuracy test failure

PVT delivery accuracy test fails

Ranked causes

1. PCA set not primed properly (common)
2. Defective power supply PWA (occasional)
3. Defective motor assembly (occasional)

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

DOOR OPEN alarm patient safety

Security door left open for more than two minutes without button press

Ranked causes

1. Security door left open during operation (common)
2. Door closure not sensed by infuser (occasional)
3. Defective door lock switch (occasional)

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

Electrical safety test failure

Electrical safety test fails during PVT

Ranked causes

1. Insufficient earth connection (common)
2. Defective AC power cord plug (common)
3. Defective AC power cord (occasional)

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

Indicator test failure

Status indicator does not light or operate during PVT test

Ranked causes

1. Loose/damaged ribbon cable (common)
2. Defective CPU/display PWA (occasional)
3. Defective power supply PWA (occasional)

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

LOW BATTERY alarm (flashing battery symbol) caution

Battery power level approaching critical depletion

Ranked causes

1. Battery power nearly depleted (common)
2. No battery operation or short operating time (occasional)
3. Battery pack is defective or exceeded useful life (occasional)

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

OCCLUSION alarm patient safety

Back pressure detected in delivery line or syringe assembly

Ranked causes

1. Kinked, occluded tubing, closed slide clamp, or blocked venipuncture device (common)
2. Occlusion pressure setting out of calibration (occasional)
3. Defective occlusion pressure switch (occasional)

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

Patient control jack test failure

Patient control pendant jack does not operate during PVT test

Ranked causes

1. Loose connection (common)
2. Defective interconnect PWA cable (common)
3. Defective patient pendant jack (occasional)

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

Security door test failure

Door lock or security door does not operate during PVT test

Ranked causes

1. Loose connection (common)
2. Door lock switch out of adjustment or defective (common)
3. Defective power supply PWA (occasional)

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

Service test mode test failure

PVT test fails during service mode initialization

Ranked causes

1. Infuser not in cold start (common)
2. Defective touchswitch (occasional)
3. Defective CPU/display PWA (occasional)

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

CHECK INJECTOR message displayed patient safety

Injector improperly installed, missing, or sensor not detecting injector

Ranked causes

1. Injector improperly installed or missing (common)
2. Injector sensor misaligned or out of adjustment (occasional)

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

CHECK SYRINGE message displayed patient safety

Syringe assembly (vial and injector) improperly installed or missing

Ranked causes

1. Syringe assembly improperly installed or missing (common)
2. Defective or misadjusted injector sensor switch (occasional)

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

CHECK VIAL message displayed patient safety

Vial improperly installed, missing, or sensor not detecting vial

Ranked causes

1. Vial improperly installed or missing (common)
2. Vial sensor misaligned or out of adjustment (occasional)

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

EMPTY SYRINGE alarm patient safety

Syringe empty or nearly empty (approximately 1 mL may remain)

Ranked causes

1. Syringe depleted (common)
2. Empty syringe switch out of calibration (occasional)

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

INFUSER IN RESET message displayed

Infuser in reset mode after alarm or user reset action

Ranked causes

1. Normal reset state after alarm cleared (common)
2. RESET/START pressed while security door locked (occasional)

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

LOW SYRINGE alarm (PCA Plus only) patient safety

Approximately 5 mL of solution remaining in syringe

Ranked causes

1. Low syringe level reached during infusion (common)
2. Low syringe switch out of calibration (occasional)

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

No AC or battery operation caution

Infuser cannot operate on AC line power or battery

Ranked causes

1. Fuse blown (common)
2. Defective power supply PWA (occasional)

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

No audible alarm or audible alarm level control not working patient safety

Audio alarm does not sound or volume control does not function

Ranked causes

1. Defective audible level switch (common)
2. Defective power supply PWA (occasional)

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

Occlusion alarm does not trigger at expected pressure patient safety

Infuser fails to sound alarm and display OCCLUSION message when system pressure reaches threshold.

Ranked causes

1. Pressure sensor failure or miscalibration (common)
2. Alarm circuitry malfunction (occasional)

First check

Monitor pressure gauge when stopcock is closed after fluid discharge

Test point: Digital pressure meter (DPM) reading
Expected: -008 and lower: 14.0 to 19.0 psig; -010 and higher: 12.5 to 17.5 psig when alarm triggers, -008: 14.0-19.0 psig; -010+: 12.5-17.5 psig
Tools: Digital pressure meter (0 to 50 psig), Bio-Tek DPM II

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

PCA plus continuous test failure

PCA plus continuous infusion mode test fails during PVT

Ranked causes

1. Set not installed or primed properly (common)
2. Infuser not set up properly (common)

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

Unit does not deliver correct volume patient safety

Infuser fails to deliver expected fluid volume during loading dose administration.

Ranked causes

1. Pump mechanism wear or calibration drift (common)
2. Air in administration set or vial (occasional)

First check

Measure delivered volume during two 10 mL loading doses

Test point: Graduate or marked test tube
Expected: 20±1 mL total volume, ±1 mL
Tools: Graduate or marked test tube readable to 0.2 mL increments or smaller

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

12/24 hour clock selection test failure

PCA Plus fails to verify clock format selection during PVT

Ranked causes

1. Defective CPU/display PWA (common)

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Calibration: Door lock switch caution

Adjustment of door lock switch to ensure switch actuation is heard when door is locked and unlocked. Recommended tool: needle nose pliers.

Ranked causes

1. Door lock switch not actuating properly when door is locked or unlocked (common)

First check

Test switch actuation with door lock actuator arm pressed

Test point: Door lock actuator arm and switch
Expected: Switch actuation audible (click or signal)
Tools: Needle nose pliers

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

Calibration: Injector sensor switch adjustment caution

Adjust injector sensor switch position and gap for proper operation on PCA Plus Series Infusers with final assemblies 850-04250-002 through 850-04250-008.

Ranked causes

1. Injector sensor switch requires repositioning for proper detection (common)

First check

Verify switch bracket position and gap from case

Test point: Injector sensor switch bracket
Expected: Parallel to surface and 1/32 inch from infuser case, 1/32 inch

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

Calibration: LCD intensity caution

Adjustment of LCD display brightness using resistor R19 trim pot so screen is readable from approximately three feet distance.

Ranked causes

1. LCD brightness out of specification (common)

First check

Verify LCD readability during adjustment

Test point: LCD display screen
Expected: Display readable from distance of approximately three feet
Tools: Trim pot tool, AC power

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Calibration: Occlusion alarm switch and pressure high voltage

Occlusion alarm switch test and adjustment using modified syringe with water and pressure meter to verify alarm triggers within specified pressure range

Ranked causes

1. Occlusion alarm switch triggering outside specified pressure range (unknown)

First check

Modify syringe plunger for test

Test point: Syringe plunger
Expected: Top two ribs removed cleanly, no rough material; light silicone oil coating applied to remaining rib

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

Calibration: Occlusion alarm switch and pressure (-008 and lower) caution

Adjustment of occlusion alarm switch contact and pressure threshold to trigger between 14–19 psig. Switch button must contact actuator without opening switch prematurely.

Ranked causes

1. Occlusion alarm switch misaligned or pressure threshold out of specification (common)

First check

Examine switch button contact with switch actuator

Test point: Occlusion alarm switch
Expected: Switch button in contact with actuator, not opened

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

Calibration: Occlusion alarm switch and pressure (-010 and higher) caution

Adjustment of occlusion alarm switch contact and pressure threshold to trigger between 12.5–17.5 psig. Switch actuator must contact button without prematurely opening switch.

Ranked causes

1. Occlusion alarm switch misaligned or pressure threshold out of specification (common)

First check

Examine switch actuator contact with switch button

Test point: Occlusion alarm switch
Expected: Switch actuator in contact with button, not tripping switch

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

Calibration: Real-time clock (PCA Plus II)

Setting real-time clock time and date via LCD menu after initial installation, time change, or complete battery discharge. No tools required.

Ranked causes

1. Real-time clock not set or reset required (common)

First check

Navigate to CHANGE screen for time/date entry

Test point: LCD touchswitches and display menu
Expected: LCD displays CHANGE? screen with flashing time/date fields
Tools: Touchswitches [NO], [YES/ENTER], [REVIEW CHANGE]

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

Calibration: Real-time clock verification (PCA Plus II)

Optional verification via PVT if infuser may have been damaged during clock setting procedure.

Ranked causes

1. Infuser may have been damaged during real-time clock setting (rare)

First check

Execute full PVT self-test

Test point: Full infuser system
Expected: PVT passes all checks per Section 5.2

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Calibration: Syringe empty switch caution

Syringe empty switch adjustment using syringe limit gauge to trigger alarm when syringe reaches empty state

Ranked causes

1. Syringe empty switch not triggering at correct empty level (unknown)

First check

Install gauge and move cradle to 0.3 inch position

Test point: Syringe limit gauge dial
Expected: Dial reads approximately 0.3 inch; LCD displays PURGE THE SYSTEM NOW?

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

Calibration: Syringe low switch caution

Syringe low switch adjustment using syringe limit gauge to trigger alarm at correct fill level

Ranked causes

1. Syringe low switch not triggering at correct fill level (unknown)

First check

Install syringe limit gauge in cradle

Test point: Cradle with gauge installed
Expected: Dial reads approximately 0.05 inch

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

Calibration: Syringe plunger modification

Modify syringe plunger by removing top two ribs and applying silicone oil to prevent friction during occlusion pressure testing

Ranked causes

1. Unmodified syringe plunger causes friction and false pressure readings (unknown)

First check

Remove syringe plunger

Test point: Syringe plunger
Expected: Plunger cleanly separated from syringe barrel

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

Calibration: Vial sensor switch caution

Vial sensor switch adjustment to detect vial presence with proper bracket positioning

Ranked causes

1. Vial sensor switch misaligned or not detecting vial (unknown)

First check

Verify vial sensor switch detects vial

Test point: Vial sensor switch actuator arm
Expected: Switch clicks when rod inserted approximately 1/16 inch

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Calibration: Vial sensor switch adjustment caution

Adjust vial sensor switch position for proper detection on PCA Plus Series Infusers with final assemblies 850-04250-002 through 850-04250-008.

Ranked causes

1. Vial sensor switch requires repositioning for proper detection (common)

First check

Verify switch click off position

Test point: Vial sensor switch
Expected: Switch clicks off when moved up slowly

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

CHECK 4-HR LIMIT message displayed patient safety

Four-hour dose limit parameter error detected

Ranked causes

1. Four-hour dose limit less than PCA dose (common)

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

CHECK SETTINGS message displayed patient safety

Security door closed and locked before setup was complete

Ranked causes

1. Security door closed prematurely during setup (common)

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Injector sensor switch malfunction patient safety

Injector bolus function does not work or sensor does not respond

Ranked causes

1. Injector sensor switch failure or improper soldering (common)

First check

Verify wire soldering to replacement switch terminals

Test point: Injector sensor switch terminals
Expected: Two black wires soldered to center terminal, brown wire to outside terminal

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

LCD test failure

LCD display does not respond during PVT test

Ranked causes

1. Defective CPU/display PWA (common)

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

LED test failure

Indicator LED does not light during PVT test

Ranked causes

1. Defective CPU/display PWA (common)

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

MALFUNCTION XX alarm (internal failure detected) caution

Infuser self-test detected internal system failure with error code

Ranked causes

1. Internal system failure detected by self-test (occasional)

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Memory test failure

Internal RAM, External RAM, or ROM test fails

Ranked causes

1. Defective CPU/display PWA (common)

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Motor assembly failure or improper coupling patient safety

Syringe does not advance, infusion stalled or motor does not run

Ranked causes

1. Motor assembly worn, damaged, or improperly coupled to lead screw (common)

First check

Verify coupling alignment before motor installation

Test point: Lead screw and motor gear case shaft flats
Expected: Flats aligned; coupling pin engages both flats

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

Occlusion pressure switch malfunction patient safety

Occlusion alarm does not trigger or triggers incorrectly during infusion

Ranked causes

1. Occlusion pressure switch failure or incorrect wiring (common)

First check

Verify correct wire soldering to switch terminals

Test point: Occlusion pressure switch terminals
Expected: Wires soldered per model version: -008/Lower (orange front, black center, blue front) or -010/Higher (orange front, blue center, black front)

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Patient pendant assembly test failure

Patient pendant assembly does not function during PVT test

Ranked causes

1. Defective patient pendant assembly (common)

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Patient pendant tone selection test failure

PVT fails to verify patient pendant tone selection configuration

Ranked causes

1. Defective CPU/display PWA (common)

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Real time clock test failure

PVT test fails on real time clock or elapsed days check

Ranked causes

1. Defective CPU/display PWA (common)

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Select RX concentration test failure

Software version 3.1 or higher required for RX concentration selection test

Ranked causes

1. Incorrect software revision (common)

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Slide assembly wear or mechanical failure patient safety

Syringe does not move smoothly, grinding noise, or motor stalls during infusion

Ranked causes

1. Lead screw worn, binding, or insufficient lubrication (common)

First check

Verify lead screw lubrication

Test point: Lead screw surface
Expected: Even grease coating along entire length

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Software version test failure

PVT test fails on software version check

Ranked causes

1. Defective CPU/display PWA (common)

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Error codes

Code	Meaning	Trigger	Severity
`1A`	MALF line went low could not return to normal	Line state failure during operation	critical
`1B`	MALF line went low could not return to normal	Line state failure during operation	critical
`1C`	MALF line did not go low soon enough after power-up	Power-up timing failure	critical
`1D`	Malfunction line went high too soon	Line timing error	critical
`1E`	Watchdog circuit failure during real-time operation	Watchdog timer circuit failure	critical
`2A`	Power-up diagnostic failed	Startup self-test failure	critical
`2B`	Nonvolatile RAM checksum test failed	RAM checksum error	critical
`3A`	Motor failed to rotate	Motor does not turn when commanded	error
`3B`	MOTOR BAD signal from motor driver circuitry	Motor driver circuit failure	error
`4A`	LCD timeout error	LCD communication timeout	error
`4B`	LCD data readback error	LCD data does not match readback	error
`4C`	Nonvolatile RAM test failed	RAM self-test failure	error
`4D`	EPROM checksum test failed	EPROM checksum error	error
`4F`	LED segment defective	LED segment self-test failure	warning
`4G`	Real-time clock stopped	RTC clock not running	error
`4H`	Touchswitch stuck on front panel	Touchswitch sensed as continuously pressed	error
`4K`	LED error	LED self-test failure	warning
`4L`	Voltage error		error
`4N`	Error in timer T1		error
`4O`	Error in timer T2		error
`4P`	Program error		error
`4Q`	CPU stack error		error
`4R`	Analog-to-digital converter error		error
`5A`	Undetermined error		error

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

Community

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.