Infusion pumps · LifeCare family

Hospira LifeCare PCA3: troubleshooting and error codes

The ServiceForge knowledge base holds 41 documented symptoms for the Hospira LifeCare PCA3, with 70 ranked causes, 18 diagnostic checks with test points and expected values, and 102 error codes. Each symptom below shows its causes and the first check; the rest is one connection away. Connect ServiceForge to your AI

Symptoms

Self test or module test failure caution

Self test or service mode tests fail indicating component defect

Ranked causes

1. MCU PWA defective (common)
2. LCD assembly defective (occasional)
3. Numeric display PWA defective (occasional)
4. Icon display PWA defective (occasional)
5. Keypad defective (occasional)
6. Door lock assembly defective (occasional)
7. Mechanism assembly defective (occasional)
8. Patient pendant assembly defective (rare)

First check

Turn pump off and on, allow self test to complete

Expected: Self test passes without errors

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

Empty vial sensor test failure caution

Empty vial detection sensor fails self test diagnostic

Ranked causes

1. Vial sensor switch misaligned (common)
2. Defective mechanism assembly (common)
3. Defective MCU PWA (occasional)

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

Icon display indicator test failure caution

Icon display PWA fails self test diagnostic

Ranked causes

1. Defective icon display PWA (common)
2. Icon display PWA connection fault (common)
3. Defective MCU PWA (occasional)

First check

Verify icon display connection

Test point: Icon display connector to MCU PWA
Expected: Connection fully seated and secure

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

LCD backlight test failure caution

LCD backlight circuit or lamp fails self test

Ranked causes

1. Defective LCD assembly backlight (common)
2. LCD assembly connection fault (common)
3. Defective MCU PWA (occasional)

First check

Verify LCD assembly connection

Test point: LCD connector to MCU PWA
Expected: Connection fully seated and secure

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

LCD display test failure caution

LCD assembly or display electronics fails self test

Ranked causes

1. Defective LCD assembly (common)
2. LCD assembly connection fault (common)
3. Defective MCU PWA (occasional)

First check

Verify LCD assembly connection

Test point: LCD connector to MCU PWA
Expected: Connection fully seated and secure

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

LED numeric display test failure caution

LED numeric display PWA fails self test

Ranked causes

1. Defective numeric display PWA (common)
2. Numeric display PWA connection fault (common)
3. Defective MCU PWA (occasional)

First check

Verify numeric display PWA connection

Test point: Display connector to MCU PWA
Expected: Connection fully seated and secure

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

Occlusion switch error patient safety

Defective occlusion sensor fails to detect line blockage

Ranked causes

1. Occlusion alarm switch maladjustment (common)
2. Mechanism assembly failure (occasional)
3. MCU PWA malfunction (rare)

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

Occlusion test failure patient safety

Occlusion detection system fails diagnostic test

Ranked causes

1. Infusion set not properly primed or installed (common)
2. Occlusion alarm switch misaligned (common)
3. Defective mechanism assembly (occasional)

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

Screw rotation error caution

Motor steps and screw rotations not in proportion, possible lubrication or mechanism issue

Ranked causes

1. Lead screw lubrication inadequate (common)
2. Mechanism assembly failure (occasional)
3. MCU PWA malfunction (rare)

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

Syringe mechanism test failure caution

Syringe drive mechanism fails self test diagnostic

Ranked causes

1. Vial sensor switch misaligned (common)
2. Defective mechanism assembly (common)
3. Defective MCU PWA (occasional)

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

Delivery accuracy test failure patient safety

Pump delivery volume or rate does not meet accuracy specifications

Ranked causes

1. PCA set not properly primed (common)
2. Mechanism assembly defective (occasional)

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

Door lock test failure caution

Door lock assembly fails self test diagnostic

Ranked causes

1. Defective door lock assembly (common)
2. Defective MCU PWA (occasional)

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

Keypad test failure caution

Pump keypad or keypad interface fails self test

Ranked causes

1. Defective keypad (common)
2. Defective MCU PWA (occasional)

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

Self test fails during verification patient safety

Device fails self-test verification when powered on, with alarm message displayed and system not proceeding to SELF TEST COMPLETE screen.

Ranked causes

1. Software or memory integrity failure (unknown)
2. Electronic function malfunction (unknown)

First check

Verify AC power connection

Test point: AC power indicator on front panel
Expected: AC power indicator illuminated

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

Alarm circuit test failure caution

Alarm speaker or alarm circuit fails self test

Ranked causes

1. Defective MCU PWA (common)

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

Battery fault caution

Battery malfunction: open circuit, over-discharge, or short circuit

Ranked causes

1. Battery defective (open, over-discharged, or shorted) (occasional)

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

Calibration: Injector sensor switch caution

Injector sensor switch requires positioning and varnish sealing to ensure proper detection

Ranked causes

1. Injector sensor switch misalignment (common)

First check

Verify switch bracket position parallel to surface

Test point: Switch bracket
Expected: Parallel to surface, 1/32 inch from front enclosure

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

Calibration: Lead screw lubrication caution

Lead screw requires cleaning and lubrication with thin coating of grease

Ranked causes

1. Lead screw dry or contaminated with old grease and residue (common)

First check

Remove old grease and residue from lead screw

Test point: Lead screw threads
Expected: All old grease and residue completely removed
Tools: Isopropyl alcohol, cotton swabs or small brush

1 more check 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 patient safety

Occlusion alarm switch must trigger at 15±5 psi to ensure proper line blockage detection

Ranked causes

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

First check

Attach DPM to patient line

Test point: End of patient line via three-way stopcock
Expected: DPM connected and zeroed

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

Calibration: Vial sensor switch caution

Vial sensor switch requires adjustment to detect vial presence correctly

Ranked causes

1. Vial sensor switch misalignment (common)

First check

Move switch up until it clicks off

Test point: Vial sensor switch
Expected: Audible click-off

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

Charger fault caution

Battery charger is faulty and cannot charge battery

Ranked causes

1. Charger failure (occasional)

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

CPU test failure caution

Central processing unit fails self test diagnostic

Ranked causes

1. Defective CPU (common)

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

Door improperly secured

Door secured on wrong screen or no operator input for two minutes

Ranked causes

1. Door secured on wrong screen or timeout (common)

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

Door left open

Door is left open or unlocked for more than two minutes

Ranked causes

1. Door not secured (common)

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

Electrical safety test failure high voltage

AC power cord or electrical safety components defective

Ranked causes

1. Defective AC power cord (common)

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

Infusion paused

Infusion stopped by operator pressing START/PAUSE button

Ranked causes

1. Operator pressed START/PAUSE button (common)

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

Injector not detected patient safety

Vial is detected but injector is not properly seated in cradle assembly

Ranked causes

1. Improper injector seating (common)

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

Low battery patient safety

Operating on battery power with less than 30 minutes of battery life remaining

Ranked causes

1. Battery capacity depleted (common)

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

Low battery power during operation patient safety

Battery indicator flashing on front panel while operating on battery power, indicating insufficient battery capacity for reliable device operation.

Ranked causes

1. Battery requires recharge (common)

First check

Verify AC power connection and indicator status

Test point: AC power indicator on front panel
Expected: AC power indicator illuminated indicating charging

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

No battery installed in device patient safety

Device prompts BATTERY NOT INSTALLED message during startup or service mode, indicating battery compartment is empty.

Ranked causes

1. Battery missing from compartment (common)

First check

Verify battery compartment access

Test point: Battery access cover on device
Expected: Battery access cover present and accessible

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

Occlusion detected patient safety

Tubing or delivery line is occluded, blocking fluid flow

Ranked causes

1. Occlusion in delivery path (common)

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

Patient pendant assembly test failure patient safety

Patient pendant assembly fails self test diagnostic

Ranked causes

1. Defective patient pendant assembly (common)

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

RAM memory test failure caution

Pump RAM memory fails self test diagnostic

Ranked causes

1. Defective MCU RAM (common)

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

Real-time clock test failure caution

Real-time clock RTC circuit fails self test diagnostic

Ranked causes

1. Defective RTC (common)

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

ROM memory test failure caution

Pump ROM/EPROM memory fails self test diagnostic

Ranked causes

1. Defective EPROM (common)

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

Rotation mechanism test failure caution

Syringe rotation drive mechanism fails self test

Ranked causes

1. Defective mechanism assembly (common)

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

Self test failure

PVT self test does not complete successfully

Ranked causes

1. Infusion pump self test error (common)

First check

Power cycle the pump and run self test

Test point: Pump power switch
Expected: Self test completes without errors

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

Service mode MCU test failure caution

Microcontroller unit PWA fails service mode testing

Ranked causes

1. Defective microcontroller PWA (common)

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

Syringe empty patient safety

Empty vial detected, no medication available for infusion

Ranked causes

1. Empty vial installed (common)

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

Syringe not properly loaded patient safety

Syringe (vial and injector) not properly seated in cradle assembly

Ranked causes

1. Improper syringe seating (common)

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

Vial not properly loaded patient safety

Injector detected but vial not properly seated in cradle assembly

Ranked causes

1. Improper vial seating (common)

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

Error codes

Code	Meaning	Trigger	Severity
`170`	Interrupt Overlap	Interrupt failure	error
`171`	Invalid Interrupt	Invalid or unused interrupt	error
`172`	Stack Error	RAM error	critical
`173`	Task Dead Error	Periodic task or interrupt stopped running	critical
`174`	Kernel Error	Kernel failure	critical
`175`	Watchdog Error	MCU fails to strobe watchdog within timeout	error
`176`	Cancel Timer Error	Timer message cancelled unsuccessfully	error
`200`	Motor Overdelivery Condition	Motor running faster than expected	critical
`201`	Motor underdelivery condition	Motor running slower than expected	critical
`202`	Motor runaway	Motor running without permission	critical
`203`	Excessive rate	Programmed infusion rate exceeds maximum limit	error
`204`	Mode error	Unexpected operating mode detected	critical
`205`	Motor step time error	Motor step timing out of valid range	critical
`206`	Rate error	Unexpected infusion rate detected	critical
`207`	Delivery Volume Error	Volume infused out of range	error
`310`	5-Volt Error	Two voltage readings outside 4.7 V - 5.3 V range	critical
`311`	Lithium Battery Error	Lithium battery voltage below minimum	error
`313`	Battery current error	Battery charge current exceeds safe limit	critical
`480`	Configuration Data	Failed CRC of pump configuration data	critical
`481`	Infusion Data	Failed CRC of infusion data	critical
`482`	Program Data	Failed CRC of program data	critical
`483`	Flash Checksum Error	Failed checksum at startup or during operation	critical
`484`	Stored Protocol Data	Failed CRC of stored protocols	critical
`485`	Motor state error	Invalid rate, restart state, or bad events in motor software	critical
`486`	History Corruption	History data corrupted	error
`487`	Motor Data Error	Failed CRC of motor data	error
`488`	Drug Table Data Error	Failed CRC of drug table data	error
`489`	User Interface Data Error	Failed CRC of saved user interface data	error
`490`	Error Log Data Error	Failed error log checksum	error
`491`	Background Data Error	Inconsistent background data	error
`492`	Switch Data Error	Corrupted switch data	error
`493`	Mirror data mismatch	Data in RAM does not match data in FLASH	critical
`493`	Mirror data mismatched - Data in RAM does not match data in FLASH		error
`494`	UI state error	User interface state ID out of valid range	critical
`494`	UI state error - User interface state ID out of range		error
`495`	Backlight data error	Invalid display data for backlight	critical
`496`	Vial manager data checksum error	CRC failure of vial manager data	critical
`497`	Power data error - Failed CRC of battery charging data		error
`497`	Power data checksum error	CRC failure of battery charging data	critical
`498`	Display data error	Invalid LCD display data detected	critical
`499`	Alarm data error	Invalid alarm message data detected	critical
`550`	Power down error	Improper system shutdown detected	critical
`551`	Intertask message error	Illegal message between software tasks	critical
`552`	Invalid function parameter	Invalid parameter data passed to function	critical
`553`	Invalid message	Invalid kernel message detected	critical
`554`	Invalid mode - Invalid user interface mode		error
`554`	Invalid mode	Invalid UI mode state detected	critical
`555`	Clock change error	Invalid date/time set detected	warning
`556`	Invalid UI state action	Invalid UI action code detected	critical
`557`	Invalid alarm - Illegal alarm message data		error
`557`	Invalid alarm	Illegal alarm message data	critical
`558`	Mode change error	Illegal mode change message	critical
`559`	Invalid UI stack - User interface stack is corrupted or full		error
`559`	Invalid UI stack	UI stack corrupted or full	critical
`620`	RAM address error - Address lines stuck high, stuck low, or shorted together		critical
`620`	RAM address error	RAM address lines stuck or shorted	critical
`621`	Chip ID error	Register does not contain expected value	critical
`621`	Chip ID error - Register does not contain expected value		critical
`622`	Clock RAM error - Data or address communication errors		error
`622`	Clock RAM error	Data or address communication errors in clock RAM	critical
`623`	External RAM error	Failed read/write operations on external RAM	critical
`623`	External RAM error - Failed read/write operations on external RAM		error
`624`	LCD backlight error	Backlight current out of range	critical
`625`	Battery icon LED error	Battery icon LED current out of range	critical
`626`	Audible alarm error	Alarm buzzer voltage out of valid range	critical
`627`	LCD readback error	Display data does not match RAM data	critical
`627`	LCD readback error - Display data does not match RAM data		error
`628`	LED numeric display error	Digit segment current out of valid range	critical
`629`	Clock time error	RTC and MCU are out of synchronization	critical
`629`	Clock time error - RTC and MCU out of synchronization		error
`630`	Screw rotation error - Motor steps and screw rotations not in proportion		error
`630`	Screw rotation error	Motor steps and lead screw rotations not proportional	critical
`631`	LCD timeout error - LCD does not acknowledge data within hardware specific-time		error
`631`	LCD timeout error	LCD does not acknowledge data within timeout period	critical
`633`	Print error - Failed UART loopback test		error
`633`	Print error	Failed UART loopback test with printer	critical
`634`	ADC voltage reference error	Analog-to-digital converter voltage out of range	critical
`635`	Stuck key	Keypad button held for more than 2 minutes	warning
`635`	Stuck key error - Key stuck for more than two minutes		warning
`636`	Motor winding excessive current	Motor winding current exceeds 200 mA limit	critical
`637`	Motor winding open circuit	Motor winding current below 75 mA minimum	critical
`638`	Motor voltage error	Motor supply voltage out of acceptable range	critical
`639`	Contrast voltage error	LCD contrast voltage out of range	critical
`640`	Internal RAM error - Failed read/write operations on internal RAM		error
`640`	Internal RAM error	Failed read/write operations on internal RAM	critical
`641`	Occlusion switch error	Occlusion sensor malfunction detected	critical
`642`	Empty syringe switch error	Empty syringe sensor malfunction detected	critical
`643`	Injector switch error	Injector sensor malfunction detected	critical
`644`	Watchdog timer error	Watchdog timer failure	critical
`645`	Barcode reader error	Three consecutive barcode read attempts failed	critical
`645`	Barcode reader error - Three consecutive attempts to read barcode failed		error
`Battery Fault`	Battery internal fault detected (open circuit, over-discharged, or shorted)	Battery monitoring detects OB (open), OV (over-discharged), or SH (short)	warning
`Check Injector`	Injector not detected when vial is present	Vial detected but injector missing	warning
`Check Settings`	Door secured on wrong screen or timeout after no key press for 2 minutes	Door locked on screen other than Setup/Press Start, or inactivity timeout	warning
`Check Syringe`	Syringe not properly positioned in cradle	Syringe detector sees improper loading	warning
`Check Vial`	Vial not properly positioned or injector mismatch	Injector detected but vial not properly loaded	warning
`Door Open`	Door has been left open or unlocked for over 2 minutes	Door open/unlocked timeout	warning
`Empty Syringe`	Syringe medication reservoir is empty	Empty syringe sensor activated	warning
`Infuser Paused`	Infusion delivery has been paused by operator	START/PAUSE button pressed during infusion	info
`Low Battery`	Battery power remaining is critically low	Battery charge falls below 30 minutes of operating time	warning
`Occlusion`	Delivery line or mechanism is blocked	Occlusion detected by sensor	warning
`Pendant Fault`	Patient pendant connection or operation fault	Open circuit or short detected in pendant, or incompatible/stuck pendant	warning

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.