Troubleshooting Terumo Infusion Pumps: Error Codes & Fixes

Terumo infusion pumps deliver precise medication and fluid administration in critical care environments. Understanding error codes and implementing proper troubleshooting procedures ensures reliable pump operation and patient safety.

Overview

Modern Terumo infusion pumps feature sophisticated error detection systems that monitor pump performance, fluid delivery, and safety parameters continuously. When faults occur, the system generates specific error codes to help technicians diagnose and resolve issues efficiently.

Error Code Reference Table

Error Code	Description	Possible Causes	Resolution Steps
ERR-101	Occlusion Detected	Kinked tubing, closed clamp	Check tubing pathway, verify clamp positions
ERR-205	Motor Stall	Mechanical obstruction	Inspect pump mechanism, lubricate if needed
ERR-301	Flow Sensor Failure	Sensor contamination	Clean sensor, replace if damaged
ERR-305	Flow Rate Sensor Malfunction	Electrical fault in sensor	Replace flow sensor assembly
ERR-401	Power Supply Error	Voltage fluctuation	Check power source, test battery backup
ERR-502	Memory Checksum Error	Corrupted firmware	Reload firmware, replace memory module
ERR-603	Door Open	Pump door not secured	Close door properly, check door switch
ERR-705	Air in Line	Air bubble detection	Prime tubing, check connections
ERR-808	Low Battery	Battery needs replacement	Replace battery pack, verify charging
ERR-901	Internal Communication Error	Board communication failure	Reset pump, check internal connections

Detailed Troubleshooting Procedures

ERR-101: Occlusion Troubleshooting

Occlusion errors are the most common infusion pump problems:

Step 1: Visual Inspection

- Trace entire tubing pathway from bag to patient

- Look for kinks, twists, or compression points

- Verify all clamps are open

- Check IV site for infiltration or phlebitis

Step 2: Pressure Testing

- Remove tubing from pump mechanism

- Manually compress tubing to test flexibility

- Replace tubing if stiff or damaged

- Verify proper tubing installation in pump

Step 3: Sensitivity Adjustment

- Access pump settings menu

- Adjust occlusion pressure limit if appropriate

- Test with known good tubing set

- Document pressure threshold settings

ERR-305: Flow Rate Sensor Issues

Flow sensor malfunctions require systematic evaluation:

Diagnosis Process:

1. Sensor Inspection:

- Remove pump door and inspect sensor window

- Clean with alcohol wipe if contaminated

- Check for cracks or damage to sensor housing

- Verify LED and photodetector alignment

2. Electrical Testing:

- Measure sensor output voltage (should be 0-5V DC)

- Test sensor continuity with ohmmeter

- Verify proper connector seating

- Check sensor cable for damage

3. Calibration Verification:

- Run pump at known flow rates (1, 5, 10, 25 mL/hr)

- Compare actual vs. displayed flow rates

- Document any deviations >±5%

- Perform sensor recalibration if needed

ERR-401: Power System Diagnostics

Power-related errors affect pump reliability:

AC Power Analysis:

- Verify 120V AC ±10% at wall outlet

- Check power cord continuity

- Test ground fault circuit protection

- Measure power consumption under load

Battery System Testing:

- Check battery voltage (should be 12V DC)

- Test backup power duration (minimum 4 hours)

- Verify charging circuit operation

- Replace battery if capacity <80% of rated

Pump Mechanism Maintenance

Motor Assembly Service

When motor stall errors occur frequently:

Inspection Checklist:

- Remove pump head cover

- Inspect cam mechanism for wear

- Check motor mounting bolts (torque: 2.5 Nm)

- Lubricate cam bearings with approved grease

- Test motor current draw (<200 mA normal)

Motor Replacement Procedure:

1. Disconnect power and remove battery

2. Remove motor assembly screws (4x M4)

3. Disconnect motor wiring harness

4. Install new motor (Part #IP-MOTOR-004)

5. Calibrate pump delivery accuracy

6. Test all operational modes

Tubing Sensor Calibration

Accurate flow detection requires proper sensor alignment:

Calibration Steps:

1. Install reference tubing set (Terumo #TE-IS201)

2. Access calibration mode via service menu

3. Run calibration sequence at 25 mL/hr

4. Adjust sensor gain to achieve ±2% accuracy

5. Test at multiple flow rates

6. Save calibration parameters to memory

Safety System Verification

Alarm Testing

All safety alarms must function correctly:

Audio Alarm Test:

- Verify alarm volume >65 dB at 1 meter

- Test all alarm tones (occlusion, empty, low battery)

- Check alarm silence function (max 2 minutes)

- Ensure proper alarm escalation sequence

Visual Indicator Test:

- Verify LED brightness and color accuracy

- Test display visibility from 2 meters

- Check backlight function in low light

- Confirm alarm message clarity

Delivery Accuracy Verification

Pump accuracy is critical for patient safety:

Gravimetric Testing:

- Use precision scale (±0.1g accuracy)

- Test multiple flow rates over 1-hour periods

- Calculate accuracy: (Delivered/Expected) × 100%

- Accuracy must be within ±5% for all rates

- Document results in calibration log

Safety Precautions

⚠️ CRITICAL SAFETY REQUIREMENTS

- Always use manufacturer-approved tubing sets

- Verify pump accuracy before clinical use

- Test all alarm functions after maintenance

- Never defeat or bypass safety systems

- Maintain proper grounding for electrical safety

- Follow sterile technique when handling fluid pathways

- Verify proper medication calculation and programming

- Ensure backup pump availability during maintenance

Advanced Diagnostic Tools

Service Software Utilities

Terumo provides specialized diagnostic software for advanced troubleshooting:

- Pump Analyzer Pro: Comprehensive pump testing and calibration

- Data Logger: Records pump performance parameters

- Firmware Update Tool: Maintains current software versions

- Error Log Viewer: Analyzes historical error patterns

Test Equipment Requirements

Professional pump servicing requires:

- Infusion Pump Analyzer (IDA-4 or equivalent)

- Digital flow meter with ±1% accuracy

- Pressure transducer (0-15 psi range)

- Battery load tester

- Oscilloscope for signal analysis

Preventive Maintenance Schedule

Weekly Tasks:

- Visual inspection of pump exterior

- Test basic pump functions

- Clean exterior surfaces per protocol

- Check power cord integrity

Monthly Tasks:

- Verify delivery accuracy at 3 flow rates

- Test battery backup duration

- Clean air intake filters

- Update maintenance log

Quarterly Tasks:

- Complete functional safety test

- Calibrate all sensors

- Update firmware if needed

- Replace worn components proactively

External References

1. Terumo Infusion Systems Technical Manual TE-300 Series (terumo-medical.com/technical-support)

2. FDA Infusion Pump Safety Guidelines (fda.gov/medical-devices/infusion-pumps)

3. OSHA Healthcare Electrical Safety Standards (osha.gov/healthcare)

*Last Updated: November 9, 2025*

*Reading Time: 9 minutes*

---

⚠️ Important: This guide summarizes safe repair practices based on industry best practices and manufacturer guidelines. Always consult the official manufacturer manual for model-specific procedures. Medical equipment repair should only be performed by qualified personnel.