Alaris™ Syringe Pump MK4: Technical Service Manual

Alaris™ Syringe Pump MK4
Technical Service Manual
s

Contents
General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Product Familiarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Purpose of this manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Conventions Used in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
General precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Front panel and main display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Configuration and Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Access codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Handsfree Bolus (175). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Dedication options (301/302) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Data Set Activation (612). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Power Lock (711). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Configuration options (251). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Data Set Transfer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Data Set Upload and Download (401 and 499). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Download CQI Event Log (402). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Calibration procedures (243). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SYRINGE CLAMP calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
PLUNGER POS (position) calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SYRINGE FORCE calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
LINE PRESSURE calibration – Alaris CC Syringe Pump only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
BATTERY calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Visual Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Recommended Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Updates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Upgrading software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Plunger Backplate Spring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Battery Test and Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Replace the Main Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Self-test Procedure (123). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Self-tests included in full test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Self-tests not included in full test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Comms Test (123). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Calibration Verification Mode (240). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Performance Verification Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1000SM00024 Issue 4 2/80


Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Review logs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Event Log download. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Information Logs (376) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Software fault codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
PL8 / PL9 Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Failure causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Actions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Exception error handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
General fault diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Circuit Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Functional module block diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Module overview functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Control PCB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Pressure Transducer (Model CC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Power Supply Unit PCB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Display PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Corrective Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Corrective Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Access to Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Rear case and subassemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Power Supply Unit and Speaker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
AC power inlet, PE stud and magnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Pole clamp and RS232. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Rail cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Front case and subassemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Control PCB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Display PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Chassis PCB and Plunger assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Chassis assembly and Pressure Transducer (Model CC only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Syringe Sizing assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Chassis assembly breakdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Plunger assembly breakdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Pressure Transducer Assembly (Model CC only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Keypads and labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1000SM00024 Issue 4 3/80


Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Electromagnetic Compatibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Guidance and Manufacturer’s Declaration – Electromagnetic Emissions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Guidance and Manufacturer’s Declaration - Electromagnetic Immunity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Guidance and Manufacturer’s Declaration—Electromagnetic Immunity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Recommended Separation Distances for LIFE SUPPORT Equipment between portable and mobile RF
communications equipment and the Alaris Syringe Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Information on Disposal for Users of Waste Electrical and Electronic Equipment . . . . . . . . . . . . . . . . . . . . . 65
Information on Disposal in Countries outside the European Union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Battery Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Spare Parts Listing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Electrical Parts Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Front Case Parts Listing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Rear Case Parts Listing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Keypads and Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Transmission Parts Listings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Test Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Fitting and Replacement Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
General assembly information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Torque guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Lockbox Accessory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Lockbox Cleaning Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Pump Battery Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Lockbox Parts Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Service Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Document History. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Software Upgrade Record. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1000SM00024 Issue 4 4/80

General Information
1 General Information
Introduction
The Alaris™ Syringe Pumps MK4 (Pump) are designed to deliver a continuous and accurate infusion whenever small fluid volumes need
to be administered with great precision. High performance, comprehensive alarm protection and sophisticated monitoring systems
combined with simple operation make these syringe pumps suitable for both general and critical infusions in a variety of areas within a
hospital.
Please refer to the Alaris Syringe Pump MK3 Technical Service Manual (1000SM00001) for all servicing information
A for the MK1, 2 and 3 versions.
Product Familiarity
Ensure full familiarity with this Pump by carefully studying the Directions For Use (DFU) prior to attempting any repairs or servicing.
As part of a policy of continuous improvement, product enhancements and changes are introduced from time to time.
Purpose of this manual

This Technical Service Manual shows how to set up, test and maintain the following Alaris Syringe Pump MK4 models:
• Alaris GH Plus Syringe Pump
• Alaris GH Guardrails™ Plus Syringe Pump
• Alaris CC Plus Syringe Pump
• Alaris CC Guardrails Plus Syringe Pump
• Alaris PK Plus Syringe Pump
• Alaris Enteral Plus Syringe Pump
It is intended for use by personnel experienced in medical equipment testing and maintenance procedures.
This manual has been prepared for use by Qualified Service Personnel only.
CareFusion recommends that all servicing should only be carried out by CareFusion certified Qualified Service Personnel.
Note: Throughout this manual the pump software terminology, syringes used and disposables used vary for the Alaris Enteral Plus
Syringe Pump, e.g. Infusion is Delivery, extension set is feeding tube, etc. See the relevant DFU for complete information.
However all tests and procedures will remain the same, unless otherwise stated.
It is important to ensure that you only refer to the most recent version of the Directions for Use and Technical Service
A Manual for your CareFusion products. These documents are referenced on www.carefusion.com. Copies can be
obtained by contacting your local CareFusion representative.
1000SM00024 Issue 4 5/80

General Information
Conventions Used in this Manual

BOLD Used for Display names, self-test codes, controls and indicators referenced in this manual, for example,
Battery Indicator, access code 212, ON/OFF button.
'Single quotes' Used to indicate cross-references made to another section of this manual. For example, see Chapter 2,
'Configuration and Calibration'.
Italics Used to refer to other documents or manuals. For example, refer to the relevant Directions for Use (DFU) for
further information. Also used for emphasis, for example, ...if the gap still measures less than...
Wherever this symbol is shown a Hints and Tips note is found. These notes provide useful advice or
information that may help to perform the task more effectively.
Wherever this symbol is shown an Update note is found. A typical example is drawing attention to a software
upgrade that should be confirmed has been installed.
Wherever this symbol is shown an Important note is found. These notes highlight an aspect of test or
A maintenance that is important to know about.
General precautions
Please read the general Operating Precautions described in the Directions for Use carefully prior to using the
Pump.
This Pump contains static-sensitive components. Observe strict precautions for the protection of static
sensitive components when attempting to repair and service the Pump.
An explosion hazard exists if the Pump is used in the presence of flammable anaesthetics. Exercise care to
locate the Pump away from any such hazardous sources.
A
An electrical shock hazard exists if the pumps casing is opened or removed. Refer all servicing to Qualified
Service Personnel.
M
This Pump is protected against the effects of high energy radio frequency emissions and is designed to fail safe
if extremely high levels of interference are encountered. Should false alarm conditions be encountered, either
remove the source of the interference or regulate the infusion by another appropriate means.
L
If the Pump is dropped, subjected to excessive moisture, humidity or high temperature, or otherwise
suspected to have been damaged, remove it from service for inspection by Qualified Service Personnel.
When connected to an external power source, a three-wire (Live, Neutral, Earth) supply must be used. If the
 integrity of the external protective conductor in the installation or its arrangement is in doubt, the Pump
should be operated from the battery.
1000SM00024 Issue 4 6/80

General Information
Front panel and main display

The display shown is for general guidance only. For Pump specific front panel and main display information refer to relevant Directions
For Use.
Syringe Type Fitted / Drug Name / Profile* Time Remaining Icon
Infusion Status Pressure Information** /

Pressure Icon (if enabled)
Infusion Rate Volume Infused

Blank Softkeys Pressure button
* “Profile” is only available on an Alaris Syringe Pumps with a Data Set loaded.
** Pressure Information is only displayed on the Alaris CC Syringe Pumps.
Controls and indicators

a ON/OFF button - Press once to switch the Pump on. Press and hold down for 3 seconds to switch the Pump off.
b RUN button - Press to start the infusion. The Green LED will flash during infusion.
h HOLD button - Press to put the infusion on hold. The amber LED will be lit while on hold.
MUTE button - Press to silence alarm for two minutes. To re-enable the alarm audio press the Mute button a
second time.
R Note: Attention alarm - When not in alarm press and hold until four audible beeps are sounded for 15 (60
for PK) minutes silence.
PURGE/BOLUS button - Press to access PURGE or BOLUS soft keys. Press and hold down soft key to operate.
i PURGE the extension set during set up.
• Pump is on hold
• Extension set is not connected to the patient
• Volume Infused (VI) is not added
BOLUS fluid or drug delivered at an accelerated rate.
• Pump is infusing
• Extension set is connected to the patient
• VI is added
d OPTION button - Press to access optional features.
e PRESSURE button - Press to display the pumping pressure and alarm level.
g BLANK SOFTKEYS - Use in conjunction with the prompts shown on the display.
f CHEVRON keys - Double or single for faster/slower, increase or decrease of values shown on main display.
BATTERY indicator - When illuminated, indicates that the Pump is running on the internal battery. When
j flashing, indicates that the battery power is low, with less than 30 minutes of use remaining.
AC POWER indicator - When illuminated, indicates that the Pump is connected to an AC power supply and the
k battery is being charged.
1000SM00024 Issue 4 7/80

Configuration and Calibration
2 Configuration and Calibration

Access codes
The syringe Pump software contains a number of configuration and test routines that can be accessed by the user. The majority of tests
are menu driven from a technical access code (see below).
Note: The Pump
should be power
cycled after entering
any new calibration or
configuration information
prior to performing any
validation tests.
Codes available on Alaris PK Plus Syringe Pumps:

Code Description
123 Self Test Procedure
166 External Reprogramming
175 Handsfree Bolus
243 Calibration Selection Menu
251 User Configuration Menu
376 Service Access Menu
401 Upload Data Set to Pump
499 Download Data Set from Pump
611 Cold Start (RAM Clear)
612 Data Set activation
711 Power Lock
Codes available on Alaris GH/CC/Enteral Plus Syringe Pumps:

Code Description
123 Self Test Procedure
166 External Reprogramming
240 Calibration Verification Mode
243 Calibration Selection Menu
251 User Configuration Menu
301 Fully Dedicated (CC only)
302 Semi-dedicated (CC only)
376 Service Access Menu
401 Upload Data Set to Pump (Not available for the Alaris Enteral Plus Syringe Pump)
402 Download CQI Event Log from Pump (Guardrails Software enabled Pumps only)
611 Cold Start (RAM Clear)
Each menu (and some unique items) has its own three-digit access code that can be entered using the following procedure:
1. Hold down b and turn the Pump on.
2. Enter the required access code using the f keys and the NEXT softkey.
3. When the required code shows on screen, press OK to confirm.
1000SM00024 Issue 4 8/80

Handsfree Bolus (175)

Enable or disable the Handsfree Bolus. If enabled pressing i button displays screen prompting for hands free or hands on. Default
volume after clear setup is 0.0. Upper amount restricted to bolus volume limit in general options or drug protocol bolus volume limit.
Dedication options (301/302)

Fully Dedicated (set using access code 301) will remind a user that a pressure disc must be fitted to start any infusion. In this mode
occlusion pressures are always displayed in mmHg.
Semi-Dedicated (set using access code 302) will remind a user that a pressure disc must be fitted when drugs and dosing features are
used. When a pressure disc is not in use, pressure levels L-0 to L-10 will be displayed.
Data Set Activation (612)

This code is used to load the predefined Pump configuration and drug setup into the non-volatile storage. It is necessary to enter the
code 612 after a cold start (code 611); the configuration and drug setup will then be available in normal operation.
Alternatively a data set may be uploaded as appropriate. See directions for use contained within the Alaris PK Editor Software package.
Power Lock (711)

Available on the Alaris PK Plus Syringe Pump.
Disabled The new alternative Power Down sequence now allows the user to Power Down the Pump whilst the infusion is
suspended (on hold) in TCI mode and predictive TIVA mode.
Enabled The Power Down sequence (Power Lock) remains the same where the user may only Power Down the Pump by stopping
the infusion, selecting ‘new operation’ from the options menu, confirming the selection, then Powering Down the Pump.
1000SM00024 Issue 4 9/80

Configuration options (251)

Enter access code 251 to display the User Configuration menu:
General Options See 'General Options' table later in this chapter.
Clock Set Set the current date and time. To set the clock, use f and NEXT to adjust and OK to store.
Language Configure the language used for messages shown on display.
Select language required using f and SELECT to store.
Contrast Set the display panel contrast. Use f to adjust contrast and OK to store.
Enable Syringes See 'Enable Syringes' later in this chapter.
(Enteral Plus only)
General Options
Option Description
NURSE CALL FITTED Enables Nurse Call (hardware option).
NURSE CALL INVERT When enabled, the nurse call output is inverted.
RS232 SELECTED Sets the Pump’s communications to use RS232 (hardware option).
REMINDER SIGNAL When enabled there is an audible notification, consisting of four beeps every 10 minutes for the Low
Battery and Near End of Infusion alarms.
NEOD When disabled, delivery will continue until end of delivery is reached.
(Enteral Plus only)
CAP RATE Sets the maximum value for delivery rate.
(Enteral Plus only)
Enable Syringes (Enteral Plus only)

This option is used to pre-configure the syringe brand and size permitted for use on the pump. Select all permitted syringes and disable
any that should not be used.
1. Select ENABLE SYRINGES from the Configured Options menu using the f keys and press the OK softkey.
2. Use the f keys to scroll through the list of syringe brands and press SELECT to access syringe sizes.
3. Use the f keys to scroll through the list of syringe sizes and press MODIFY to enable/disable a syringe size(s) within the
brand.
4. When the desired modifications have been selected press the QUIT softkey to return to the Configured Options menu.
1000SM00024 Issue 4 10/80

Data Set Transfer

Data Set Upload and Download (401 and 499)
Upload Data Set to an Alaris GH/CC/PK Plus Syringe Pump (401)
Using the Alaris Plus Editor Transfer Tool or Alaris PK Editor Software Transfer Tool allows a released Data Set to be uploaded to the
Pump.
Download Data Set from an Alaris PK Plus Syringe Pump (499)
Using the Verification Tool allows an uploaded Data Set in the Pump to be downloaded to a PC for comparison and verification, where
applicable.
Note: After data set upload
it is advisable to switch the
Pump off and then wait 10
seconds before powering
on again. Also the new
parameters will not take
effect until the Pump has
been powered up in normal
operation mode and a new
profile has been selected.
Download CQI Event Log (402)

Download CQI Event Log from a Pump (402)
Using the CQI Event Log Downloader allows the CQI Event Log to be downloaded from an Alaris Syringe Pump to a PC for use with the
Guardrails CQI Reporter. The Guardrails CQI Reporter is a program for querying and reporting on the collective event data allowing the
user to analyse trends in medication administration and track medication errors.
Warning -
A At no time should the Alaris Plus Editor Transfer Tool, CQI Event Log Downloader or the Alaris PK Editor Software be
used to upload to or download from a Pump while the Pump is connected to a patient.
Note: For more

information relating to the
Alaris Plus Editor, the Alaris
PK Editor Software and the
Guardrails CQI Reporter
refer to the relevant
Directions For Use supplied
with the software.
1000SM00024 Issue 4 11/80

Calibration procedures (243)

Enter access code 243 to display the Calibration Selection menu (see Access Codes).
SYRINGE CLAMP calibration

• Fit calibration tool into position on Pump as shown in Steps 1-2 and close the
clamp.
• At each step, CAL is displayed if value is within tolerances.
• Press CAL softkey to store calibration point.
Calibration tool required: 1000TG00095
Note: If CAL is not displayed, Note: The Pump should be
check for correct positioning of power cycled after entering any
calibration tool. new calibration or configuration
If calibration cannot be information prior to performing
performed, repairs to Pump may any validation tests.
be necessary.
Note: The calibration values
shown on the displays are for
illustrative use only and may
vary.
Step 1
Step 2
Step 3
1000SM00024 Issue 4 12/80

PLUNGER POS (position) calibration

• Fit calibration tool into position on Pump as shown in Steps 1-3.
• At each step, CAL is displayed if value is within tolerances.
• Press CAL softkey to store calibration point.
Note: If CAL is not displayed,

Calibration tool required: 1000TG00095
check for correct positioning of
calibration tool.
If calibration cannot be
performed, repairs to Pump may
be necessary.
vary.
Step 1
Channel for locking clip
Step 2
Close-up of calibration tool,
showing locking clip in position.
Step 3
Locking clip
Step 4
1000SM00024 Issue 4 13/80

SYRINGE FORCE calibration
Note: To convert Kilograms

of Force (kgf ) to Newtons
(N) multiply by 9.806650. For
example 10kgf = 98.07N.
vary. Calibration tool required:
0000TG00200 (top) or
0000TG00020 (bottom)
Excessive force will damage the plunger mechanism. Do not apply more than 10kgf ±0.05kgf to the plunger
A mechanism at any time.
Fit Calibration tool and position plunger as shown in Steps 1 to 3, zero the gauge. At each step press CAL softkey when required
calibration force is reached.
Note: If CAL is not
displayed, check for
correct positioning
of tool. If calibration
cannot be performed,
repairs to Pump may be
necessary.
Step 1
0kgf ±0.05kgf
1000SM00024 Issue 4 14/80

Step 2
3kgf ±0.05kgf
Step 3
10kgf ±0.05kgf
Step 4
Use of the 0000TG00200 Digital Occlusion Testgear.

A The 0000TG00200 Occlusion testgear uses a digital force gauge to register applied forces.
Please refer to the MecMesin Compact Gauge Operation Instructions supplied for detailed operational information
and power options and requirements.
To prepare the testgear for use, load into the syringe Pump.
• Ensure there is nothing touching the testgear plunger (such as the syringe plunger drive).
• Turn on the Compact Gauge using the On/Zero key.
• Select kg force units, and MAX reading option.
• If the display indicates other than 0.00kg, zero the system using the On/Zero key.
Operate the system as required for performing the calibration activity.
Before the next use, ensure the MAX reading is cleared using the On/Zero key.
1000SM00024 Issue 4 15/80

LINE PRESSURE calibration – Alaris CC Syringe Pump only

Tools required:
• Pressure gauge (range 0-1400 mmHg) (Tolerance +/- 0.1% Full Scale Accuracy)
• Dedicated pressure sensing disc extension set (i.e. G30402M)
• 50ml Luer-lock syringe
Dedicated pressure sensing disc extension set
50ml Luer-lock syringe Pressure Transducer Pressure gauge
Load pressure disc infusion set into transducer. Connect infusion set to syringe and gauge. Using syringe, apply pressure required as
shown at steps 1-3. At each step press CAL softkey when required calibration pressure is displayed on pressure gauge.
Note: The calibration values shown on the displays are for illustrative use only and may vary.
Step 1
25mmHg ± 1mmHg
Step 2
500mmHg ± 1mmHg
Step 3
1000mmHg ± 1mmHg
Step 4
1000SM00024 Issue 4 16/80

BATTERY calibration
1. C onnect the Pump to AC power.
2. Select BATTERY CALIBRATION from menu and press OK.
3. The Pump will automatically run the battery calibration. Battery calibration cycles the battery through a charge, discharge and re-
charge sequence during which the gas gauge within the battery pack will be updated with a measurement of the current capacity
of the cells.
Battery compartment should be ventilated during calibration (open battery cover). Pump may fail calibration if too
A hot, so care should be taken not to calibrate too many pumps in close proximity (in a docking station, for example).
Ensure that the battery is supported as the battery compartment is opened.
Disconnecting the AC power at any time during calibration will cause battery calibration to fail.
A
4. When calibration is complete, the following is shown on the display:
1 4
2
5
3 6
Value Description Pass Criteria

1 Battery Capacity Pack capacity value updated after measured Greater than 2100mAh
discharge phase (if changed).
2 Current Battery Charge Level Current charge in pack. n/a
3 Battery Voltage Current pack voltage. n/a
4 Initial Charge Time Time taken during initial charge phase. Initial charge Lower than 2 hours 59 minutes
phase checks pack is fully charged and if not it is
charged.
5 Discharge Time Time taken during measured discharge phase. Pack Between 4 hours 15 minutes and 10
is discharged to determine how much charge is hours
available from the pack.
6 Final Charge Time Time taken during final charge phase. Pack is fully Lower than 2 hours 59 minutes
recharged ready for use.
ll pass criteria (see table above) should be met and the Pump should display FINISH at the end of the calibration otherwise
5. A
calibration has failed. If calibration has failed retry calibration or replace battery.
A new battery or battery that has been in storage may fail its initial calibration run, from these states most batteries
A require conditioning with at least 3 charge discharge cycles to achieve their maximum capacity. Therefore batteries
failing an initial calibration run should not immediately be considered defective, once cycled most initial failures will
show improvement and pass on a second calibration attempt.
6. Press OK to exit.
Note: The plunger drive will
move automatically during the
discharge phase. The plunger
drive must be positioned
away from the end of travel, at
least the middle of the travel,
and not be obstructed during
calibration (remove syringes
etc).
1000SM00024 Issue 4 17/80

Preventative Maintenance
3 Preventative Maintenance
To ensure the Pump remains in good operating condition, routine and preventative maintenance inspections are required. Routine
maintenance inspections should be performed by hospital/facility before each use, see Directions For Use for details.
Preventative maintenance inspections should be performed at least every three years.
For the preventative maintenance inspection the following should be performed:
• Full visual inspection of the Pump, internal and external
• Fitting of all updates required
• Battery test and/or replacement
• Clean the Pump
• Performance Verification Procedure
Following all spare part replacement and repair activities, testing must be performed in accordance with the
A Performance Verification Procedure (PVP). Additional testing and calibration may be required after certain repairs
are completed, see table in Chapter 6 Corrective Maintenance for more information.
Visual Inspection
Open the Pump, as per Chapter 6 Corrective Maintenance and visually inspect the interior of the Pump.
Visually inspect the exterior of the Pump checking the following:
• Labels should be replaced as required if not flat, legible or fully adhered.
• Check Keypad for any sign of wear and replace as required.
• Case components must be checked for damage and replaced if necessary.
• Check the pole clamp is not damaged and that it functions correctly.
• Inspect the AC power supply plug and cable for damage.
• The case should be clean and free from IV solution residue, especially near moving parts.
• Check for dried solution deposits on accessible areas of pressure transducer and plunger mechanism.
1000SM00024 Issue 4 18/80

Recommended Cleaning
To ensure this Pump remains in good operating condition, it is important to keep it clean and carry out the routine procedures
described below. All servicing should only be performed by Qualified Service Personnel.
Thoroughly clean external surfaces of the Pump, by wiping over with a lint-free cloth, lightly dampened with warm water and a standard
disinfectant/detergent solution.
Do not use the following disinfectant types:
• NaDcc (such as PRESEPT)
• Hypochlorites (such as CHLORASOL)
• Aldehydes (such as CIDEX)
• Cationic Surfactants >1% (such as Benzalkonium Chloride)
• Iodine (such as Betadine)
Recommended cleaners are:
Brand Concentration
Hibiscrub 20% (v/v)
Virkon 1% (w/v)
The following products were tested and are acceptable for use on the Alaris Plus Syringe Pump range if used in accordance with the
specified manufacturer’s guidelines.
• Warm soapy water
• Mild detergent in water (e.g. Young’s Hospec)
• 70% Isopropyl Alcohol in water
• Chlor-Clean
• Clinell Universal wipes
• Hibiscrub
• TriGene Advance
• Tristel Fuse sachets
• Tristel Trio wipes system
• Tuffie 5 wipe
• Virkon Disinfectant
Before cleaning always switch off and disconnect from the AC power supply. Never allow fluid to enter the casing and
A avoid excess fluid build up on the Pump.
Do not use aggressive cleaning agents as these may damage the exterior surface of the Pump.
Do not steam autoclave, ethylene oxide sterilise or immerse this Pump in any fluid.
1000SM00024 Issue 4 19/80

Updates
Upgrading software
When upgrading a Pump from one software version to another where the first or middle digit changes, cold start
will be required before and after software upgrade, unless otherwise stated in a Technical Information Notice.
Calibration will also be required after software upgrade and cold start.
Complete and return the 'Software Upgrade Record' in the 'Appendix' section after performing any software
A upgrade.
Tools required
• The Software Distribution Disk (See table below)
• IrDA port on PC or Comms Port
• Programming kit 1000SP01749 (Includes Programme Header and IrDA cable)
• RS232 cable DEC001
• Version 3.1 Software Maintenance Utility (SMU) 1000SP01748
Preparation
• CareFusion recommend that RS232 be used for all updates where possible.
• To enable RS232 enter access code 251.
• Select General Options from the menu.
• Select RS232 Selected and enable.
IrDA power-down test

To check PC is set up correctly for communication with Alaris Syringe Pumps the Power Down Test needs to be performed on one Alaris
Syringe Pump only as follows:
1. Load the IrDA Power Down Test program on your PC.
2. Select GO on the PC software program.
3. Align the IrDA converter with the Pump IrDA window (optimum distance is 5cm).
4. Connect to serial port.
5. Enter access code 166.
6. Press Yes to continue Bootstrap.
7. Select IrDA interface.
8. Select a Baud rate of 115200.
9. The Pump will then display Bootstrap in progress.
10. Press the a button to silence the alarm.
11. Select Transmit on PC. Check progress bar moves on PC and Pump powers down.
Software Versions available

Syringe Pump Model Software
1000SP01930
Alaris GH Syringe Pump
(MP v4.3.6)
1000SP01930
Alaris GH Guardrails Syringe Pump
(MP v4.3.6)
1000SP01931
Alaris CC Syringe Pump
(MP v4.3.6)
1000SP01931
Alaris CC Guardrails Syringe Pump
(MP v4.3.6)
1000SP01905
Alaris PK Plus Syringe Pump
(MP v3.4.5)
1000SP01916
Alaris Enteral Plus Syringe Pump
(MP v4.4.0)
Key: MP = Main Processor.
1000SM00024 Issue 4 20/80

Soft bootstrap
1. Load the software program onto your PC. Start the MP Only version of relevant Pump software. Check the correct Pump type is
displayed.
2. Select GO.
3. Connect RS232 cable.
4. Connect to serial port.
5. Enter access code 166.
6. Press Yes to continue Bootstrap.
7. Select RS232 interface.
8. Select a Baud rate of 115200.
9. The Pump will then display Bootstrap in progress.
10. Press the a button to silence the alarm.
11. Select Start on SMU. Monitor progress of all selected channels.
Hard bootstrap
1. Load the software program onto the PC.
2. Start the relevant Pump software.
Note: Only main or safety processor software should be programmed in a single session to avoid synchronisation errors. i.e. select
either the MP Only or SP Only software file.
3. Disconnect the battery and separate the Pump, to gain access to the control board
4. Fit the Programming Adaptor JTAG SP onto the control board and set the following switch positions:
• SW1, SW2 and SW3 = ON, SW4 = Not used (do not press), SW5 = OFF
5. Reconnect the battery. The Pump will alarm, press and hold the a button for 2 seconds to silence.
6. Align the IrDA converter Pump with the IrDA window (optimum distance is 5cm), or connect RS232 cable.
7. Connect to serial port
8. Ensure the SMU is configured to the corresponding serial port and select a baud rate of 19200
9. Select Start on PC. Monitor progress of all selected channels. The main processor software is the largest file and may take up to 50
minutes to complete.
10. Repeat process remaining software file, MP or SP as necessary.
11. Power down Pump.
Cold start
Carry out a cold start if the Pump has changed software version. Refer to documentation supplied with the software disk to see if cold
start is required.
1. Enter access code 611, then power down when prompted.
2. Perform a full calibration.
Caution - Potential Erasure of Data:
A Cold Start erases all information from the Pump. This feature should only be used when changing between
incompatible software versions. Full recalibration and reconfiguration will be required. CareFusion technicians
should not re-instate drug information (this must be left to the customer).
Power Failure
Failures may occur when using laptops when communicating with Alaris Syringe Pumps, due to power
requirements.
External power supply may be used in conjunction with IrDA or RS232 cable to compensate for lack of power
from laptop.
Please Note IrDA data transfer can be affected by bright sunlight or fluorescent lighting.
1000SM00024 Issue 4 21/80

Plunger Backplate Spring Replacement

Recommended during every Preventative Maintenance and at the minimum every three years, that the plunger backplate spring is
replaced.
If the spring had not been replaced during the previous check, the spring needs to be replaced at the next intervention and at each
preventative maintenance as recommended.
A kit of 10 replacement springs is available, part number 1000SP01589.
1. Remove three screws holding plunger backplate.
Screws (x3)
2. Remove the plunger backplate.

Note: Be cautious when removing as parts may
become loose. Placing the Pump in a vertical
orientation may assist with maintaining
components in place.
Plunger Backplate
3. Visually inspect the interior of the plunger, replace
any broken components. See Chapter 6 Corrective
Maintenance for further details.
4. Remove the spring from the plunger backplate.

5. Fit a new spring to the plunger backplate.
6. Refit the plunger backplate.
Plunger Backplate
7. Fit the three screws into the plunger backplate.
Spring
1000SM00024 Issue 4 22/80

Battery Test and Replacement

To test the battery perform the battery calibration, as outlined in the procedure in Chapter 2 Configuration and Calibration, and verify
that all pass criteria are met. If pass criteria are not met then replace the battery.
Battery charge retention will eventually degrade. So where retention is critical the internal battery should be replaced every three years.
Replace the Main Battery

1. Remove the two case screws in battery cover, remove cover and battery.
2. Fit new battery.
3. Replace battery cover and secure with 2 screws.
Battery Cover
Battery
It is essential that the battery pack is calibrated after fitting as failure to do so will degrade the quoted auxiliary
A battery power on this product.
The battery pack used in this Alaris Syringe Pump is manufactured by CareFusion and includes a proprietary PCB
A (printed circuit board) designed specifically for the Alaris Syringe Pump, and in conjunction with Alaris Syringe
Pump software, controls battery use, charge and temperature. Any use of battery packs that are not manufactured
by CareFusion in the Alaris Syringe Pump is at your sole risk, and CareFusion does not provide any warranty for or
endorsement on any battery packs that are not manufactured by CareFusion. CareFusion product warranty shall not
apply in the event the Alaris Syringe Pump has suffered damage or premature wear, or malfunctions or otherwise
operates incorrectly, as a result of use with a battery pack that is not manufactured by CareFusion.
1000SM00024 Issue 4 23/80

Self-test Procedure (123)

Self-tests included in full test
Enter access code 123 to view the Test Selection menu (see Access Codes in chapter 2). Refer to table below for the tests in each menu
item.
Test Section Test Action
Software info Displays the software version.

Software
Data Set Info Displays the Data Set information. (pumps with data sets only)
Safety ID Check displays the version of the safety ID.
Safety Processor Safety LED Check red LED illuminated.
Safety Alarm Check Backup alarm sounds.
Serial Number Check displays serial number of Pump.
Language Check displays correct language.

Full only
Real-time Clock Check displays correct date and time.
Service Date Check displays date when service is next required.
Disc Detect Check the display changes correctly to indicate if a disc is Out or In (Model CC only).
Line Pressure Check pressure is 000mmHg +/-20mmHg with no pressure applied (Model CC only).
Motor Encoder Check motor runs and Passed is displayed.
Check display indicates Drive Engaged or Disengaged when clutched/declutched.

Note: Whilst slowly declutching the plunger ensure there is no movement of the
Drive Engage plunger until after the display shows Drive Disengaged. Any movement
before Drive Disengaged will indicate if the Carriage PCB is incorrectly
positioned or if there is slight wear of the half nut.
Sensor
Plunger Fit Check display indicates if the Plunger button is Out or In.
Plunger Position Check display smoothly and continuously changes during full plunger travel.
Insert the syringe size calibration tool (1000TG00095) and check the following values are
displayed for diameters inserted:
Syringe Clamp
12mm diameter = 11.5 to 12.5mm
32mm diameter = 31.5 to 32.5mm
Syringe Force Check motor runs and syringe force is displayed.
Battery Battery Check displays values in CAP, CHR and VOL; no dashes should be seen.
Audio Audio Speaker Check the main audible alarm sounds.
Display Check that all of the display pixels are illuminated.
Backlight Check that the backlight switches from LOW to HIGH when indicated.
Battery LED Check the Battery LED (Amber) flashes.
Visual Indicator Start LED Check the Start LED (Green) flashes.
Stop LED Check the Stop LED (Amber) flashes.
Warning LED Check the Warning LED (Amber) flashes.
Alarm LED Check the Alarm LED (Red) flashes.
Key Keypad Press the key indicated and check changes to next key.
Comms Comms RS232 only. Check Nurse call and RS232 operation.
1000SM00024 Issue 4 24/80

Self-tests not included in full test

Test Section Test Action
Remote Remote Check the function of the IrDA output for remote access
Syringe clamp Displays calibration values for Closed and Open positions.
Plunger position Displays calibration values for Left, Middle and Right positions.
Calibration records
Syringe force Displays calibration values for 0, 3 and 10 kgf.
Line pressure Displays calibration values for 25, 500 and 1000mmHg (Model CC only)
Linearity Check the mechanism runs full travel and graph displays smooth linear travel.
Linearity
Occlusion base Check the occlusion base level is within tolerance shown on graph.
Comms Test (123)

Select COMMS TEST from the displayed menu.
Note: Section only applicable if RS232 Hardware option is fitted.
No specific customer test equipment is available to conduct the RS232 on nurse call alarm tests. It is assumed that the customer will
have associated systems that make use of the RS232 and nurse call options, hence:
The nurse call system can be tested, once connected to the customer facility, by running the Pump and simulating an alarm condition
(e.g. Disengaging the drive while running).
The RS232 system can be tested by communicating with the Pump using a customer application.
If no customer systems are available for in-use testing, the following connections to the 9 pin D type output socket will permit testing. It
is recommended that all test connections are made via a 9 way D type plug that can be fitted into the Pump socket.
Test Description
RS232 Test Only available when Nurse Call option is fitted.
Note: NURSE CALL FITTED and RS232 SELECTED must be enabled () in access code 251 General Options
for this test to work. Connect the 9-pin D type connector to the 9 pin D type output socket at the rear
of the Pump. The display ‘_ _ _ _’ will change to PASS if the communications test is successful.
Nurse Call Only available when Nurse Call option is fitted.
Note: NURSE CALL FITTED and RS232 SELECTED must be enabled () in access code 251 General Options
for this test to work. Locate the 9-pin D type connector at the rear of the Pump. Check that the Nurse
Call relay switches from NC to NO connections during test.
RS232 pinout GND DSR RXD TXD NC C
5 4 3 2 1
9 8 7 6
NC NC O CTS
COM
Pin Number Required Action Comments

(Pump Socket Id)
1 Nurse call relay - normally closed connection With nurse call test in progress - Confirm continuity with pin 5 -
Alternately switches with pin 8.
2 Link pin 2 to pin 3 RS232 Tx and RX test link. With RS232 test in progress - Confirm
PASS is displayed on test screen.
3 See pin 2 -----
4 Not used -----
5 0 volt line With respect to pin 7.
6 Not used -----
7 Apply 9 to12 volts DC RS232 Power supply - with respect to pin 9.
8 Nurse call relay - normally open connection With nurse call test in progress - Check continuity to pin 5 -
Alternately switches with pin 1.
9 Nurse call relay - common connection ----
1000SM00024 Issue 4 25/80

Calibration Verification Mode (240)

The Calibration Verification Mode allows Qualified Service Personnel to verify the required calibration in normal operation mode by
selecting to use the Calibration Verification profile. This tech mode screen allows activation of this profile with the required settings only
for the next time the Pump is powered up in normal operation mode. Confirmation of this profile on power up is required. This profile
and the appropriate dedication mode set to allow verification will be discarded when the Pump is powered down.
1. Enter the access code 240.

2. Pressing the OK key will activate the Calibration Verification profile as defined below as the currently selected profile, clear the
current drug setup, and return to the access code screen.
3. Pressing the QUIT key will return to the access code screen
Note: The Calibration Verification profile Name will be CALIBRATION VERIF.
CALIBRATION VERIF. settings:
• Profile name is displayed on the main screen during normal operation mode. This provides a clear indication of the Pump being
set in this profile. Likewise all logging will be against this profile and can be filtered out with the CQI PC package,
• Infusion Rate Maximum will be 200ml/h
• Pressure Maximum will be 1000mmHg / L10
• Number of Syringe Brands will be 1 i.e. BD Plastipak
• Syringe enabled will be the BD Plastipak 50ml syringe model
Note: If BD Plastipak 50ml physical characteristics are not available in the current data set then these settings will be extracted from
the default data set.
• Profile will not have any drug setups
• The Calibration Verification profile will take the default values for all remaining parameters, except ml/h will be the only enabled
dosing only unit and Auto Save will be disabled.
• The Calibration Verification profile will count as an additional profile in the data set only for the next time the Pump is powered
up in normal operation mode, but will not be selectable from the list of data set profiles.
1000SM00024 Issue 4 26/80

Performance Verification Procedure

Model / Serial Number: Service Order / Inventory Number:
Hospital Name / Reference: Software Version:
Inspection Physical inspection and clean

Error Log ch4 Check/set serial number, set service date (optional)
376
Check all functions in full test
Check date and time is correct (set as required (251) ch2
Full Test ch3
Syringe size detection test
123
• 12 mm spacer (11.5 to 12.5)
• 32 mm spacer (31.5 to 32.5)
Alarms functionality check
Infusing Drive Disengaged, Check Syringe, AC power fail, Pressure Disc out (CC), Near End of Infusion, End of Infusion
(Use access code 240) Ensure Pump works on battery and AC power
Linear speed test*

Pump set to 200 ml/h, syringe type BD Plastipak 50, for a distance of 15 mm. ______ mins ______ secs
2 mins 27.01 secs to 2 mins 30.59 secs
Occlusion test
Verification Tests CH3 Pump set to 100 ml/h, syringe type BD Plastipak 50, alarm level L-3,
(For Alaris GH/CC/ 2.4 kgf to 3.8 kgf _____________ kgf
Enteral Plus Syringe
OR Dedicated (CC), alarm level 200 mmHg, drive occlusion at
Pumps use access
code 240) 2.4 kgf to 3.8 kgf
Line pressure readings (CC)
Alarm set to 50 mmHg – Pump alarms 40 mmHg to 60 mmHg _____________ mmHg
Alarm set to 750 mmHg – Pump alarms 710 mmHg to 790 mmHg
_____________ mmHg
Setup Set rate to zero (or lowest value possible), Clear Volume Infused and VTBI
Clear Error / Alarm/Battery logs (as required)
Class I Type CF Test results are stored:
Test in accordance with the standard Electronically ¨
EN 60601-1 and test equipment operation Print-out ¨
Electrical Safety Tests manual. PASS / FAIL
Other ¨
____________________
Verification
Performed By _______________________________ ___________________ _____________________
Sign Print Date
chX
indicates the chapter number in the Technical Service Manual (TSM) - 1000SM00024.
E.G. CH3 = Refer to TSM Chapter 3
* Latest issue of the plunger protector jig (0000JG00014 Issue 7) has been improved so that the needle of the dial
A gauge rests upon the plunger head (avoid resting the needle on the moulding flash line) of the Pump. This improves
the linear speed accuracy test results as any variation caused by the jig movement during the test are eliminated.
1000SM00024 Issue 4 27/80

Troubleshooting
4 Troubleshooting
Review logs
Event Log download
For downloading Event Logs from Pumps please contact your local CareFusion representative.
Information Logs (376)

Use access code 376 to view the information logs (see Access Codes in chapter 2).
Log View Notes
Option to view the time and date at which

Service Displays the last 10 fault codes.
they occur.
Will not be available if there is no data in the
Clear Service Clears any information stored in the service log.
service log.
Displays the complete event log (maximum 1500 events except
Alaris Syringe Pumps (with Plus software), Alaris Guardrails Syringe Option to view the time and date at which
Event
Pumps and Alaris Enteral Plus Syringe Pump which have one year they occur.
of events).
Key Displays the last 200 key presses and the time they occurred. Does not record while in Tech mode.
Use Displays the hours of use since reset and since last cold start. Press OK to clear hours since reset.
Access code 376 provides the following additional service options:

Service Date Set the date when Pump will display Service due and any service message entered.
Service Message Enter message to be displayed on service date.
Serial Number Record the serial number of the Pump.
Unit Reference Free-form text field for user reference only.
Event Log Access provided when standard power-up mode leads to errors such that the Event Log access from the
Options d button cannot be accessed.
PCB Identification Allows Control PCB ID to be reviewed. (Pumps with Guardrails Safety Software only)
1000SM00024 Issue 4 28/80

Troubleshooting
Software fault codes

The following errors, MT1, DE1, PF1, PP1 and SC1 may be experienced if the self test operation or calibration
A operation has been accessed by quitting from the configuration menu. If these are displayed the Pump should be
power cycled and these operations entered directly.
Code Module Failure Action/Replace

AC1 AC alarm manager failure
AC Alarm manager Control PCB
AC2 AC UCO failure
AD1 ADC Converter Voltage reference/Power regulation Control PCB
AM1 Audio status output driver
Audio manager Control PCB
AM2 UCO failure
AS1 Software execution
AS2 Audio status monitoring input ADC
Audio Status Speaker, wiring or Control PCB
AS3 Speaker current test at power up (open circuit)
AS4 Speaker current test at power up (shorted)
BT1 Battery gas gauge
BT2 Battery cell voltage is low
Battery Battery or Control PCB
BT3 Battery cell voltage is high
BT4 Battery discharging when connected to AC power.
CK1 Clock Excessive timing drift Control PCB
DE1 Drive engagement software module Control PCB
DE2 Drive Engage Detect Drive engagement opto self test Plunger drive flexi, Control PCB or
DE3 Emitter in wrong state Transmission PCB flexi
DB1 Drug database file system
DB2 Drug database file retrieval
Drugs Manager Control PCB
DB3 Drug database file storage
DB4 CRC Error
DS1 Dosing retrieval failure
DS2 Dosing storage failure
DS3 Dosing data failure
DS4 Dosing drug library failure
Dosing Manager Control PCB
DS5 Dosing patient data failure
DS6 Dosing IDFS failure
DS7 Dosing Data Set manager failure
DS8 Dosing Profile manager failure
DSM1 Data Set loading failure
DSM2 Data Set integrity failure
Upload or check Data Set
DSM3 Data Set incompatible format
DSM4 Data Set CRC failure
DSM5 Data Set read failure Upload or check Data Set Control
DSM6 Data Set element CRC failure PCB
Data Set Manager
DSM7 Data Set storage failure
DSM8 Data Set storage retrieval failure
DSM9 Data Set data corruption
Control PCB
DSM10 Data Set not available
DSM11 Data Set profile name mismatch
DSM12 Data Set last selected profile not available
1000SM00024 Issue 4 29/80

Troubleshooting

EV1 Open log file at power up
EV2 File storage software module
EV3 Log read index
EV4 Log write index
EV5 Log data read
EV6 Log data write
EV7 Event Log Log data seek Control PCB
EV8 Log repair failure
EV9 Log format failure
EV10 Log reporting failure
EV11 Log extracting failure
EV12 Log pack failure
EV13 Log unpack failure
FD1 Fluid delivery software module
FD2 Alarm manager software module
FD3 Plunger drive software module
FD4 Pressure monitor software module
FD5 Syringe software module
Fluid Delivery Control PCB
FD6 User configuration software module
FD7 Fluid delivery setup data retrieval
FD8 Fluid delivery setup data storage
FD9 Fluid delivery critical data
FD11 VI cross check error
FL1 Open fluid log file at power up
FL2 File storage software module
FL3 Log read index
FL4 Log write index
FL5 Log data read
FL6 Log data write
FL7 Fluid Log Log data seek Control PCB
FL8 Log repair failure
FL9 Log format failure
FL10 Log reporting failure
FL11 Log extracting failure
FL12 Log pack failure
FL13 Log unpack failure
GG1 Gas Gauge Communications with gas gauge Battery or Control PCB
GR1 Guardrails Limit Guardrails Limit failure Control PCB
IM1 Data corrupt Control PCB
Set Serial Number in access code
IM2 Serial number to set
376
Identification Manager
Set RTC in access code 251.
IM3 RTC to set
Control PCB
IM4 Storage failure Control PCB
1000SM00024 Issue 4 30/80

Troubleshooting

KL1 Open key log file at power up
KL2 File storage software module
KL3 Log read index
KL4 Log write index
KL5 Log data read
KL6 Log data write
KL7 Key Log Log data seek Control PCB
KL8 Log repair failure
KL9 Log format failure
KL10 Log reporting failure
KL11 Log extracting failure
KL12 Log pack failure
KL13 Log unpack failure
Keypad key stuck down for 10 seconds at power up or
KY1 Keypad key pressed continuously for more than five
Keypad minutes Keypad or Control PCB
KY2 Line failure

LC2 LCD control parameter storage
LCD Control PCB or Display PCB
LC3 LCD display memory test
ME1 Motor encoder module software
ME2 Overrun detected
Motor Encoder Motor encoder or Control PCB
Motor encoder interrupt service software run when
ME3
encoder is disabled
MT1 Motor module software
Encoder has failed, preventing motor software
MT2
continuing to run
Safety processor has failed, preventing motor software
MT3
continuing to run
MT4 Motor rotation in wrong direction
Check motor wire connections, opto
MT5 Motor rotation speed has drifted flag not slipping and encoder gear is
MT6 Running at wrong rate not in line with opto. Control PCB.
Stepper Motor
MT7 Motor rotation detected when it should be stopped If fault persists, contact your local
CareFusion, Alaris Products service
MT8 Motor not rotating when it should be representative
MT9 Motor rotation inhibit control of Safety Processor
MT10
MT11 Motor rotation travel data has reached maximum value
MT12
MT13 Motor critical data
NC1 ADC preventing nurse call operation
NC2 Monitor signal is out of range Control PCB or RS232/Nurse Call
Nurse Call
NC3 Relay current monitor drive PCB
NC4 Safety processor failure
PA1 Patient Data retrieval failure
PA2 Patient Data storage failure
Patient Data Control PCB
PA3 Patient Data data error
PA4 Patient Data IDFS error
PB1 Plunger button module software
Plunger drive flexi, Control PCB or
PB2 Plunger Button Plunger button opto self test
Transmission PCB flexi
PB3 Emitter in wrong state
1000SM00024 Issue 4 31/80

Troubleshooting

PC1 PIP Controller software module
PC2 PIP Controller critical data
PC3 Phase module critical data
PIP Controller Control PCB
PC4 Fluid delivery software module
PC5 PIP Controller setup data retrieval
PC6 PIP Controller setup data storage
PD1 Pressure disc module software
PD2 Pressure Disc Pressure disc opto self test Pressure disc opto or Control PCB
PD3 Emitter in wrong state
PF1 Plunger fitment software module
Optos,Cables, Control PCB or
PF2 Plunger Fitment Gripper opto module software
Plunger assy.
PF3 Plunger button opto module software
PFM1 Profile storage failure
PFM2 Profile retrieval failure
PFM3 Profile Manager Profile startup failure Control PCB
PFM4 Profile data corruption
PFM5 Profile not found
PG1 Plunger gripper module software
Plunger gripper opto, Transmission
PG2 Plunger Grippers Plunger gripper opto self test
PCB, or Control PCB
PG3 Emitter in wrong state
PL1 Plunger drive software module
PL2 Alarm manager software module
Control PCB.
PL4 Plunger position monitor software If fault persists, contact your local
PL5 Motor software module CareFusion, Alaris Products service
representative
PL6 Syringe software module
PL7 User configuration option software
Plunger Drive Excessive plunger drive travel deviation when See next page.
PL8
stationary Perform Plunger Postion and
Syringe Force calibrations.
Carriage assembly, Motor plate,
Linear Potientiometer.
PL9 Excessive plunger drive travel deviation when in motion
If fault persists, contact your local
CareFusion, Alaris Products service
representative
1000SM00024 Issue 4 32/80

Troubleshooting
PL8 / PL9 Error

Introduction
PL8 and PL9 are alarm codes code that are triggered when the Pump observes deviation within the linear measurement system.
Deviation is calculated between the measured value (linear potentiometer) and the calculated values derived from the motor travel. The
alarms are designed to detect failures within the transmission.
Failure causes
• Worn half nut
• Fluid ingress on or around the linear potentiometer
• Loose motor plate bearing
• Contact resistance linear potentiometer/Chassis PCB
Diagnosis
To establish where the fault lies perform the following test and checks:
• Perform precondition test as detailed in the Syringe Force Calibration procedure see Chapter 2, Configuration and Calibration. If
the Pump does not reach 10kgf this would indicate a worn half nut.
• Perform test on the drive engage function to indicate if the Carriage PCB is incorrectly positioned or if there is slight wear of the
half nut. From the Self Test 123 select Sensor and then Drive Engage. Whilst slowly declutching the plunger ensure there is no
movement of the plunger until after the display shows Drive Disengaged.
• Open the case and internally inspect the Pump for any signs of fluid ingress.
• With the case open and the mechanism not declutched, try to push the plunger in the direction shown in figure 1. Check that
there is no movement of the motor plate bearing (figure 2). If there is movement this would indicate a loose motor plate bearing.
Actions
Motor Plate
bearing
Figure 1 Figure 2
• Replace the carriage assembly (1000SP01107) if the half nut is worn, as indicated by precondition test.
• Reposition the Carriage PCB if the Drive Engage test fails. Move Carriage PCB by loosening the screw, slide the Carriage PCB and
retighten the screw. The correct position of Carriage PCB can be confirmed by repeating the Drive Engage test.
• Replace the motor plate (1000SP01799) if the motor plate has a loose motor plate bearing.
• Replace any parts damaged by fluid ingress.
• Perform Plunger Position and Syringe Force calibrations, see Chapter 2, Configuration and Calibration.
• Testing must be performed in accordance with the Performance Verification Procedure (PVP), see Chapter 3, Preventative
Maintenance.
1000SM00024 Issue 4 33/80

Troubleshooting

PM1 Pressure measurement software
PM2 Pressure sensor
PM3 Syringe force
PM4 Pressure Measurement User configuration options Control PCB
PM5 Syringe
PM6 Setup retrieval failure
PM7 Setup storage failure
PP1 Plunger position monitor software
Control PCB
PP2 ADC
Plunger position linear
PP3 Plunger position sensor
Plunger Position potentiometer.
PP4 Monitor Plunger position sensor calibration Calibrate linear travel
PP5 Plunger position cal data retrieval
PP6 Plunger position cal data storage Control PCB
PP7 Drive engagement software
PS1 Pressure sensor software module
Control PCB
PS2 ADC
PS3 Current reading invalid
PS4 Voltage (Normal) reading invalid Pressure sensor or Control PCB
PS5 Voltage (Test) reading invalid
Pressure Sensor
PS6 Pressure sensor calibration Calibrate pressure sensor
PS7 Pressure sensor cal data retrieval
Control PCB
PS8 Pressure sensor cal data storage
PS9 Pressure sensor amplifier gain
Pressure sensor or Control PCB
PS10 Pressure sensor shift failure
SC1 Syringe clamp software module
Control PCB or syringe clamp
SC2 ADC
potentiometer
SC3 Syringe clamp sensor readings
Syringe Clamp
SC4 Syringe clamp calibration Calibrate syringe clamp
SC5 Syringe clamp cal data retrieval
Control PCB
SC6 Syringe clamp cal data storage
SD1 Service data file retrieval
SD2 SD Data Service data file storage Perform Cold start. Control PCB
SD3 Service data file contents
SF1 Syringe force sensor software
Control PCB
SF2 ADC
SF3 Syringe force sensor current reading
SF4 Syringe force sensor normal reading Motor plate or Control PCB
SF5 Voltage (test) reading
Syringe Force
SF6 Syringe force sensor calibration Calibrate syringe force
SF7 Syringe force cal data retrieval
Control PCB
SF8 Syringe force cal data storage
SF9 Syringe force sensor amplifier Motor plate or Control PCB
SF10 Syringe force output Calibrate syringe force. Motor plate.
1000SM00024 Issue 4 34/80

Troubleshooting

SP1 Safety processor program memory
SP2 Safety Processor Safety processor ID version Control PCB
SP3 Safety processor
SV1 Service Log software module
SV2 File storage software module
SV3 Log read index
SV4 Log write index
SV5 Log data read
SV6 Log data write
SV7 Service Log Log data seek Control PCB
SV8 Log repair failure
SV9 Log format failure
SV10 Log reporting failure
SV11 Log extracting failure
SV12 Log pack failure
SV13 Log unpack failure
SY1 Syringe manager software module
SY2 Syringe clamp Control PCB
SY4 Plunger fitment
SY5 Plunger button stuck in Check plunger button. Control PCB.
Syringe Manager
SY6 Syringe data table retrieval
SY7 Syringe data table storage
Control PCB
SY8 Syringe configuration retrieval
SY9 Syringe configuration CRC
TC0 No fault found
TC1 TCI data corruption
TC2 TCI not configured
Contact your local CareFusion, Alaris
TC3 PK / TCI TCI incorrect state
Products service representative
TC4-12 PK Model error 4-12
TC13 PK Model parameters error
TC14 PK Model init error
UC1 User config. option file retrieval
UC2 User config. option file storage Control PCB
User Config. options
UC3 User config. option data retrieval
UC4 User configuration model Perform Cold start
UT1 User timer master clock
User Timer Control PCB
UT2 User timer software request
1000SM00024 Issue 4 35/80

Troubleshooting
Exception error handling

Exception errors, include Assertion Errors and Enum Failure Errors, are used to trap logical errors in the software execution.
The Pump will display the error type, the title of the software module in which the error occurred and the line number. The user should
make a note of these for use in diagnosis. This information is stored in the service log (access code 376).
After an error, the Pump will not store information when powered down. When the Pump is switched on again, the user should always
confirm clear setup if this is not done automatically.
General fault diagnosis

Parts to Check/Test
Labels and Keypads
AC power Lead
Control PCB
Display PCB
Mechanism
Power PCB
Front Case
Rear Case
Battery
Fuses
Dropped or damaged      
Exposed to fluids          
General Fault
No battery power   
No AC power power     
Delivery rates out of tolerance   
1000SM00024 Issue 4 36/80

Circuit Descriptions
5 Circuit Descriptions
Functional module block diagram
Transmission
Control PCB
Start/Stop Linear Travel

J13
Keypad Potentiometer
Keypad
Rate/Soft
J14
and LED Transmission
J8
Keypad Motor
Indicators Interface Plate
Function
J15
Keypad
J4 PL5
Real-time Chassis PCB

Display
Display Clock
IrDA
J16
PCB and
Backlight
CCFL
J1 J2
Backlight
Backup
Battery
Syringe sizing Syringe

J9
potentiometer Clamp
Safety
Main Processor
Processor Carriage PCB
Main Audio
J18
Audio Alarm Backup PL1

Speaker
Speaker
Plunger
Pressure
Pressure PCB
J11
Transducer
Transducer
(Model CC)
Stepper
J7
Motor Drive Motor
RS232/ Battery with

J2
Nurse Call Power Gas Gauge AC

J6
Distribution power
Serial
Inlet
Comms (Battery
Charger)
Programme Power PCB
J1
Header
1000SM00024 Issue 4 37/80

Module overview functional description

The Alaris Syringe Pumps are designed to be serviced generally to major assembly level. The PCBs are designed as non-serviceable
items and as such, can only be replaced as complete parts.
The major assemblies are:
• Control PCB
• Power Supply Unit PCB
• Display PCB
• Battery
• Transmission
• Transducer (Model CC)
CareFusion will make available, on request, circuit diagrams which will assist appropriately qualified technical personnel to repair those
parts of the device which are designated by the manufacturer as repairable.
Control PCB
Contains the main processor module, which provides the control functions for almost all aspects of the Pump. It drives and monitors
all other modules using the program code stored in the flash eprom. The main processor runs the main application program. The main
processor directly interfaces to:
• Safety Processor
• Keypads
• Display
• Real Time Clock
• Communications Switch to IrDA and RS232 (optional) interfaces
• Nurse Call Output
• Indicator LEDs
• Audible Alarm
• Motor – controller and dual channel coil driver DAC
• System Sensors (including: syringe clamp, plunger position, drive engagement opto, plunger button opto, syringe force sensor,
line pressure sensor, pressure disc opto, motor encoder, AC power).
• Backlight
• Power supply
• Battery gas gauge
The function of the Safety Processor Module is to ensure the correct operation of the Main Processor by constantly exchanging data. If
an error is detected, the module can independently disable the stepper motor that drives the transmission. Additionally, it can create
both audible and visible alarms using its dedicated piezoelectric buzzer, alarm LED and, if fitted, the Nurse Call Interface.
The Safety Processor controls (independent of main processor):
• Audio sounder
• Visual indicator LED
• Control signal to inhibit motor drive
• Power supply hold up control
Pressure Transducer (Model CC)

Monitors the line pressure when the pressure disc is inserted and flags the presence of a pressure disc. The Control PCB checks the
transducer for presence of a pressure disc and the line pressure when a disc is present.
Power Supply Unit PCB

The Power Supply Unit (PSU) is a single output switched-mode power supply rated at 15 VDC/1.6 A continuous duty. The PSU has a wide
input voltage range of 85 to 264VAC, 47-63 Hz single phase.
Display PCB
The Pump uses a Cold Cathode Fluorescent Lamp (CCFL) as a backlight for the negative mode LCD display. The CCFL Backlight Supply
Module generates the high voltages required to drive the lamp and facilitates software based brightness control.
1000SM00024 Issue 4 38/80

Battery
The Battery Pack Module provides system power in the absence of a AC power supply.
The Battery Pack Module consists of six 1.2V 2.7Ah NiMH battery cells connected in series, a thermal fuse, thermal circuit breaker and Gas
Gauge Module sealed in a heat shrink sleeving.
The Gas Gauge Module is permanently connected across the battery terminals so that it can monitor terminal voltage, charge /
discharge current and the battery pack temperature.
Through charge monitoring information, from the Gas Gauge Module, the Control PCB Main Processor Module determines the battery
charge level and hence ‘Battery Low’ and ‘Battery Empty’ conditions.
Battery capacity will reduce over time.
Battery calibration will update the Gas Gauge Module with ‘up to date’ battery capacity information.
If the battery pack fails to achieve the calibration limits, it is recommended that the battery pack is replaced and calibration performed.
Transmission
The Transmission Interface Module provides the Pump with the capability of monitoring a number of critical parameters associated with
the transmission operation. The device can detect failures or incorrect operation of the transmission and prevent incorrect drug dosage
administration.
The electronics for this module occupy three separate PCBs that are located in various areas of the transmission as follows:
Plunger PCB Located inside the Plunger Holder Assembly. Contains the electronics that detect correct syringe plunger
location and gripper motion.
Carriage PCB Located on the Transmission Carriage. Contains electronics that detect correct engagement of the Half Nut
with the Leadscrew.
Chassis PCB Located on the Chassis Extrusion. This facilitates measurement of motor speed, syringe drive force and linear
plunger position. Additionally, the IrDA compliant infrared transceiver is positioned on the reverse side of
this PCB. The stepper motor which drives the mechanical transmission of the Pump is controlled by the Motor
Drive module on the Control PCB.
1000SM00024 Issue 4 39/80

Corrective Maintenance
6 Corrective Maintenance
This chapter contains procedures required to properly disassemble, repair and replace parts and then to reassemble the Pump.
Following all spare part replacement and repair activities, testing must be performed in accordance with the Performance Verification
Procedure (PVP), see Chapter 3, Preventative Maintenance. Additional testing and calibration may be required after certain repairs are
completed, see table below for more information.
Ensure the Pump is disconnected from the AC power supply and switched off before attempting to service.
A The Pump contains static-sensitive components and therefore strict ESD precautions should be observed at all
times.
Always protect the plunger holder and syringe clamp when the Pump is upside down. For regular servicing, the use
of the case support cradle Part No. 0000JG00047 is recommended.
Batteries should be disposed of as outlined by the local country regulations. Do not send batteries back to the
manufacturer.
For fastener torque settings, please refer to Appendix Fitting and Replacement guidelines.
Only use CareFusion recommended spare parts.
Repair/Replacement of
Syringe Size clamp /
Pressure Transducer
Labels and Keypads
potentiometer
Control PCB
Display PCB
Chassis PCB
Mechanism
Power PCB
Front Case
Rear Case
Battery
Performance Verification Procedure           
Battery Calibration  
Test/calibration to perform
Syringe Clamp Calibration   

Plunger Position Calibration     
Line Pressure Calibration   
Syringe Force Calibration     
 = Required
Blank = Optional
1000SM00024 Issue 4 40/80

Access to Pump
Replacement Procedure
1. Remove the two case screws in battery cover, remove cover and battery.
2. Remove the six case screws.
3. Model CC only: Insert a flat-blade screwdriver into the blanking plug of transducer, prise plug away from transducer and remove
securing screw.
4. Carefully separate case halves and disconnect cables.
5. Where necessary, remove the foot rivets with a flat-blade screwdriver and remove the feet from the case. Refer to additional
information on the following page concerning rivet orientation.
6. Reassemble in reverse order.
(H/F) Case Screws
C Blanking Plug
View a
B Battery Cover
I Feet
E Rear Case
D Front Case
A Battery
Note: It is essential that the battery pack is calibrated after fitting as failure to
do so will degrade the quoted auxiliary battery power on this product.
Item Description Part Number

a Primary Battery (SP) 1000SP01798
b Alaris SP, Battery Cover/Handle Kit 1000SP01121
c Alaris CC, Transducer Blanking Plug 1000ME01317
d Alaris SP MK4 Front Case Kit GH 1000SP01664
Alaris SP MK4 Front Case Kit CC 1000SP01665
Alaris SP MK4 Front Case Kit GH GR 1000SP01666
Alaris SP MK4 Front Case Kit CC GR 1000SP01667
Alaris SP MK4 Front Case Kit PK Plus 1000SP01909
Alaris SP MK4 Front Case Kit Enteral Plus 1000SP01919
e Alaris SP MK4 Rear Case Kit GH 1000SP01662
Alaris SP MK4 Rear Case Kit CC 1000SP01663
Alaris SP MK4 Rear Case Kit PK Plus 1000SP01910
Alaris SP MK4 Rear Case Kit Enteral Plus 1000SP01920
f Alaris SP, Main Case Screws x80 1000SP01325
g Alaris SP, Case Sealing Cord (1M) (internal, not shown) 1000ME00311
h Alaris SP, Fixings Kit (screws, washers etc) 1000SP00466
i Alaris SP, Adhesive Foot Kit 1000SP00595
1000SM00024 Issue 4 41/80

Pressure Transducer View a
Captive Nut
Blanking Plug
Screw
Pressure Transducer
1000SM00024 Issue 4 42/80

Rear case and subassemblies

Power Supply Unit and Speaker
1. Disconnect the PSU cable.
2. Remove the three PSU screws.
3. Remove earth wire tab.
4. Remove PSU and insulator.
5. Unbend the cable clips.
6. With a pair of soft-faced pliers, carefully compress the catch holding the internal speaker and pull the speaker up and out.
C PSU Screws
B PSU
A Speaker
Cable Clip

a Alaris SP, Main Speaker Kit 1000SP01130
b MK4 PSU Assy 1000SP01609
c Alaris SP, Fixings Kit (screws, washers etc) 1000SP00466
d Alaris SP, PSU Cable Assembly (not shown) 1000SP00094
1000SM00024 Issue 4 43/80

AC power inlet, PE stud and magnet
1. emove two nuts to remove PE stud.
R
2. Remove the two screws on AC power inlet.
3. Remove AC power inlet and retainer.
4. Remove magnet by lifting one end.
Retainer
B AC power Inlet
C Magnet
E AC power Inlet Retainer Screws

a ALARIS SP/LVP PE STUD KIT (not shown) 1000SP00467
b Alaris SP MK4 Mains Inlet Kit 1000SP01653
c Alaris SP/GP/GW, Magnet - Pump Detect 1000ME01303
d FUSE, ANTISURGE, 1.25A - 02131.25MXP (not shown) 0000EL00993
e Alaris SP, Fixings Kit (screws, washers etc) 1000SP00466
1000SM00024 Issue 4 44/80

Pole clamp and RS232
1. Remove three pole clamp screws.
2. Remove two tube restraint screws.
3. Remove two nuts and washers from RS232 socket screws.
4. Unbend cable clips.
C RS232 Socket Connector

B Tube Restraint RS232
A Pole clamp
D
Restraint
screw
D Pole Clamp screw
The Pole Clamp Arm material has been changed to a stronger material to prevent the arm from bending when
tightened.
The Pole Clamp Arm spares kit replaces parts of the Pole Clamp assembly to address bent or slipping Pole
Clamps. Note: There is no requirement to remove the V Clamp.
V Clamp (remains fixed to Apply small amount of Castrol

the Pump case). LMX grease to this surface.
Apply Loctite 270 here.

Spring
D Arm clamp
Ball Bearing
D Modified Knob
Pole Clamp Screw. Pivot Screw (Torque to 2Nm
using Driver)
Apply Loctite 270 here.

a Alaris SP/LVP Pole Clamp 1000SP00115
b Alaris SP, RS232 Tube Restraint 1000ME01214
c Alaris SP MK4 RS232 Connector Kit 1000SP01654
d Alaris SP, Fixings Kit (screws, washers etc) 1000SP00466
1000SM00024 Issue 4 45/80

Rail cam
1. Remove screw from lever release.
2. Remove screw from lever rail cam.
3. Remove locking washer from spring.
D V-Seal
C Lever Release
A Rail Cam Kit
V-Seals Orientation
B Cam Rail
Clamp Kit
Check the Lever Release V-Seal for cracking if fluid ingress is suspected. Replace any cracked V-Seal with new
seal, spares kit 1000SP01747, and also apply Sapphire Aqua-Sil Silicone Grease or equivalent. The addition of
the silicone grease extends the life of the V-Seal when exposed to certain cleaning chemicals.

a Alaris SP, Rail Cam Kit 1000SP01114
b ALARIS SP/LVP RAIL CAM KIT 1000SP01323
c Alaris SP, Cam Release Lever Only Kit 1000SP01324
d Alaris Lever Release V-Seal Kit 1000SP01747
1000SM00024 Issue 4 46/80

Front case and subassemblies

Control PCB
1. Remove the retaining screw and disconnect all flexi and cable connections.
Note: When fitting
Control PCB ensure
all flexi and cables are
routed clear of PCB.
A Control PCB
B Retaining screw
A Cold Start operation (611) should be performed on the Pump, when a new Control PCB has been fitted and prior
A to calibrating the Pump.

a Alaris GH Plus Control PCB Spares Kit 1000SP01947
a Alaris GH Plus GR Control PCB Spares Kit 1000SP01948
a Alaris CC Plus Control PCB Spares Kit 1000SP01949
a Alaris CC Plus GR Control PCB Spares Kit 1000SP01950
a Alaris PK Plus Control PCB 1000SP01607
a Alaris Enteral Plus Control PCB 1000SP01604
b Alaris SP, Fixings Kit (screws, washers etc) 1000SP00466
1000SM00024 Issue 4 47/80

Display PCB
1. Remove the four display fixing screws.
3. Secure the shelf keypad flexi to the display using double-sided adhesive pad.
C Screws (x4)
A Display PCB
B Gasket

a Alaris SP MK4 Display PCB Kit 1000SP01655
b Foam Gasket MK4 1000ME02061
d* Pad Self-adhesive Double-sided 12x12mm 0000ME00423
* (not shown on back of Display PCB)
1000SM00024 Issue 4 48/80

Chassis PCB and Plunger assembly
1. R emove the two Chassis PCB screws. Disconnect all cables.
2. Extend the plunger out to its full extent and fully loosen the two plunger retaining screws in the carriage.
3. Carefully remove the plunger flexi from the carriage PCB and straighten. While applying controlled force to the plunger, extract it
from the carriage and withdraw it completely.
C Plunger Screw x2 C Chassis PCB Screw x2 A Chassis PCB
Carriage PCB
B Plunger Flexi
Note: When fitting

Chassis PCB ensure
all flexi and cables are
routed clear of Motor
Encoder..

a Mk4 SP Chassis PCBA Spares Kit 1000SP01925
b Alaris SP, Plunger Assembly Kit (not shown) 1000SP01113
1000SM00024 Issue 4 49/80

Chassis assembly and Pressure Transducer (Model CC only)
1. Carefully peel away the label on the bottom of the front case to gain access to the chassis screw. Remove this screw.
2. Remove the two screws securing the syringe flange clamp.
3. Carefully withdraw the chassis.
4. Remove the two screws from the pressure transducer assembly and carefully withdraw (Model CC only).
A Chassis
F Chassis Insulator
C Pressure
Transducer
B Syringe Flange Clamp (2 piece)
B Flange Clamp
Screws E Chassis
Screw
E Pressure Transducer
Screws (x2) D Label

a Alaris SP MK4 Chassis Kit 1000SP01801
a Alaris SP MK4 Chassis Only Kit 1000SP01658
b Alaris SP, Syringe Flange (2 piece) 1000SP00570
c Alaris CC, Pressure Transducer Assy MK4 1000SP01756
d Alaris SP, Chassis Screw Cover Label 1000LB00431
f Chassis Insulator Kit 1000SP01659
1000SM00024 Issue 4 50/80

Syringe Sizing assembly
1. R emove the syringe sizing retainer screws, case brace and retainer.
2. Remove the shim and discard, then lever the syringe sizing mechanism from the housing and withdraw the potentiometer.
3. Pull the syringe clamp back to its full extent. Carefully remove the bung, screw and washer. Pull hard on the syringe clamp to
remove.
4. Carefully lever the syringe sizing mechanism from the housing and pull through the case. Remove the shaft bearing and the v-ring
seal.
5. Secure the assembly loading jig to the syringe sizing mechanism. Fit the shaft bearing and v-ring seal onto the end of the jig.
6. Lay the assembly on one side, potentiometer to the left, wires exiting upwards. The injection 'pip' feature on the
pre-moulded shaft should be visible.
7. Fit the seal protector into the upper case and load the syringe sizing mechanism. Compress the v-seal against the protector.
E Retainer Screw x2
Retainer
B Syringe Sizing Mechanism
Shim
(If Required) C Syringe Sizing Clamp
Bung
Potentiometer
Apply Castrol LMX

Grease liberally
8. W ithdraw the protector and push the syringe sizing mechanism through the hole in the front case until the flat sides locate in the
case and the potentiometer aligns with the case recess. Ensure the moulding pip is located on the side.
9. Slide the shim component, if required, down the side wall of the syringe potentiometer recess. Bend the shim 'outward'.
10. Fit the syringe sizing retainer so that the shim is visible protruding from the retainer. Fit the case brace. Secure with two screws.
11. Remove the assembly loading jig.
12. The syringe shaft flats to be moved into the open position.
13. Fit the syringe clamp over the shaft, fit the screw, washer and bung into the shaft end.
1000SM00024 Issue 4 51/80

B Syringe Sizer Kit
A Cam Kit
F Syringe Clamp Jig D Potentiometer
Check for presence of shim if the potentiometer is the earlier type with blue casing. If shim is not fitted, or the
cam has sharp edges, fit the Cam Kit on reassembly. If the cam has sharp edges or the shim is folded incorrectly,
these may cause excessive wear of areas around the front case. Mechanical movement and small changes in the
syringe diameter can result in a syringe detect failure, which may occur if shim is not present or case is worn.
Potentiometers with black casing do not require a shim to be fitted. When replacing a potentiometer that had a
shim with a new potentiometer with black casing do not re-fit the shim.
Note: Replace the foot

last if replacing the case.
If fitting a new syringe
sizing mechanism, apply
generous amounts
of grease (CASTROL
LMX) to the slot of the
mechanism and lightly
grease the v-seal.

a Alaris SP, Syringe Sizing Cam Only Kit 1000SP00170
b Alaris SP, Syringe Sizing Kit 1000SP01407
c Alaris SP, Syringe Clamp Kit (see previous page) 1000SP01123
d Alaris SP, Syringe Sizing Potentiometer 1000SP01408
f Alaris SP, Syringe Clamp Jig 1000SP00481
1000SM00024 Issue 4 52/80

Chassis assembly breakdown
1. Remove the pulley nut, washers and withdraw the pulley and toothed belt.
2. Remove three screws securing stepper motor.
3. Remove the leadscrew by driving out the roll pin using a suitable punch.
4. Remove three screws securing motor plate.
5. Remove three screws securing bearing block.
6. Remove the diablo bearing.
7. Refit plunger into carriage, declutch plunger and withdraw plunger and carriage. Hold linear potentiometer actuator and spring on
the side of the carriage.
8. Remove one screw holding carriage PCB.
D Chassis
A Chassis Assembly
E Carriage PCB
Linear Potentiometer
Diablo Bearing
I Bearing Block
B Motor
H Carriage
J Leadscrew
G Bearing Block Screw x3

G Motor screw x3 C Motor Plate
G Motor Plate Screw x3
1000SM00024 Issue 4 53/80


a Alaris SP MK4 Chassis Kit 1000SP01801
b MK4 Motor Assembly 1000SP01611
c Alaris SP, Motor Plate Kit 1000SP01799
d Alaris SP MK4 Chassis Only Kit 1000SP01658
e SP Carriage PCBA Spares Kit 1000SP01924
f Alaris SP, Strain Beam Support 1000SP00408
g Alaris SP, Fixings Kit (screws, washers etc) 1000SP00466
h Alaris SP, Carriage Kit 1000SP01107
i Alaris SP, Bearing Block Kit New Chassis 1000SP01478
j Alaris SP, Leadscrew Kit 1000SP01327
1000SM00024 Issue 4 54/80

Plunger assembly breakdown
1. R emove three screws holding plunger backplate.
2. Remove components as required. Follow diagrams step ii to step ix.
ii
H Backplate
E Backplate screws
G Plunger Fixings kit
I Intermediate tube
iii iv
F Alaris SP, Plunger Declutch Gear

a Alaris SP, Plunger Assembly Kit 1000SP01113
(Complete Plunger Assembly, not shown)
b SP Plunger PCBA Spares Kit 1000SP01923
c Alaris SP, Plunger Gripper Arm Bottom 1000ME01218
d Alaris SP, Plunger Gripper Arm Top 1000ME01219
f Alaris SP, Plunger Declutch Gear 1000ME01198
g Alaris SP, Plunger Fixings Kit 1000SP01320
h Alaris SP, Plunger Back Plate Kit 1000SP01321
i Alaris SP, Intermediate Tube 1000SP01322
j Plunger Spring B/Plate X 10 (Inside Backplate, not shown) 1000SP01589
k Plunger Gear Spare Kit x10 1000SP01632
l Declutch Tube Holder Spares Kit x10 1000SP01633
1000SM00024 Issue 4 55/80

v
C Gripper Bottom
vi
K Plunger Gear
D Gripper Top
G Plunger Fixings kit
vii a
Ensure flexible circuit exits via this slot
B Plunger Detect PCB
View on arrow a
viii ix
Ensure Keyway locates correctly

between these 2 parts
Feed flexible circuit

through this slot after L Declutch Tube Holder
routing as shown
1000SM00024 Issue 4 56/80

Pressure Transducer Assembly (Model CC only)

The following instructions detail the fitting of the Pressure Transducer Assembly.
1. Fit the mylar gasket.
D Mylar Gasket
2. A
lign the hole in the gasket with the hole in the centre disc holder and
ensure label is square to the Centre Disc Holder.
3. Use a clean wipe and apply pressure to the mylar gasket.
4. C
rease the mylar gasket along the ledge of the centre disc holder and
ensure it is well adhered along the front face of the step edge.
5. Load the spring onto the disc-detect flag shaft.
6. L ocate spring arms to spring retainer on the flag and to the recess in Centre Disc Holder
the disc holder top.
7. Rotate and install the plastic flag.
8. Fit the sealing cord starting at the break bar.
9. Load the disc holder centre onto the disc holder top.
10. Secure disc holder centre to disc holder top using
screw.
11. Load pressure transducer into assembled housing.
Sealing Cord 12. Once the PCB is located, apply pressure over the
sensor area of the PCB to ensure good location.
E Centre Disc Holder
D Flag
C Transducer Screw x4
E Centre Disc
B Top Disc Holder Holder
13. Slide the flexible circuit ferrite into place and ensure the flexible circuit Ferrite
is formed at 90° to the PCB.
14. Lower the Base Disc Holder onto the Centre Disc Holder.
15. Secure the base with the screws.
16. Use a lint-free cloth and approved cleaner to wipe the surface clean.
17. Start the gasket at the pointed end. Work around the perimeter and
minimise the gap at the join (if using cord - N/A if using single-piece
gasket).
A Pressure Transducer

a Alaris CC, Pressure Transducer Assy MK4 1000SP01756
b Alaris CC, Pressure Disc Holder 1000ME00450
d Alaris CC, Pressure Sensor Parts Kit 1000SP01326
e CC Housing Plastic Kit 1000SP01590
1000SM00024 Issue 4 57/80

Keypads and labels

1. Discard any keypads removed as they cannot be reused.
2. Ensure all residual adhesive is removed from bonding surfaces.
3. Fit replacement keypads after removing backing paper from underside. Handle replacement keypads carefully to avoid damage.
4. Apply finger pressure to keypads working from one end, to drive the air out of the adhesive/case interface.
5. Remove label(s) from case as required.
6. Clean case where replacement label(s) to be fitted.
7. Fit replacement label(s) taken from label sheet as required.
8. Ensure all keypad membrane flexi tails are routed and secured with double sided adhesive pads (0000ME00423).
To ensure an effective case fluid seal, ensure the top 5mm edge of the shelf keypad is given careful attention as
A described in step 4 above.
(A/C) Keypad
Top Edge
(A/B) Keypad
(A/D) Keypad

a Alaris SP MK4 Keypad Kit PK Plus 1000SP01908
Alaris SP MK4 Keypad Kit GH/CC 1000SP01660
Alaris SP MK4 Keypad Kit Enteral Plus 1000SP01918
b Alaris SP PK Plus MK4 On/Off Keypad Kit 1000SP01911
Alaris SP MK4 On/Off Keypad Kit 1000SP01661
Alaris SP Enteral Plus MK4 On/Off Keypad Kit 1000SP01921
c Alaris GH/CC/TIVA, Keypad - Shelf 1000LB00626
Alaris PK , Keypad - Shelf 1000LB01404
Alaris Enteral Keypad - Shelf 1000LB01526
d Two Layer Options Lbl - GH CC 1000SP01647
Two Layer Options Lbl - PK Plus 1000SP01906
Two Layer Options Lbl - Enteral Plus 1000SP01917
1000SM00024 Issue 4 58/80

C
A
Note: Item A additionally
provides a clear
window for the
combined serial
number and status
label Part No.
1000LB00590.
Note: Item B also available separately.

Part No. 1000LB00431
E
D
B (one spare)
C
E
A
PL
M
E
SA
Picture shows Alaris PK Plus Syringe Pump Label Set. Refer to the following model types for correct label set.
Alaris GH Plus Label Set MK4 (Made in UK) 1000LB01615
Alaris GH - GR Plus Label Set MK4 (Made in UK) 1000LB01616
Alaris CC Plus Label Set MK4 (Made in UK) 1000LB01617
Alaris CC - GR Plus Label Set MK4 (Made in UK) 1000LB01618
Alaris GH Plus Label Set MK4 (Made in Romania) 1000LB01645
Alaris GH - GR Plus Label Set MK4 (Made in Romania) 1000LB01646
Alaris CC Plus Label Set MK4 (Made in Romania) 1000LB01671
Alaris CC - GR Plus Label Set MK4 (Made in Romania) 1000LB01672
Alaris PK Plus Label Set 1000LB01689
Alaris Enteral Plus Label Set 1000LB01697
1000SM00024 Issue 4 59/80

Note: Label A is a blank

combined serial number
and status label. Transfer
information from old label.
This label should be used in
conjunction with the clear
protective cover from the
universal label set.
The picture above shows the label set that is available as a separate item from the standard Alaris Syringe Pump label sets.
a Instrument Label 1”x1 1/2” 1000LB00590
Use in conjunction with universal label set.
1000SM00024 Issue 4 60/80

Appendix
7 Appendix
Electromagnetic Compatibility
Warning:
• The use of any accessory, transducer, or cable with the Alaris Syringe Pump other than those specified may result in increased
emissions or decreased immunity of the Pump.
• The Alaris Syringe Pump should not be used adjacent to or stacked with other equipment, however if adjacent or stacked use is
necessary, the Alaris Syringe Pump should be observed to verify normal operation in the configuration in which it will be used.
Caution:
• The Alaris Syringe Pump is a CISPR 11 Group 1 Class A Medical Equipment System and intended for use by healthcare
professionals only.
• Medical Electrical Equipment needs special precautions regarding EMC and needs to be installed, put into service and used
according to the EMC information provided in the accompanying documents.
• Portable and Mobile RF communications can affect Medical Electrical Equipment.
• Operating the Pump near equipment which radiates high energy radio frequencies (electro surgical or cauterizing equipment,
portable radios, cellular telephones, etc.) may cause false alarm conditions. If this happens, reposition the Pump away from the
source of interference or turn off the Pump and manually regulate the flow.
Guidance and Manufacturer’s Declaration – Electromagnetic Emissions

The Alaris Syringe Pump is intended for use in the electromagnetic environment specified below.
The customer or the user of the Alaris Syringe Pump should assure that it is used in such an environment.
Emissions Test Compliance Electromagnetic Environment – Guidance
CISPR 11 The Pump uses RF energy only for its internal function in the normal product
Group 1 offering. Therefore, its RF emissions are very low and are not likely to cause
RF Emissions any interface in nearby electronic equipment.
CISPR 11
Class A
RF Emissions
EN 61000-3-2 The Pump is suitable for use in all establishments, other than domestic, and
Class A
Harmonic Emissions those directly connected to the public low-voltage power supply network that
supplies buildings used for domestic purposes.
EN 61000-3-3
Voltage Fluctuations, Complies
Flicker Emissions
1000SM00024 Issue 4 61/80

Appendix
Guidance and Manufacturer’s Declaration - Electromagnetic Immunity

The customer or the user of Alaris Syringe Pump should assure that it is used in such an environment.
EN 60601-1-2
Immunity Test Compliance Level Electromagnetic Environment – Guidance
Test Level
Floors should be wood, concrete, or ceramic tile.

EN 61000-4-2 Electro-Static ±6 kV contact ±8 kV contact (Note 2)
Discharge (ESD) If floors are covered with synthetic material, the
±8 kV air ±15 kV air (Note 2)
relative humidity should be at least 30 %.
±2 kV for power
EN 61000-4-4 ±2 kV for power supply
supply lines AC power quality should be that of a typical
Electrical Fast Transient, Burst lines
±1 kV for input/ commercial or hospital environment.
(EFT) (Note 3) N/A (Note 4)
output lines
EN 61000-4-5 ±1 kV Line(s) to
Line(s) ±1 kV Line(s) to Line(s) AC power quality should be that of a typical
Power Line Surge
±2 kV Line(s) to ±2 kV Line(s) to Earth commercial or hospital environment.
(Note 3) Earth
Power frequency magnetic fields should be at

EN 61000-4-8 Power Frequency
3 A/m 400 A/m 50 Hz (Note 2) levels characteristic of a typical location in a
Magnetic Field (50/60 Hz)
typical commercial or hospital environment.
<5 % UT (Note 1) <5 % UT

(>95 % dip in UT) (>95 % dip in UT)
for 0.5 cycle for 0.5 cycle
AC power quality should be that of a typical

40 % UT 40 % UT commercial or hospital environment.
(60 % dip in UT) (60 % dip in UT) If the user of the Pump requires continued
EN 61000-4-11
for 5 cycles for 5 cycles operation during power AC power interruptions,
Voltage Dips, Short it is recommended that the Pump be powered
Interruptions, and Voltage from an uninterruptible power supply or a
Variations 70 % UT 70 % UT battery.
(Note 3) (30 % dip in UT) (30 % dip in UT)
for 25 cycles for 25 cycles The Pump does employ an internal short
duration battery.
<5 % UT <5 % UT
(>95 % dip in UT) (>95 % dip in UT)
for 5 sec for 5 sec
Note 1—UT is the AC power voltage prior to application of the test level.
Note 2—Compliance levels raised by EN 60601-2-24.
Note 3—Performed at the Minimum and Maximum Rated Input Voltage.
Note 4—CareFusion recommends using signal cables of less than 3 metres in length and this requirement is applicable only if signal
cables are 3 metres or more in length. (EN 60601-1-2:2002, Clause 36.202.4)
1000SM00024 Issue 4 62/80

Appendix
Guidance and Manufacturer’s Declaration—Electromagnetic Immunity
LIFE SUPPORT Equipment

The customer or the user of the Alaris Syringe Pump should ensure that it is used in such an environment.
EN 60601-1-2 Compliance
Immunity Test Electromagnetic Environment – Guidance
Test Level Level
Portable and mobile RF communications equipment should be
used no closer to any part of the Pump, including cables, than the
recommended separation distance calculated from the equation
applicable to the frequency of the transmitter.
Recommended Separation Distance
3.5
d = [-----] √P
EN 61000-4-6 3 V rms 10 V rms
V1
Conducted RF 150 kHz to 80 MHz (Note 3)
12
d = [-----] √P 80 MHz to 800 MHz
3 V/m
V2
EN 61000-4-3 80 MHz to 2.5 GHz 10 V/m
Radiated RF (Note 3)
12
d = [-----] √P 80 MHz to 2.5 GHz
E1
23
d = [-----] √P 800 MHz to 2.5 GHz
E1
where P is the maximum output power rating of the transmitter in

watts (W) according to the transmitter manufacturer and d is the
recommended separation distance in metres (m).a
Field strengths from fixed RF transmitters, as determined by an

electromagnetic site survey, b should be less than the compliance level
in each frequency range. c
Interference may occur in the vicinity of equipment marked with the

following symbol:
Note 1—At 80 MHz and 800 MHz, the higher frequency range applies.
Note 2—These guidelines may not apply in all situations. Electromagnetic propagation is affected by absorption and reflection from
structures, objects, and people.
Note 3—Compliance levels raised by EN 60601-2-24.
a
The compliance levels in the ISM frequency bands between 150 kHz and 80 MHz and in the frequency range 80 MHz to 2.5 GHz are
intended to decrease the likelihood that mobile/portable communications equipment could cause interference if it is inadvertently
brought into patient areas. For this reason, an additional factor of 10/3 is used in calculating the recommended separation distance
for transmitters in these frequency ranges.
b
Field strengths from fixed transmitters, such as base stations for radio (cellular/cordless) telephones and land mobile radios, amateur
radio, AM and FM radio broadcast, and TV broadcast cannot be predicted theoretically with accuracy. To assess the electromagnetic
environment due to fixed RF transmitters, an electromagnetic site survey should be considered. If the measured field strength in the
location in which the Pump is used exceeds the applicable RF compliance level above, the Pump should be observed to verify normal
operation. If abnormal performance is observed, additional measures may be necessary, such as re-orienting or relocating the Pump.
c
Over the frequency range 150 kHz to 80 MHz, field strengths should be less than 10 V/m.
1000SM00024 Issue 4 63/80

Appendix
Recommended Separation Distances for LIFE SUPPORT Equipment between portable and mobile RF communica-
tions equipment and the Alaris Syringe Pump
The Alaris Syringe Pump is intended for use in an electromagnetic environment in which radiated RF disturbances
are controlled.
The user of the Alaris Syringe Pump can help prevent electromagnetic interference by maintaining a minimum distance between
portable and mobile RF communications equipment (transmitters) and the Alaris Syringe Pump as recommended below, according
to the maximum output power of the communications equipment.
Separation Distance According to Frequency of Transmitter

m
Rated Maximum Output
Power of Transmitter 150 kHz to 80 MHz 150 kHz to 80 MHz 80 MHz to 800 MHz 800 MHz to 2.5 GHz
Outside ISM bands In ISM bands
W 3.5 12 12 23
d = [------] √P d = [------] √P d = [ ------] √P d = [------] √P
V1 V2 E1 E1
0.01 0.03 0.12 0.12 0.23

0.1 0.11 0.38 0.38 0.73
1 0.35 1.20 1.20 2.30
10 1.11 3.80 3.80 7.28
100 3.50 12.00 12.00 23.00
For transmitters rated at a maximum output power not listed above, the recommended separation distance d in metres (m) can be
determined using the equation applicable to the frequency of the transmitter, where P is the maximum output power rating of the
transmitter in watts (W) according to the transmitter manufacturer.
Note 1—At 80 MHz and 800 MHz, the separation distance for the higher frequency range apply.
Note 2—The ISM (Industrial, Scientific, and Medical) bands between 150 kHz and 80 MHz are 6.765 MHz to 6.795 MHz; 13.553 MHz to
13.567 MHz; 26.957 MHz to 27.283 MHz; and 40.66 MHz to 40.70 MHz.
Note 3—An additional factor of 10/3 is used in calculating the recommended separation distance for transmitters in the ISM
frequency bands between 150 kHz and 80 MHz and in the frequency range 80 MHz to 2.5 GHz to decrease the likelihood that mobile/
portable communications equipment could cause interference if it is inadvertently brought into patient areas.
Note 4—These guidelines may not apply in all situations. Electromagnetic propagation is affected by absorption and reflection from
structures, objects, and people.
1000SM00024 Issue 4 64/80

Appendix
Disposal
Information on Disposal for Users of Waste Electrical and Electronic Equipment
This U symbol on the product and/or accompanying documents means that used electrical and electronic products should not be
mixed with municipal waste.
If you wish to discard electrical and electronic equipment, please contact your CareFusion affiliate office or distributor for further
information.
Disposing of this product correctly will help to save valuable resources and prevent any potential negative effects on human health and
the environment which could otherwise arise from inappropriate waste handling.
Information on Disposal in Countries outside the European Union

This U symbol is only valid in the European Union. The product should be disposed of taking environmental factors into consideration.
To ensure no risk or hazard, remove the internal rechargeable battery and the Nickel Metal Hydride battery from the control board and
dispose of as outlined by the local country regulations. All other components can be safely disposed of as per local regulations.
Battery Removal
Remove the Main Battery

1. Remove the two case screws in battery cover.
2. Remove cover and battery.
Battery Cover
Remove the Battery on Control PCB

1. Remove the Control PCB from the Pump, see 'Spare Parts
Replacement Procedures'.
2. Remove the protective plastic cover from the Control PCB.
3. Remove battery from the Control PCB. Battery
Control PCB Reverse side
Battery
1000SM00024 Issue 4 65/80

Appendix
Spare Parts Listing

Electrical Parts Listing
Part Number Description
0000EL00993 FUSE, ANTISURGE, 1.25A - 02131.25MXP
1000SP01798 Primary Battery (SP)
1000SP01408 Alaris SP, Syringe Sizing Potentiometer
1000SP01130 Alaris SP, Main Speaker Kit
1000SP01756 Alaris CC, Pressure Transducer Assy MK4
1000SP01923 SP Plunger PCBA Spares Kit
1000SP01924 SP Carriage PCBA Spares Kit
1000SP00094 Alaris SP, PSU Cable Assembly
1000SP01607 Alaris PK, Control PCB MK4
1000SP01948 Alaris GH Plus GR Control PCB Spares Kit
1000SP01950 Alaris CC Plus GR Control PCB Spares Kit
1000SP01947 Alaris GH Plus Control PCB Spares Kit
1000SP01949 Alaris CC Plus Control PCB Spares Kit
1000SP01604 Alaris Enteral Plus Control PCB MK4
1000SP01655 Alaris SP MK4 Display PCB Kit
1000SP01925 Mk4 SP Chassis PCBA Spares Kit
1000SP01609 MK4 PSU Assy
1000SP01653 Alaris SP MK4 Mains Inlet Kit
1000SP01654 Alaris SP MK4 RS232 Connector Kit
Software
1000SP01905 Alaris PK Plus (MK4) V3.4.5 S/W CD
1000SP01748 Alaris SP, SMU V3.1.0.1
1000SP01930 Alaris GH/GH GR Plus MK4 V4.3.6 SW CD
1000SP01931 Alaris CC/CC GR Plus MK4 V4.3.6 SW CD
1000SP01916 Alaris Enteral Plus SP MK4 v4.4.0 S/W CD
1000SP01754 Alaris GH/GH GR Plus MK4 V4.1.8 S/W CD
1000SP01755 Alaris CC/CC GR Plus MK4 V4.1.8 S/W CD
1000SM00024 Issue 4 66/80

Appendix
Front Case Parts Listing

1000SP00595 Alaris SP, Adhesive Foot Kit
1000SP01123 Alaris SP, Syringe Clamp Kit
1000SP01407 Alaris SP, Syringe Sizing Kit
0000ME00423 Pad Self Adhesive Double Sided 12X12mm
1000ME00450 Alaris CC, Pressure Disc Holder
1000ME00311 Alaris SP, Case Sealing Cord (1M)
1000SP01326 Alaris CC, Pressure Sensor Parts Kit
1000SP00466 Alaris SP, Fixings Kit
1000SP00170 Alaris SP, Syringe Sizing Cam Only Kit
1000SP00570 Alaris SP, Syringe Flange (2 piece)
1000SP01590 CC Housing Plastic Kit
1000SP01664 Alaris SP MK4 Front Case Kit GH
1000SP01665 Alaris SP MK4 Front Case Kit CC
1000SP01666 Alaris SP MK4 Front Case Kit GH GR
1000SP01667 Alaris SP MK4 Front Case Kit CC GR
1000SP01909 Alaris SP MK4 Front Case Kit PK Plus
1000SP01919 Alaris SP MK4 Front Case Kit Enteral Plus
1000ME02061 Foam Gasket MK4
Rear Case Parts Listing

1000SP01121 Alaris SP, Battery Cover/Handle Kit
1000SP00595 Alaris SP, Adhesive Foot Kit
1000SP01114 Alaris SP, Rail Cam Kit
1000SP00115 Alaris SP/LVP Pole Clamp
1000ME01214 Alaris SP, RS232 Tube Restraint
1000ME01303 Alaris SP/GP/GW, Magnet - Pump Detect
1000ME01317 Alaris CC, Transducer Blanking Plug
1000SP00466 Alaris SP, Fixings Kit
1000SP00467 ALARIS SP/LVP PE STUD KIT
1000SP01323 ALARIS SP/LVP RAIL CAM KIT
1000SP01324 Alaris SP, Cam Release Lever Only Kit
1000SP01325 Alaris SP, Main Case Screws x80
1000SP00589 Alaris SP, Pole Clamp Arm Kit
1000SP01662 Alaris SP MK4 Rear Case Kit GH
1000SP01663 Alaris SP MK4 Rear Case Kit CC
1000SP01910 Alaris SP MK4 Rear Case Kit PK Plus
1000SP01920 Alaris SP MK4 Rear Case Kit Enteral Plus
1000SP01747 Alaris Lever Release V-Seal Kit
1000SP01294 Alaris SP mains Retainer Kit
1000ME02052 Enteral Pole Clamp 45 Degrees
1000SM00024 Issue 4 67/80

Appendix
Keypads and Labels

1000LB01689 Alaris PK Plus, Label Set
1000LB01615 Alaris GH Plus Label Set MK4 (Made in UK)
1000LB01616 Alaris GH - GR Plus Label Set MK4 (Made in UK)
1000LB01617 Alaris CC Plus Label Set MK4 (Made in UK)
1000LB01618 Alaris CC - GR Plus Label Set MK4 (Made in UK)
1000LB01645 Alaris GH Plus Label Set MK4 (Made in Romania)
1000LB01646 Alaris GH - GR Plus Label Set MK4 (Made in Romania)
1000LB01671 Alaris CC Plus Label Set MK4 (Made in Romania)
1000LB01672 Alaris CC - GR Plus Label Set MK4 (Made in Romania)
1000LB01697 Alaris Enteral Plus Label Set
1000LB00431 Alaris SP, Chassis Screw Cover Label

1000LB00590 Instrument Label 1”x1 1/2”
1000LB00626 Alaris GH/CC/TIVA, Keypad - Shelf
1000LB01404 Alaris PK, Keypad - Shelf
1000SP01911 Alaris SP PK MK4 On/Off Keypad Kit
1000SP01921 Alaris SP Enteral Plus MK4 On/Off Keypad Kit
1000SP01661 Alaris SP MK4 On/Off Keypad Kit
1000SP01647 Two Layer Options Lbl - GH CC
1000SP01906 Two Layer Options Lbl - PK
1000SP01917 Two Layer Options Lbl - Enteral Plus
1000SP01660 Alaris SP MK4 Keypad Kit GH/CC
1000SP01908 Alaris SP MK4 Keypad Kit PK Plus
1000SP01918 Alaris SP MK4 Keypad Kit Enteral Plus
1000SM00024 Issue 4 68/80

Appendix
Transmission Parts Listings

1000ME01218 Alaris SP, Plunger Gripper Arm Bottom
1000ME01219 Alaris SP, Plunger Gripper Arm Top
1000SP01611 MK4 Motor Assembly
1000SP01113 Alaris SP, Plunger Assembly Kit
1000SP01799 Alaris SP, Motor Plate Kit
1000SP01107 Alaris SP, Carriage Kit
1000ME01198 Alaris SP, Plunger Declutch Gear
1000SP00408 Alaris SP, Strain Beam Support
1000SP01320 Alaris SP, Plunger Fixings Kit
1000SP01321 Alaris SP, Plunger Back Plate Kit
1000SP01322 Alaris SP, Intermediate Tube
1000SP01327 Alaris SP, Leadscrew Kit
1000SP01478 Alaris SP, Bearing Block Kit New Chassis
1000SP01589 Plunger Spring B/Plate X 10
1000SP01659 Alaris SP MK4 Chassis Insulator Kit
1000SP01801 Alaris SP MK4 Chassis Kit
1000SP01632 Plunger Gear Spare Kit x10
1000SP01633 Declutch Tube Holder Spares Kit x10
1000SP01658 Alaris SP MK4 Chassis Only Kit
1000SM00024 Issue 4 69/80

Appendix
Test Equipment
1000SP00373 Alaris Calibration Kit
Includes:
1000TG00080 Linear Speed Test Gear Bom
0000JG00175 Syringe Sizing Shim
1000TG00010 Syringe Sizing Spacer Bom
1000TG00011 Syringe Sizing Spacer
0000JG00014 ASENA SP & P SERIES TEST PLUNGER PROTECT
0000TG00200 Digital Occlusion Test Gear (Cal)
0000TG00033 Test Gear Stopwatch
1000TG00095 Linear Sizing Spacer Bom
1000TG00055 Syringe Sizing Spacer Bom
1000TG00059 Linear Sizing Spacer Bom
5000SP00010 Spare Key Elec/mech P5000
0000TG00032 Test Gear Magnet PCAM
0000JG00047 Alaris SP, Case Cradle Jig

0000JG00053 ASENA SP, TEST, PE STUD SOCKET
1000SP01749 Alaris SP Mk4 Programming Header PCB
DEC001 Alaris SP/GW/GP, RS232 Cable, Pump to PC
1000SP00481 Alaris SP, Syringe Clamp Jig
1000ME01466 Alaris Pole Clamp, Snake Eye Driver
G30402M EXT SET, 200cm, P-DISC
0000EL00837 PROGRAMMER INFRA RED
1000SM00024 Issue 4 70/80

Appendix
Fitting and Replacement Guidelines

General assembly information
1. wide range of self-tapping fasteners are available.
A
2. PT screws are for plastic, self-tapping applications.
3. TAPTITE screws are for metal self thread-forming applications. These can be recognised by a triangular cross-section on the end.
4. Almost all fasteners on the Alaris Syringe Pumps are self-tapping and have the potential to be over-tightened (over-torqued).
5. The force required to create a thread for the first time is more than when reassembling a previously made joint.
6. Always use the correct torque level when first making an assembly stage.
7. Take care with the torque applied when re-assembling parts. Less torque is required, so a hand tool may be more appropriate.
8. In many situations a stripped thread will require replacement of the failed component.
9. The head patterns of the fasteners are of the following types:
• Pozi Number 1 (smaller X head)
• Pozi Number 2 (larger X head)
• Torx Number T8 (Small star profile, used typically on countersunk parts with smaller heads - Backplate / AC power Inlet / Carriage
PCB screw).
• Torx Number T10 (Medium star profile, used on the majority of Alaris Syringe Pump Torx fasteners)
• Torx Number T20 (Larger star shape, typically for case securing screws)
• M3 (Hex head with 5.5mm across flats (AF) drivers)
• M4 nuts (Hex head with 7mm across flats (AF) drivers)
10. Always select the correct tool and bit pattern for the fastener.
Torque guide
Note: Where a torque
level is not stated then
fixing should be hand
tight.
1. When selecting a torque for a servicing activity, be aware that refastening will require less torque than the initial manufacture.
2. Use this information as a guide to the 'do not exceed' torque levels when servicing the equipment. When servicing it is
recommended that torque is applied gradually until the component is secure. In any process do not exceed the stated levels.
3. If a torque driver is available for servicing this will help control the applied torque. Otherwise, be aware that excess force may cause
the component to fail.
Plunger Drive Assembly:
Stage Description Component Description Qty Established Process Torque
Intermediate Tube Bearing Plate Screw - PT K30x8 Pan Hd Torx (T10) 2 50 cNm
Fixing Gripper Gears Screw - PT K22x12 Pan Hd (T6) 2 50 cNm
Screw on the Backplate Assembly Screw - PT K30x12 Csk Torx (T8) Rogard 3 40 cNm
Main Chassis Assembly:
Mount motor onto motor plate Screw - M3x12 Pan Hd Torx (T10) 3 25 cNm
Mount motor plate to chassis assembly Screw - Taptite M4x10 Csk Pozi 3 1.1 Nm
Attach drive belt and leadscrew pulley Nut - M4 Full 1 40 cNm
Secure Carriage PCB to carriage Screw - PT K30x6 Csk Pozi 1 30 cNm
Secure carriage plate to carriage Screw - PT K30x6 Pan Hd Torx (T10) 1 40 cNm
Secure bearing block to chassis Screw - Taptite M4x10 Csk Pozi 3 1.1 Nm
1000SM00024 Issue 4 71/80

Appendix
Front Case Assembly:

Secure syringe sizing retainer Screw - PT K30x8 Csk Pozi 2 40 cNm
Attach syringe clamp Screw M3 x 8 Pan Hd Torx (T10) 1 50 cNm
Secure display / mounting brackets to front case Screw PT K30x12 Csk Pozi 4 40cNm
Secure syringe flange clamp to chassis / bearing Screw - PT K30x14 Pan Hd Torx (T10) 2 70 cNm
block
Secure chassis to front case Screw M3x8 Taptite Csk Pozi 1 50 cNm
Secure plunger drive to carriage Screw - PT K30x6 Pan Hd Torx (T10) 2 50 cNm
Secure RS232 option Spacer 8mm Hex Br/Ni Pl M3x6mm 4 hand tight
Nut M3 St. St A2 4 40 cNm
Screw M3x6 Pan Hd Pozi Z+C 4 40 cNm
Secure Control board Screw - M3x8 Pan Hd Torx (T10) 1 46cNm
Secure Chassis PCB to chassis Screw - M3x8 Taptite Pan Hd 2 75 cNm
Secure Model CC pressure transducer assembly Screw - PT K30x12 Pan Hd Torx (T10) 2 70 cNm
to front case
Assembly Rear Case:
Attach pole clamp to rear case Screw - M3x8 Pan Hd Torx (T10) 3 70 cNm
Attach pole clamp arm to pole v clamp Pivot screw 1 2 Nm
Secure rail clamp to cam Screw - PT K30x10 Csk Torx (T8) Rogard 1 65 cNm
Attach camera lever Screw PT K30x8 Pan Hd Torx (T10) 1 60 cNm
Secure AC power inlet assy to retainer Screw - PT K30x12 Csk Torx (T8) Rogard 2 30 cNm
Secure PE stud M6 Nut 2 hand tight
Secure PSU to case Screw - PT K30x8 Pan Hd Torx (T10) 3 30 cNm
Secure earth lead to PSU metal frame Screw M3x6 Pan Hd Pozi 1 hand tight
Fit tube restraint / RS232 cover Screw PT K30x8 Csk 2 40 cNm
Fit RS232 male / female connectors Jack Socket RS232 P8000 1 hand tight
Secure Model CC pressure transducer assembly Screw - M3x10 BTN Torx (T10) 1 20 cNm
to rear case
Final Assembly:
Secure front case to rear case Screw PT K40x12 Pan Hd Torx (T20) 6 125 cNm
Secure battery cover / handle Screw PT K40x12 Pan Hd Torx (T20) 2 90 cNm
Pressure Transducer Assembly for Model CC only:
Secure disk holder centre to top Screw PT K30x8 Pan Hd Torx (T10) 1 50 cNm
Secure disk holder base to centre Screw PT K30x8 Pan Hd Torx (T10) 4 50 cNm
1000SM00024 Issue 4 72/80

Appendix
Lockbox Accessory
The optional lockbox is a available in two configurations:
• Rate Unlocked lockbox (1000SP01884) - is designed to allow • Rate Locked lockbox (1000SP01885) - is designed to prevent
the user to adjust rate whilst infusing. rate change whilst infusing. If using this lockbox users would
need to put the Pump on hold and open the lockbox to
change the rate.
Lockbox Cleaning Instructions

Routine cleaning may be performed whilst lockbox remains on Pump. Thorough cleaning of Pump may require removal of the lockbox
assembly.
Tools required to remove lockbox cover and base plate:
• T20 Torx Driver
• 4mm Hex Driver
• Small Flat blade screwdriver
1. Remove clear cover by removing the two screws using a 4mm hex wrench;
set screws and compression spring aside for reassembly. Note the location
of the spring (between the clear cover and the Baseplate) and that the
longer screw is used on the right side.
2. Use recommended cleaners to clean cover, set aside.
3. Remove base plate by removing the screw on the lower right side of the
backside of Pump.
4. On the front right side, open cosmetic covers with a small screwdriver or
suitable tool to remove two screws with a Torx T-20 driver; sets aside for
reassembly.
5. Use recommended cleaners to clean base plate and external surfaces of
the Pump.
6. After Pump and lockbox are clean and completely dry, align the lockbox
Base Plate as before. Secure the rear arm of the Baseplate using the screw
removed in step 3. The technique that should be used on this [thread-
forming] fastener is to slowly turn the screw counter-clockwise until a click
is felt that engages the screw with the previously formed thread. Then turn
the screw clockwise and tighten to 1.0 ±0.1nm.
7. Secure the front of the Baseplate using the two screws with cosmetic
covers removed in step 4; do not tighten fully.
1000SM00024 Issue 4 73/80

Appendix
8. Before tightening the screws fully, rotate the screw cover so that the hinge
part of the cover is orientated at the 3 o’clock position. This will enable the
caps to be opened easily for future servicing; recommended torque is 1.0
±0.1nm.
9. To replace the clear cover, first insert the spring (removed in Step 1) into
the round spring hole (on the right side of the Baseplate). Then position
the clear cover over the spring and secure in place with the (longer) large
screw removed in Step 1. Install the remaining screw on the left side; the
recommended torque for both large screws is 2.5 ±0.1nm.
• Bumpers should be replaced as required

• Cosmetic screw covers should be replaced as required
The lockbox assembly is designed to be removed twice annually for thorough cleaning, if hospital protocol requires
A more frequent removal of the base plate for cleaning it may reduce the life of the Pump case.
1000SM00024 Issue 4 74/80

Appendix
Pump Battery Replacement

The following steps are needed to replace a battery in a Syringe Pump that has been fitted with the Lockbox Option:
1. Orientate the Syringe Pump/Lockbox on its back, on a non-skid work surface, and open the Lockbox Cover.
2. Use a long flat blade screwdriver or suitable tool to gently pry open the cosmetic screw covers, use a Torx T-20 to remove the two
screws and set screws aside for reassembly.
3. Close the Lockbox cover and invert the Syringe Pump/Lockbox onto its face.
4. Use a Torx T-20 to remove the two screws of the Battery Cover, and slide the Battery Cover to the left to gain access to the battery, set
screws aside for reassembly.
5. After servicing/replacing the battery, replace the Lockbox Battery Cover by engaging flanges and grooves, and sliding the cover to
the right.
NOTE: The lockbox is attached to the Syringe Pump using thread-forming screws. If the screws are overtightened, the Syringe Pump
can be permanently damaged. To prevent overtightening, it is recommended to use a torque driver and to adhere to the
torque values specified in the sections that follow.
NOTE: The recommended technique for re-installing a thread-forming screw is to place the screw in the hole and slowly turn it
counter-clockwise until a click is felt as the screw helix finds the previously formed thread. Then turn the screw clockwise and
tighten to the recommended torque. If the screws are overtightened, the Syringe Pump can be permanently damaged.
6. Secure the Battery Cover to the Syringe Pump by replacing the screws removed in Step 4 and tightening to 1.0 Nm ± 0.1 Nm (9.0 in-
lb. ± 0.9 in-lb.).
7. Invert the Syringe Pump/Lockbox onto its back.
8. Re-install the screws with cosmetic covers removed in Step 2, but do not tighten fully. Before tightening the screws, rotate the
cosmetic screw covers so that the hinge part of the cover is orientated at the 3 o’clock position after tightening, (this may require the
hinges to be orientated at 9 o’clock or 12 o’clock before tightening and rotating into position as the screw is tightened, etc.). This will
enable the covers to be opened more easily for future servicing; tighten screws to 1.00 Nm ± 0.1 Nm (9.0 in-lb. ± 0.9 in-lb.).
NOTE: The 3 o’clock position is a guideline to aid future servicing and is not critical to the function of the part. Covers are fully
functional should the hinge get rotated further or even get damaged or break.
9. Snap cosmetic screw covers shut until an audible click is heard. Open and close the Lockbox Cover a few times to ensure smooth
action before returning to service.
1000SM00024 Issue 4 75/80

Appendix
Lockbox Parts Replacement

Remove lockbox as per cleaning instructions.
A
E
B
I 2x
I2 x D
3x I
F
I

a Lockbox Battery Cover Spares Kit 1000SP01984
b Baseplate, Lockbox 1000ME02114
c Clear Cover, Titration (Without Key Cover) 1000ME02117
c Clear Cover, No Titration (With Key Cover) 1000ME02123
d Lockbox Lock Mechanism and Keys Kit 1000SP01983
e Spring, Lockbox Cover 0000ME00913
f Shoulder Screw, Right 1000ME02119
g Shoulder Screw, Left 1000ME02120
h Cover Stop Pin, Lockbox 1000ME02121
i Lockbox Fastener Spares Kit 1000SP01982
1000SM00024 Issue 4 76/80

Appendix
Service Contacts
For service, contact your local CareFusion Affiliate Office or Distributor.
AE DE HU PT
CareFusion, CareFusion, CareFusion, CareFusion,
PO Box 5527, Tullastr. 8-12 Döbrentei tér 1, Avda. São Miguel, 296 Atelier 14
Dubai, United Arab Emirates. 69126 Heidelberg, H-1013 Budapest, 2775-751 Carcavelos, Lisboa
Deutschland. Magyarország. Portugal
Tel: (971) 4 28 22 842 Tel: (49) 6221 305 0 Tel: (36) 1 488 0232 Tel: +351 219 152 593
Tel: (36) 1 488 0233
Fax: (971) 4 28 22 914 Fax: (49) 6221 305 216 Fax: (36) 1 201 5987 Fax: +351 219 152 598
AU DK IT SE
3/167 Prospect Highway, Firskovvej 25 B, Via Ticino 4, Hammarbacken 4B,
PO Box 355 2800 Lyngby, 50019 Sesto Fiorentino, 191 46 Sollentuna,
Seven Hills, NSW 2147, Danmark. Firenze, Italia. Sverige.
Australia.
Tel: (61) 1800 833 372 Tlf. (45)70 20 30 74 Tél: (39) 055 30 33 93 00 Tel: (46) 8 544 43 200
Fax: (61) 1800 833 518 Fax. (45)70 20 30 98 Fax: (39) 055 34 00 24 Fax: (46) 8 544 43 225
BE ES NL US
Erembodegem-Dorp 86 Edificio Veganova, De Molen 8-10, 10020 Pacific Mesa Blvd.,
B-9320 Erembodegem Avenida de La Vega, nº1, 3994 DB Houten, San Diego, CA 92121,
Belgium. Bloque 1 - Planta 1, Nederland. USA.
28108 Alcobendas, Madrid,
España.
Tel: +32 (0) 2 267 38 99 Tel: (34) 902 555 660 Tel: +31 (0)30 2289 711 Tel: (1) 800 854 7128
Fax: +32 (0) 2 267 99 21 Fax: (34) 902 555 661 Fax: +31 (0)30 2289 713 Fax: (1) 858 458 6179
CA FR NO ZA
235 Shields Court, Parc d’affaire le Val Saint Quentin Fjordveien 3 Unit 2 Oude Molen Business Park,
Markham, 2, rue René Caudron 1363 HØVIK Oude Molen Road, Ndabeni,
Ontario L3R 8V2, 78960 Voisins le Bretonneux Norge. Cape Town 7405, South Africa.
Canada. France
Tel: (1) 905-752-3333 Tél: (33) 01 30 02 81 41 Tel: (47) 64 00 99 00 Tel: (27) (0) 860 597 572
Tel: (27) 21 510 7562
Fax: (1) 905-752-3343 Fax: (33) 01 30 02 81 31 Fax: (27) 21 5107567
CH FI NZ
CareFusion, CareFusion, CareFusion,
A-One Business Centre Kuortaneenkatu 2, 14B George Bourke Drive,
Zone d’activitiés Vers-la-Pièce 00510 Helsinki Mt Wellington 1060,
n° 10 PO Box 14-518,
1180 Rolle / Switzerland Panmure 1741, Auckland,
New Zealand
Ph.: 0848 244 433 Tel: +358 207871 090 Tel: 09 270 2420
Freephone: 0508 422734
Fax: 0848 244 100 Fax: 09 270 6285
CN GB PL
康尔福盛（上海）商贸有限公司 CareFusion, Becton Dickinson Polska Sp. z o.o.
地址：上海市浦东新区张杨路 The Crescent, Jays Close, ul. Osmańska 14
500号24楼E.F.G.H单元 Basingstoke, 02-823 Warszawa
Hampshire, RG22 4BS, Polska.
United Kingdom.
电话： +86-21-60369369 Tel: (44) 0800 917 8776 Tel: (48) 22 377 11 00
400 878 8885
传真： +86-21-60369399 Fax: (44) 1256 330860 Fax: (48) 22 377 11 01 Rev. O
1000SM00024 Issue 4 77/80

Appendix
Document History
Issue Date Author Update Description
1 April 2016 Ian Tyler Initial release of MK4 TSM
2 May 2016 Ian tyler Correction of Alarm Presets
Update of spare parts
3 January 2017 Ian Tyler Section in Appendix for Lockbox Accessory
Updates to Preventative Maintenance and Troubleshooting sections
4 February 2017 Ian Tyler Update to Preventative Maintenance section
1000SM00024 Issue 4 78/80

Appendix
Software Upgrade Record

Please fill out the table below and return to the local CareFusion representative, see Service Contacts for address details, to ensure the
records are upto date so that any future product actions can be directed to the correct institution(s).
Hospital Name: Country:
Product SKU Serial Number Processor/Software Date Updated Comments/Reference

version after upgrade (dd/mm/yyyy) (e.g. Field Safety Notice number,
Information Notice number, etc.)
Signature: Name: Position:
1000SM00024 Issue 4 79/80

CareFusion, Alaris, Guardrails and the CareFusion
Logo are trademarks or registered trademarks of
CareFusion Corporation or one of its subsidiaries.
All rights reserved.
All other trademarks are property of their
respective owners.
© 2017 CareFusion Corporation or one of its
affiliates. All rights reserved.
CareFusion Switzerland 317 Sarl,

t A-One Business Centre, Z.A Vers –La-
Pièce n° 10, CH-1180, Rolle
CareFusion UK 305 Ltd., The Crescent,

EC REP Jays Close, Basingstoke, Hampshire,
RG22 4BS, UK
carefusion.com

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What is the purpose of this technical service manual?

What are some of the calibration procedures described in the manual?

What are some of the calibration procedures described in the manual?

Alaris™ Syringe Pump MK4

Technical Service Manual

1000SM00024 Issue 4 2/80

1000SM00024 Issue 4 3/80

1000SM00024 Issue 4 4/80

Purpose of this manual

1000SM00024 Issue 4 5/80

Conventions Used in this Manual

1000SM00024 Issue 4 6/80

Front panel and main display

Infusion Status Pressure Information** /

Infusion Rate Volume Infused

Controls and indicators

d OPTION button - Press to access optional features.

1000SM00024 Issue 4 7/80

2 Configuration and Calibration

Codes available on Alaris PK Plus Syringe Pumps:

Codes available on Alaris GH/CC/Enteral Plus Syringe Pumps:

1000SM00024 Issue 4 8/80

Handsfree Bolus (175)

Dedication options (301/302)

Data Set Activation (612)

Power Lock (711)

1000SM00024 Issue 4 9/80

Configuration options (251)

Enable Syringes (Enteral Plus only)

1000SM00024 Issue 4 10/80

Data Set Transfer

Download CQI Event Log (402)

Note: For more

1000SM00024 Issue 4 11/80

Calibration procedures (243)

SYRINGE CLAMP calibration

1000SM00024 Issue 4 12/80

PLUNGER POS (position) calibration

Note: If CAL is not displayed,

Channel for locking clip

1000SM00024 Issue 4 13/80

SYRINGE FORCE calibration

Note: To convert Kilograms

1000SM00024 Issue 4 14/80

Use of the 0000TG00200 Digital Occlusion Testgear.

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LINE PRESSURE calibration – Alaris CC Syringe Pump only

Dedicated pressure sensing disc extension set

50ml Luer-lock syringe Pressure Transducer Pressure gauge

1000SM00024 Issue 4 16/80

Value Description Pass Criteria

1000SM00024 Issue 4 17/80

1000SM00024 Issue 4 18/80

1000SM00024 Issue 4 19/80

IrDA power-down test

Software Versions available

1000SM00024 Issue 4 20/80

1000SM00024 Issue 4 21/80