Everything to Know About Infusion Pump Repair

Infusion pumps are among the most widely used devices in healthcare, delivering fluids, medications, and nutrients to vulnerable patients with precision and accuracy. From intensive care units to oncology clinics and even home care settings, these systems are relied upon daily for accurate, continuous therapy. Due to this critical role, an infusion pump failure is more than an inconvenience; it can disrupt patient care, delay treatments, and pose serious safety risks.

Like all biomedical equipment, infusion pumps require ongoing maintenance and occasional repair. For biomedical engineers, HTM professionals, and hospital operations teams, staying on top of pump performance means fewer emergencies, better patient outcomes, and reduced costs. This guide provides a comprehensive overview of common infusion pump problems, the repair process, and best practices to ensure your fleet is performing at its best. For a deeper dive, our post on types of infusion devices gives you a full picture of how these systems operate within modern healthcare.

What is an Infusion Pump?

First, what is an infusion pump? An infusion pump is a medical device designed to deliver fluids, medications, or nutrients directly into a patient’s body in carefully controlled amounts. Unlike manual IV drips, IV pumps provide precision and consistency, which is especially critical in high-risk therapies like chemotherapy, pain management, or neonatal infusions.

These devices are nearly universal across healthcare:

Hospitals and ICUs rely on this medical equipment for critical drug delivery, nutrition, and fluid management. In fact, by 2018, almost 89.5 percent of U.S. hospitals had already adopted smart infusion pump technology, underscoring the integral role they play in modern care.
Outpatient clinics use them for chemotherapy, specialty infusions, and pain management, where accuracy directly impacts treatment outcomes.
Home care programs are increasingly relying on ambulatory pumps that enable patients to maintain their independence while still receiving treatment.

Because these devices must run reliably around the clock, repair and maintenance programs are non-negotiable. Even seemingly minor problems, such as flow inaccuracies, can pose real safety risks. A 2023 systematic review found that pumps often face reliability challenges at low flow rates, making regular inspection and calibration essential for patient safety.

Common Infusion Pump Issues

Infusion pumps are sophisticated devices, but even small failures can compromise patient safety. Here are some of the most frequent issues:

Pump Not Delivering Medication

A blockage in the tubing or an occlusion in the line is the most common culprit. Air bubbles, kinked lines, or improperly primed tubing can interrupt flow. Beyond basic troubleshooting, pumps may require recalibration to confirm that their flow rates are accurate. If the device repeatedly fails despite clear lines, the internal motor or pressure sensors may need repair.

Case in Point: In a pediatric unit, a nurse notices a child’s infusion is taking longer than expected. On inspection, a kink in the line is slowing delivery. This type of situation highlights the importance of staff double-checking setups and why calibration tests are crucial for patient safety.

Alarms Going Off Without Cause

“Nuisance alarms” frustrate staff and can lead to alarm fatigue. In many cases, these alarms stem from overly sensitive sensors or dirty connectors. Routine cleaning and recalibration often restore accuracy. However, persistent false alarms may indicate a failing pressure sensor or software issue that requires service.

Case in Point: A large Midwest hospital notices a spike in nuisance alarms across its fleet of syringe pumps. Biomedical engineers trace the issue to residue buildup on sensors and worn control buttons. By introducing quarterly cleaning and replacing heavily used panels, they significantly reduced false alarms. This improvement reduces unnecessary service calls and downtime, while increasing caregivers' confidence in the pumps’ reliability.

Pump Not Turning On or Responding

Electrical failures range from something as simple as a blown fuse to deeper circuit board issues. Always check the external power supply, cable integrity, and battery health before escalating the problem. If the pump remains unresponsive, professional service is required to inspect internal wiring or replace control boards.

Case in Point: During setup for a post-op patient, a pump fails to power on. A quick swap to a spare pump prevents a delay in administering antibiotics, while the faulty unit is sent to biomed for inspection. The issue turns out to be a worn power cord, reminding teams why cord checks are part of routine maintenance.

Flow Rate Inaccuracy

When the prescribed rate does not match the actual delivery, patients can receive too much or too little medication. This is particularly dangerous for high-risk therapies like chemotherapy or pediatric infusions. Flow issues may result from worn drive mechanisms, improper calibration, or degraded tubing. Annual preventive maintenance should include a flow accuracy test to detect these issues before they affect patient care.

Case in Point: At a dialysis center, a pump delivers fluids at a slower rate than programmed. Technicians discover that worn rollers in the mechanism are causing resistance. Replacing the rollers and recalibrating the pump ensures accuracy before the issue impacts treatment.

Battery or Power Issues

Infusion pumps depend on reliable power, especially in transport and home care. Batteries that drain too quickly can disrupt treatment. Common causes include aging cells, poor charging practices, or damaged charging ports. Replacing batteries on a regular schedule, typically every 2 to 3 years, helps prevent sudden failures.

Case in Point: A patient receiving chemotherapy experiences a near pump shutdown when the battery begins to fail mid-treatment. Because the facility has a proactive battery replacement program in place, a backup pump is deployed immediately. The therapy continues uninterrupted, ensuring both safety and patient confidence.

The Infusion Pump Repair Process

Repairing an infusion pump involves more than swapping parts; it’s about methodical troubleshooting, calibration, and documentation to ensure compliance and safety.

Initial Troubleshooting

Start with visible checks: cords, tubing, connectors, and error messages.
Perform a reset to rule out temporary glitches.
Document the issue in the medical equipment log to track recurring problems.

Calibration and Reprogramming

IV pumps can drift over time, causing dosage errors. Calibration ensures accuracy.
Use manufacturer-approved tools or software to reprogram flow settings.
Verify consistency through test runs to confirm reliable delivery.

Component Replacement

Identify faulty parts, such as motors, sensors, batteries, or control boards.
Always use OEM-approved or equivalent parts from trusted suppliers like PartsSource infusion pumps.
Document replaced parts and test the device under load before returning it to service.

Professional Repair Services

Complex repairs may require the services of certified service providers.
Ensure technicians follow manufacturer IFUs and healthcare regulations.
Maintain service reports for compliance with The Joint Commission and FDA guidelines.

Best Practices for Infusion Pump Maintenance and Repair

Regular Inspection and Testing

Daily checks: verify alarms, displays, and battery status.
Monthly checks: test flow rates, confirm accuracy, and inspect external wear.
Annual service: full calibration, electrical safety tests, and software updates.

Keep Pumps Clean and Sanitized

Use hospital-grade disinfectants safe for plastics.
Focus on fluid pathways, keypads, and handles.
Document cleaning to align with infection prevention protocols.

Monitor Battery Health

Replace batteries proactively, not reactively.
Track cycle counts and age in asset management systems.
For guidance on selecting the correct voltage and chemistry, see our post on Choosing Battery Voltage for Medical Equipment.

Infusion Pump Repair FAQs

How often should infusion pumps be serviced?

Most manufacturers recommend preventive maintenance every 12 months, though high-use units may require more frequent checks. Service should include calibration, safety testing, and battery replacement as needed.

Who is responsible for infusion pump repair?

In most hospitals, biomedical engineering or HTM teams are responsible for handling routine maintenance and minor repairs. Complex repairs or warranty work are often managed by the manufacturer or certified service vendors.

Can biomedical teams repair infusion pumps in-house?

Yes, many issues, such as battery swaps, tubing occlusions, or calibration, can be handled in-house. However, circuit board failures or software problems usually require outside support.

What is the cost of infusion pump repair compared to replacement?

Repairing a pump is often more cost-effective than replacing it, especially for high-end smart pumps. Replacement becomes necessary if repair costs exceed 60–70% of the purchase price or if the medical equipment is nearing the end of its life.

Conclusion: Trust PartsSource for Reliable Infusion Pump Repair Solutions

The performance of infusion pumps directly affects patient safety, workflow efficiency, and regulatory compliance. Proactive maintenance, timely repair, and accurate calibration can prevent problems before they disrupt care.

Whether you’re comparing IV pump brands, exploring types of infusion devices, or learning what an infusion pump is used for, one thing is consistent: these devices only deliver safe, reliable therapy if they’re properly maintained.

PartsSource supports biomedical engineers, clinical teams, and procurement professionals with OEM and compatible infusion pump parts, fast shipping, and expert repair guidance. Explore our catalog of infusion pumps and accessories to keep your fleet in top condition and your patients receiving the care they depend on.