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What This Guide Helps With
Troubleshoots failure of an emergency hand crank or external pump coupling to engage because of alignment, obstruction, damage, or incorrect positioning.
Step-by-Step Troubleshooting
1. Protect the Patient and Maintain Blood Flow
A hand-crank engagement problem can compromise the ability to maintain circulation during a pump-drive failure.
Do not troubleshoot the affected pump while it is supporting a patient. Ensure the perfusion team has an alternate verified means of maintaining required flow before Clinical Engineering evaluates the problem.
If the failure occurred during a case, remove the affected pump position from clinical dependence before testing.
Expected outcome: Patient circulation is supported by a verified alternate method and the affected pump can be safely evaluated.
2. Confirm the Exact Engagement Problem
Ask the perfusionist whether:
- The crank would not insert
- It inserted but would not lock or couple
- It coupled but slipped
- The pump would not rotate
- Excessive force was required
- The problem affected one pump position or multiple positions
Inspect the crank and coupling without forcing them together.
Expected outcome: The failure is identified as an insertion, alignment, coupling, retention, or rotation problem.
3. Verify the Correct Emergency Crank and Intended Pump Position
Confirm that the available hand crank or manual-drive accessory is the correct approved accessory for the S5 configuration and intended pump position.
Check for mislabeled, misplaced, or incompatible accessories stored with the system.
Expected outcome: The correct emergency accessory is being used with the intended pump mechanism.
4. Inspect the Hand Crank
Examine the emergency crank for:
- Bent shaft
- Damaged engagement features
- Cracks
- Excessive wear
- Corrosion
- Debris
- Missing or loose external parts
- Evidence that it was dropped or forced
Do not attempt to straighten, machine, or modify the crank.
Expected outcome: The crank is physically intact and capable of engaging normally.
5. Inspect the Pump Coupling
With the equipment safely out of service and the pump stationary, inspect the accessible coupling point for:
- Debris or foreign material
- Damage
- Misalignment
- Deformed engagement surfaces
- Obstructions
- Loose externally accessible parts
Do not insert tools into the coupling or disassemble the drive mechanism.
Expected outcome: The coupling is unobstructed and appears mechanically intact.
6. Verify Pump Position and Mechanical Alignment
Ensure the pump mechanism is in the proper stationary condition for emergency crank engagement according to normal approved operation.
Gently align the crank with the coupling without forcing it. Small rotational adjustment may allow engagement if the mating features were initially misaligned.
Never use excessive force.
Expected outcome: The crank seats and couples positively using normal hand pressure. If it engages correctly and remains secure, proceed to functional verification.
7. Check for Binding Before Applying Manual Rotation
Once engagement is confirmed, carefully assess whether the pump can be rotated manually using an approved unloaded or controlled test setup.
Stop if there is:
- Abnormal resistance
- Grinding
- Binding
- Intermittent locking
- Slipping
- Visible coupling movement without pump rotation
Expected outcome: Manual rotation is smooth, mechanically consistent, and directly drives the intended pump mechanism.
8. Compare With Another Verified Pump Position or Known-Good Crank
If available and permitted, compare the affected pump position with another equivalent verified pump position.
A known-good compatible crank may help determine whether the problem follows the crank or remains with the pump coupling.
Do not interchange accessories if compatibility is uncertain.
Expected outcome: The fault is isolated to either the emergency crank/accessory or the affected pump position.
9. Verify Normal Powered Pump Operation
After completing the mechanical inspection and with the emergency crank removed, verify normal powered pump operation in a controlled setup.
Confirm:
- Smooth rotation
- Normal start and stop
- No abnormal noise
- No visible mechanical instability
- Normal applicable status indications
A pump that binds during manual operation should not be considered acceptable merely because powered operation appears normal.
Expected outcome: Both manual emergency drive and normal powered operation function reliably.
10. Stop and Escalate if Engagement Is Unreliable
If the hand crank cannot be positively engaged, slips, binds, or requires excessive force, remove the affected equipment from service.
Emergency manual-drive capability must not be assumed to be available if it cannot be demonstrated during testing.
Expected outcome: Equipment with unreliable emergency pumping capability is prevented from returning to clinical use.
If the Problem Persists
External causes such as wrong accessory, debris, visible damage, pump position, and simple alignment have been ruled out.
Remaining possibilities may include internal coupling wear, drive-mechanism damage, mechanical misalignment, or another service-level mechanical problem.
The affected equipment should be:
- Removed from service
- Labeled Out of Service
- Sent for repair or bench evaluation
- Evaluated using appropriate LivaNova documentation and approved service tools
- Repaired only by qualified personnel
- Tested for both powered and emergency manual operation before return to service
Knowing when to stop rather than forcing a mechanical emergency coupling is proper troubleshooting.
Clinical Use Tip
Emergency hand-crank function should be immediately available to the perfusion team; an accessory that cannot be positively engaged should be treated as a safety failure.
Work Order Documentation (CCR Method)
CCR = Complaint, Cause, Resolution
Complaint
What was reported by the clinical staff.
Example:
"Perfusion reported that the emergency hand crank could not be fully engaged with one S5 pump position during a pre-use check."
Cause
What was observed during troubleshooting.
Example:
"Clinical Engineering found debris in the externally accessible pump coupling that prevented the crank from seating completely."
Resolution
What action was taken.
Example:
"The obstruction was removed without disassembly, and the crank was verified to engage securely and rotate the pump smoothly before powered operation was also functionally tested."
Helpful Details to Include (If Known)
- Pump position affected
- Emergency crank identification
- Whether the crank inserted, locked, slipped, or bound
- Visible crank condition
- Visible coupling condition
- Foreign material or obstruction found
- Comparison with another pump position
- Known-good crank substitution
- Manual rotation result
- Powered pump verification
- Final device status
Final Thought
Emergency manual-drive capability is a patient-safety function, not an area for forceful trial-and-error repair. Inspect the accessory and coupling logically, verify smooth engagement and operation, and escalate any unresolved mechanical problem before the equipment is returned to clinical service.
That is successful troubleshooting.