Stryker LUCAS 3

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Manual Reference

Manufacturer Recommendation / AEM Status

Manufacturer-Listed PM Items

The manufacturer-listed preventive maintenance procedure includes:

Cleaning the device according to the Instructions for Use.
Check/replace bellows if not intact or clean.
Check/replace suction cup if not intact or clean.
Check/replace patient straps.
Check/replace stabilization strap.
Check/replace carrying bag.
Check/update device software.
Check for errors and warnings by starting the device and letting it run for one minute.
Clean electric fan and mesh grill.
Lubricate the compression module.
Lubricate the claw lock.
Perform a function check.

The service manual notes to use the PIP checklist 3326789 Rev C to record PIP results during the maintenance procedure.

Manufacturer-Listed Frequencies

PM frequency: Not specified in the provided service manual.

The manual lists a preventive maintenance procedure but does not provide a time-based PM interval in the provided service manual. Facility PM interval should be based on the manufacturer IFU/PIP checklist if available, facility policy, service history, device risk, and applicable regulatory requirements.

Manufacturer-Listed Part Numbers and Substances

Manufacturer-listed substances and service materials include:

Carry Ball Screw Grease: 21576-000018
PTFE Spray Lubricant: 21576-000023
Compressed Air, Can: 21300-001335
Thread Lock Fluid: 11996-000220

Common accessory/service replacement items listed in the manual include:

LUCAS Battery, dark gray: 11576-000080
LUCAS 2 Suction Cup, 3-pack: 11576-000046
LUCAS Stabilization Strap: 21576-000074
LUCAS 2 Patient Strap pair: 11576-000050
LUCAS 3 Refurbishing Kit: 21576-000079
LUCAS 3 Hood Assembly: 21576-000080
LUCAS 3 Support Leg: 21576-000081
LUCAS 3 Control Board: 21576-000082
LUCAS 3 Protective Board: 21576-000091
LUCAS 3 Communication Board: 21576-000085
LUCAS 3 Version 3.1 Communication Board: 21576-000097

Post-Repair Safety Inspection Requirements

The manual states that after each repair or maintenance, a Function Check should be performed to establish all vital functions of the device.

The manual also states that a qualified Technical Support person should inspect any device that has been dropped, damaged, or abused to verify that the device is operating within the performance standards listed in the Performance Inspection Procedures.

AEM Note

If a facility performs this PM at a different interval or changes the listed activities, that should be handled under the facility’s approved AEM program, risk assessment, maintenance history, and applicable regulatory requirements.

What This PM Procedure Covers

Visual and mechanical condition checks
Cleaning review
Bellows, suction cup, straps, and carrying bag inspection
Software/error/warning review
Fan and mesh grill cleaning
Compression module lubrication
Claw lock lubrication
Mechanical and electronic function check
Electrical safety documentation fields for facility policy use

Required Tools and Equipment

Manufacturer-listed standard tools include:

Torx screwdriver T10, T20, T25 or Torx key set
Phillips screwdriver PH1
Small flat screwdriver
Flat screwdriver 5.5 x 0.8 mm
Adjustable torque screwdriver, minimum range 0.6–4.0 Nm
PH1 bit
Flat 5.5 x 0.8 mm bit
Torx T10, T20, T25 bits
Hammer
Mandrel cutting
Adjustable pliers
ESD pliers
Protection kit
Micro SD card reader
USB to USB mini cable
Non-knurled flat nose plier
USB programming cable
REDEL extracting tool

Special tools listed:

Hood Holder Bracket Service Tool: 100838-00
Mandrel, LUCAS Hinge Insertion optional tool: 300040-00
USB Programming Cable: 160423-00

Required software listed:

LUCAS 3 Program Loader 3.0: 21340-000846
LUCAS 3 Program Loader 3.1: 21340-000852
LUCAS 3 Report Generator: free download from LIFENET
DT Express: free download from LIFENET

For a routine scheduled PM that does not involve disassembly, use only the tools and software needed for the facility’s PM scope. Do not open the device unless trained, authorized, and following the service manual.

Step-by-Step PM Procedure

1. Remove Device From Clinical Readiness Area

Action: Remove the LUCAS 3 from clinical use/ready stock for scheduled PM. Verify no patient use is in progress.

Expected outcome: Device is available for inspection, cleaning verification, functional testing, and documentation.

2. Confirm Device Identification

Action: Record model, serial number, asset number, software version if checked, and battery serial number if applicable.

Expected outcome: Device identity matches the work order and service documentation.

3. Review Service History and Damage History

Action: Check for recent drops, damage, abuse, malfunction reports, failed starts, battery warnings, compression alarms, or user complaints.

Expected outcome: Any device with drop/damage/abuse history is inspected by qualified technical support and verified against the PIP/performance standard before return to service.

4. Clean Device

Action: Clean the device according to the LUCAS 3 Instructions for Use. Do not use unapproved cleaning methods.

Expected outcome: Device is clean and suitable for inspection.

Why it matters: Dirt, fluids, and debris can hide mechanical damage, affect straps and locks, and contaminate moving assemblies.

5. Inspect Bellows

Action: Check the bellows for cleanliness, cracks, tears, looseness, deformation, or improper seating.

Expected outcome: Bellows is intact, clean, and correctly installed.

Remove from service if: Bellows is torn, damaged, contaminated beyond cleaning, loose, or not properly seated.

6. Inspect Suction Cup

Action: Check suction cup for cleanliness, cracking, deformation, wear, secure attachment, or contamination.

Expected outcome: Suction cup is intact, clean, and attached correctly.

Remove from service if: Suction cup is damaged, excessively worn, contaminated, or does not attach properly.

7. Inspect Patient Straps, Stabilization Strap, and Carrying Bag

Action: Inspect all fabrics, Velcro, buckles, stitching, strap hardware, and carrying bag condition.

Expected outcome: Patient straps, stabilization strap, and carrying bag are clean and functional. Velcro and buckles are not worn and function correctly.

Remove from service if: Straps or buckles are damaged, worn, contaminated, missing, or do not secure correctly.

8. Check Battery Condition and Age/Use Indication

Action: Install a charged battery. Review battery indicator behavior. Check for battery replacement indications or warnings.

Expected outcome: Battery is recognized and supports normal device operation.

Manual-backed replacement condition: The manual lists battery-related indications for battery used more than 200 times or more than 200 minutes with compressions each month or older than 3–4 years. It also lists battery replacement recommended for “TOO MANY USES” and “TOO OLD BATTERY” charger CPU entries.

Remove from service if: Battery is not recognized, depleted, too old, over-use warning is present, damaged, leaking, or unable to support operation.

9. Check/Update Software

Action: Connect using LUCAS 3 Program Loader when required by PM scope or facility procedure. Check software version and update if applicable per the service manual and authorized service process.

Expected outcome: Software version is documented and updated if required by facility/manufacturer service process.

Do not return to service if: Software update fails, checksum/version verification fails, or service tool reports unresolved errors/warnings.

10. Check for Errors and Warnings

Action: Start the device and let it run for approximately one minute. Use LUCAS 3 Program Loader to review device errors/warnings if required by facility procedure or if any abnormal behavior is observed.

Expected outcome: No active or stored errors/warnings that affect safety or function.

Remove from service if: Any high-priority alarm, self-test fault, internal fault, compression out-of-range alarm, battery fault, temperature fault, communication fault affecting operation, or repeated warning is present.

11. Clean Electric Fan and Mesh Grill

Action: If performing full service-level PM with hood removed, cover the Carrier Ball Screw hole with tape to keep dust out of the lubrication area. From inside the device, clean the fan and mesh grill with compressed air. Remove dust from areas requiring lubrication. Remove tape when complete.

Expected outcome: Fan and mesh grill are clean, and dust is not blown into the lubrication area.

Caution: Do not contaminate the Carry Ball Screw lubrication area.

12. Lubricate Compression Module

Action: Use only Carry Ball Screw Grease 21576-000018. With the hood off, pull down the piston and adjustment tube until the Carry Ball Screw is visible in the lubrication hole. Apply 0.5 mL of grease to the Carry Ball Screw. Move the piston manually up and down 5 times over the full range.

Expected outcome: Carry Ball Screw is lubricated and piston movement is smooth.

Remove from service if: Piston binds, moves roughly, makes unusual noise, or does not move through full travel smoothly.

13. Lubricate Claw Lock

Action: Use PTFE Spray Lubricant 21576-000023. Spray a small quantity on movable claw lock parts, including gliding surfaces of the claws, axle entry points into plastic, and locking pin. Open and lock the mechanism repeatedly to work in the lubricant.

Expected outcome: Claw locks move freely and lock/unlock correctly.

Remove from service if: Claws do not lock securely, release unexpectedly, bind, or fail the mechanical claw lock function check.

14. Perform Mechanical Function Check - Piston

Action: With the device off, pull the suction cup down and up. Verify the decompression spring moves smoothly and without unusual noise. Slowly pull down until the Carry Ball Nut reaches its lower position. Push suction cup back to top position.

Expected outcome: Piston travels smoothly through full range without unusual noise.

Note: Manual warns that pushing too fast may create stepped resistance because the electric motor is affected. Move slowly in one long stroke.

15. Perform Mechanical Function Check - Claw Lock Mechanism

Action: Check play between release ring and support legs. Pull release ring gently to unlock and open claws. Verify detectable play/rattle between ring and support leg. Press claw lock closed. When locked, press hard with two thumbs on the two claws.

Expected outcome: Claw mechanism locks securely, does not release under manual pressure, and release ring has expected play.

Fail condition: If the support ring is tight against the support leg with no play, the check has failed. If the claw mechanism unlocks during the locked pressure check, the check has failed.

16. Perform Electronics Function Check - Startup

Action: Turn on the device.

Expected outcome: Internal Function Test completes and ADJUST LED shows green.

Remove from service if: Startup test fails, warning LED activates, abnormal alarm occurs, or device does not enter ADJUST mode correctly.

17. Perform ACTIVE 30:2 Check

Action: Change mode to ACTIVE 30:2. Let the device run for approximately two minutes. Listen for unusual noise. Verify audible alert before ventilation pause and intermittent LED behavior at default settings.

Expected outcome: ACTIVE 30:2 LED shows green. Device runs without abnormal noise. Ventilation alert/pause behavior is correct for configured settings.

18. Perform PAUSE Check

Action: Change mode to PAUSE.

Expected outcome: PAUSE LED shows green.

19. Perform ACTIVE Continuous Check

Action: Change mode to ACTIVE continuous.

Expected outcome: ACTIVE continuous LED shows green. At default settings, LED blinks every ten strokes for ventilation alert.

20. Perform ADJUST / Adjustment Servo Check

Action: Change mode to ADJUST. Pull suction cup down to test adjustment servo. Push suction cup back to top position.

Expected outcome: Suction cup and adjustment servo move smoothly.

Remove from service if: Motion is rough, weak, noisy, binds, or does not return correctly.

21. Check Charging Sequence

Action: Connect charger/power supply to device.

Expected outcome: Battery LEDs show running light indicating charging sequence begins. Disconnect charger after verification.

Remove from service if: Charging sequence does not begin, power inlet is damaged, charger connection is intermittent, or battery fault occurs.

22. Test Transmit Mode / Service Tool Communication

Action: Follow service manual procedure to connect through Bluetooth using LUCAS 3 Program Loader when required. Verify communication works. If maintenance passed the Function Check, press Set PC Date to update Last Service Date. Press OFF in Program Loader to switch off Bluetooth communication and verify Bluetooth light is off.

Expected outcome: Device communicates with Program Loader. Last Service Date is updated after maintenance. Bluetooth turns off properly.

Important: If the device underwent repair without maintenance, the manual says not to press Set PC Date.

23. Final Review

Action: Confirm all checks passed, no unresolved alarms/errors/warnings remain, accessories are present, device is clean, battery is charged/acceptable, and all documentation is complete.

Expected outcome: Device is ready for return to service.

Electrical Safety Testing if Applicable

The provided service manual does not list a routine electrical safety test requirement or leakage current limit for scheduled PM.

Perform electrical safety testing if required by facility policy, after applicable repairs, after power inlet/power supply concerns, or under the facility’s electrical safety program.

Ground resistance measured in ohms, expected ≤ 0.5 Ω or facility/NFPA 99 criteria if different:

Result =

Touch/chassis leakage measured in microamps:

Facility limit used =