Stryker 940 Technical Document

Maintenance Manual & Operating Instructions
Cast Cutter
INSTRUMENTS
REF 940
REF 941
3/06 940-1-25 REV-H
IMPORTANT INFORMATION: File in your maintenance records
European Authorized Rep:
RA/QA Manager
Stryker France
ZAC Satolas Green Pusignan
Av. de Satolas Green
69881 MEYZIEU Cedex
France
Stryker Instruments
4100 E. Milham
Kalamazoo, Michigan
(USA) 49001
269-323-7700
1-800-253-3210
www.stryker.com

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WARNING - CAUTION - NOTE
This symbol is used to alert the reader to important safety and precautionary information. When displayed on the actual
device, it refers the user to accompanying instructions.
Please read this manual and follow its instructions carefully. The words WARNING, CAUTION and NOTE carry special meanings and
should be carefully reviewed.
WARNING: The personal safety of the patient/user may be involved. Disregarding this information could result in injury to the
patient.
CAUTION: These instructions point out special service procedures or precautions that must be followed to avoid damaging the
instrument.
NOTE: This provides special information to make maintenance easier or important instructions more clear.
Important Information

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User/Patient Safety
WARNINGS:
• Prior to each use, operate system components and inspect
for damage. DO NOT use if damage is apparent. Take
special precautions regarding electromagnetic compatibility
(EMC) when using medical electrical equipment like the Cast
Cutter REF 941. Install and place the Cast Cutter REF 941
into service according to the EMC information in this manual.
Portable and mobile RF communications equipment can affect
the function of the Cast Cutter REF 941.
• Use only Stryker approved accessories. Other accessories
may result in increased emissions or decreased immunity of
the system. Contact your Stryker sales representative for a
complete list of accessories. DO NOT modify any accessory.
Failure to comply may result in patient and/or operating room
staff injury.
• This equipment is not suitable for use in the presence of
flammable anesthetic mixture with air or with oxygen or nitrous
oxide.
•Use only Stryker Cast Cutter Blades. Titanium nitrided blades
are intended to cut synthetic casting material; and stainless
steel blades to cut plaster casting material. Ion nitrided blades
will cut synthetic or plaster casting material. See Reorder List
in this manual for details.
• Prior to use, check blades for wear. DO NOT use a dull
blade. Use of a dull blade could result in a burn injury to
tissue.
• Make sure blade is properly seated and retaining nut is
tightened before each use. An improperly tightened retaining
nut may come loose, causing blade to fracture, thereby
endangering patient and user.
• Excessive pressure, such as bending and prying with the
blade, may cause the blade to fracture. This could result in
injury to the patient or user.
• Do not cut casting material using a continuous linear motion.
Continuous contact of the blade against skin or padding will
cause a burning sensation to the underlying skin.
• Use extreme caution when cutting synthetic casting materials.
The Cast Cutter blade may overheat, causing burn to
underlying tissue.
• DO NOT remove a non-padded cast with the Cast Cutter. Skin
may adhere to the casting material which could result in injury
to the tissue.
• Your Stryker Cast Cutter is double insulated; grounding is not
required. The Cast Cutter must be completely dry when it
is used. Do not use if any moisture is apparent, which may
occur after cleaning the instrument.
• Disconnect the Cast Cutter from the electrical supply before
performing any cleaning or maintenance procedures.
• DO NOT autoclave or immerse this instrument in liquids. Do
not flush the internal vacuum line with liquids. Liquids would
seriously damage the internal components of the Cast Cutter
and create an unsafe electrical condition.
• Do not use in the presence of fluids.
• Use only identical replacement parts.
CAUTION: Stryker does not recommend using Stainless Steel
Blade REF 940-25 for cutting

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Introduction
The Cast Cutter is intended to section and remove plaster and synthetic casts.
Read and understand the information in this manual. Familiarization with the Stryker Cast Cutter prior to use is important.
For further information contact your Stryker Instruments Representative or call Stryker Customer Service at [phone].
(Outside the USA, contact your nearest Stryker Subsidiary.)
WARNING: Prior to use the Stryker Cast Cutter and blades should be operated and inspected for any damage. DO NOT use
if damage is apparent.
REF 940 Cast Cutter, 100-120V unit
REF 941 Cast Cutter, 220-240V unit
Symbol Definition
A lightening bolt within a triangle is intended to alert service personnel of the presence of dangerous voltage that may
cause injury or fatal electrical shock. Disconnect unit from electrical supply before servicing.
An exclamation point within a triangle is intended to alert the user to the presence of important operating and
maintenance (service instructions) in the literature accompanying the products.
ON/STANDARD OPERATING SPEED
STANDBY The device is not operational, although the
electrical power is still connected.
ON/HIGH SPEED
DOUBLE INSULATION
TYPE BF Applied Part
I
II

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2
3
WARNINGS:
• Clean and disinfect Cast Cutter and Cast Cutter Blades prior to each use. See Cleaning and Maintenance.
• Prior to use, check blades for wear. DO NOT use a dull blade. Use of a dull blade could result in a burn injury to tissue.
•Use only Stryker Cast Cutter Blades. Titanium nitrided blades are intended to cut synthetic casting material; and stainless
steel blades to cut plaster casting material. Ion nitrided blades will cut synthetic or plaster casting material. See Reorder
List in this manual for details.
CAUTION: The blade must be mounted on the Stryker Cast
Cutter in the following manner or damage to the equipment and
inefficiency of cutting will result.
1. Use the Cast Cutter Blade Tool included with your Cast Cut-
ter to loosen the blade retaining nut. Turn nut counterclock-
wise until it no longer turns.
2. Place the desired blade on the blade mount. Slip the blade
over the nut and posts. The posts will guide the blade into
position. Pull the blade down behind the nut. Ensure that
all four posts have engaged the blade.
3. Use the Cast Cutter Blade Tool to tighten the nut against the
blade. Turn nut clockwise. Make sure the blade is secure
and all four posts are engaged.
WARNING: Make sure blade is properly seated in the
Cast Cutter and retaining nut is tightened before each
use. An improperly tightened retaining nut may come
loose, causing blade to fracture, thereby endangering
patient and user.
Mounting the Saw Blade
1

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NOTE: The Cast Cutter must be connected to the appropriate electrical power supply.
• Use the 100-120V Cast Cutter (REF 940) with a 100-120V CastVac™ (REF 986 or 987) only.
• Use the 220-240V Cast Cutter (REF 941) with a 220-240V CastVac (REF 996) only.
The Cast Cutter can be plugged into a standard outlet. If used with a Stryker CastVac, it can be plugged directly into the vacuum
unit. See your Stryker CastVac Maintenance Manual & Operating Instructions for details.
WARNING: The ON/OFF switch is a function switch which activates the Cast Cutter. To disconnect the electrical supply,
unplug the Cast Cutter from the wall receptacle (or vacuum unit).
STANDARD OPERATING SPEED
STANDBY
HIGH SPEED
Grasp the Cast Cutter as illustrated. As pressure is put on the blade and it cuts down through the cast, the thumb serves as a depth
gauge, striking the cast as the saw blade reaches the padding beneath the casting material.
NOTE: For best control, grasp the Cast Cutter close to the saw blade with one hand, and the index finger extending under the
oscillating head. The motor portion of the Cast Cutter then serves as a counterbalance.
3-Way Switch
Turn the Cast Cutter ON using the three-way switch located near
the power cord. Select the desired speed setting, STANDARD or
HIGH. The center position is OFF.
I
II
Using the Cast Cutter

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3-Way Switch
When not in use, place the three-way
switch in the STANDBY (center) position.
The cutting action is achieved by high speed oscillation of the blade which cuts on both backward and forward strokes of
approximately 1/8" (3.2mm) excursion. For this reason, the blade should be moved slightly up and down as the cut progresses to
engage more teeth, allowing for more efficient cutting.
Resistance is felt as the blade cuts through the casting material. When the blade fully penetrates the cast, this resistance ends. At
this point, pull back on the saw, being careful not to pull the blade out of the cutting groove. Advance about one-half inch in the
direction of the cut. Continue this process the entire length of the cut. Thus, the cast is cut by a series of alternating pressures
and linear movements along the line of the cut, rather than by a steady linear progression along this line. If the blade is left too long
against the padding, the rapid oscillation gives a burning sensation to the skin beneath.
WARNINGS:
• DO NOT remove a non-padded cast with the Cast Cutter. Skin may adhere to the casting material which could result in
injury to the tissue.
• Do not cut casting material using a continuous linear motion. Continuous contact of the blade against skin or padding will
cause a burning sensation to the underlying skin.
• Do not use the blade for bending or prying open the cast. The blade could fracture and cause injury to the patient or user.
• Use extreme caution when cutting synthetic casting materials. The Cast Cutter blade may overheat and could result in
burns to patient.
CAUTION: Stryker does not recommend using Stainless Steel Blade REF 940-25 for cutting synthetic casting materials. Stryker
recommends using Ion Nitrided Blade REF 940-23 and Titanium Nitrided Blade REF 940-35 for cutting synthetic casting material.
If a skintight cast is desired, put it on with a strip of stockinette tubing or felt placed along one side of the arm or leg and draw a line
above it with an indelible pencil. The cast can then be removed more safely by cutting along this previously marked line.
Using the Cast Cutter
Power-down

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WARNING: Unplug the Cast Cutter before performing any cleaning or maintenance procedures.
Wipe the Cast Cutter with a moist cloth and a mild soap. To disinfect, wipe surfaces with isopropyl alcohol. Remove moisture with
an absorbent cloth.
Clean out the vacuum hood if required. Use a straight slot
screwdriver to remove hood and wipe away debris. See
illustration.
Lubrication: The Stryker Cast Cutter has a lifetime lubrication
system and no additional lubrication is required.
WARNINGS:
• DO NOT autoclave or immerse this instrument in liquids. Do not flush the internal vacuum line with liquids. Liquids would seriously
damage the internal components of the Cast Cutter and create an unsafe electrical condition.
• The Cast Cutter must be completely dry when it is used. Do not use if any moisture is apparent, which may occur after cleaning
the instrument.
• Do not use in the presence of fluids.
NOTE: Cast cutter blades can be disinfected with a standard disinfectant.
Cleaning and Maintenance

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NOTE: Refer to Replacement Parts List for component
information.
1. Disconnect the Cast Cutter from the electrical supply.
2. Use a screwdriver to loosen and remove the brush
caps located on each side of the Cast Cutter. Remove
and discard the used springs and brushes.
3. IMPORTANT: Insert the new brushes oriented so that
the concave surface of the brush is positioned as
indicated in the illustration. If a brush is rotated, it will
not make proper contact.
4. Place the springs onto the brush and install the brush
caps, tighten brush caps to 4-8 in-lbs (.45-.90 N·m).
5. Verify that leakage current complies with appropriate
specification.
Periodic lubrication or calibration is not required. The necessary lubrication and calibration adjustments have been made in the
factory.
WARNING: Do not use the Cast Cutter if leakage current exceeds appropriate specification (see Specifications). Return your
Cast Cutter to Stryker for service. (Outside US, return it to the nearest Stryker subsidiary).
Periodic Maintenance
Activity/Item
Source cord
3-way switch
RPM check
Interval
Annually
Annually
Annually
Tools and Equipment Required
None required
None required
Use RPM tester for correct speed
Instructions
Check for cracks. Return for repair if required.
Stop and start unit at least 5 times.
See Specifications.
Brush Replacement

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Item Description Qty. REF
A Vacuum Hood Ass'y 1 940-1-134
B Output Drive Ass'y 1 940-1-125
C O-ring 1 45-29
D Screw 4 50-33
E Lock Washer Ext. 4 12-24
F Cup Washer 1 940-1-115
G Bowed Retaining Ring 1 28-109
H Dogpoint Set Screw 1 21-129
I Blade Retention Screw 1 940-1-118
J Roller Bearing 1 81-118
K Washer 2 11-275
L Retaining Ring 1 28-111
M Brush 2 940-1-113
N Spring 2 38-49
O Brush Cap 2 58-18
P Blade Tool 1 940-50
Q Vacuum Line Cap 1 940-1-135
Replacement Parts Assembly
WARNINGS:
• Disconnect from electrical supply before servicing.
• Test leakage current after replacing brushes. See Periodic Maintenance for details.
• Use only identical replacement parts.
Replacement Parts List

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WARNINGS:
• Disconnect from electrical supply before servicing. Only the items listed in the Replacement Parts List are user serviceable.
• Disconnect from electrical supply before replacing brushes and springs.
Troubleshooting Guide
Problem
Running rough or excessive noise
Blade not cutting smoothly
Blade slips
Cast Cutter will not start
Cause
Motor brushes have worn out
Roller bearing has worn
Worn blade
Worn pins on blade mount
Switch worn out
Blown fuse or blown thermal fuse
Solution
Replace brushes and springs. Verify
leakage current. Refer toBrush
Replacement for details.
Replace roller bearing. Refer to
Replacement Parts List.
Replace blade.
Replace blade mount. Refer to
Replacement Parts List.
Return for repair.
Return for repair.
Refer all other problems to your Stryker Instruments representative or call Stryker Instruments Customer Service at 1-800-253-3210.
Outside the US, contact your nearest Stryker subsidiary.

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Model REF 940
Electrical: 100-120V~50-60Hz 1.5A
Speed: Nominal at 100V~ Nominal at 120V~
High 12,800 cpm* High 15,900 cpm
Low 7,700 cpm Low 10,700 cpm
DOUBLE INSULATED
Class II equipment
Type BF Applied Part
IPX0 Ordinary Equipment
Duty Cycle:
Time on–15 minutes
Time off–20 minutes
Weight: 2.8 lbs. (1.3 Kg)
Length: 10.0 in. (254 mm)
Height: 3.0 in (76 mm)
NOTE: Only the items listed in the Replacement Parts List are
user serviceable. In case of other operating difficulties, return to
Stryker for repair.
CSA International
• CAN/CSA-C22.2 No. 601.1 M-90
• IEC 60601-1
• UL 60601-1
Model REF 941
Electrical: 220-240V~50-60Hz 0.75A
Speed: Nominal at 230V~50Hz
High 15,900 cpm*
Low 10,700 cpm
DOUBLE INSULATED
Class II equipment
Type BF Applied Part
IPX0 Ordinary Equipment
Duty Cycle: Continuous Operation with intermittent
loading.
Time on–15 minutes
Time off–20 minutes
Weight: 2.8 lbs. (1.3 Kg)
Length: 10.0 in. (254 mm)
Height: 3.0 in (76 mm)
NOTE: Only the items listed in the Replacement Parts List are
user serviceable. In case of other operating difficulties, return to
Stryker for repair.
Meets applicable requirements of:
IEC 60601-1 Safety Requirements
* Cycles per minute.
Specifications
If the equipment experiences sporadic electrical interference:
• Turn off all electrical equipment not in use.
• Relocate electrical equipment; increase spacial distance.
• Plug equipment into different outlets.

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Temperature Relative Humidity Atmospheric Pressure
Environmental Conditions
Operation:
Storage and Transportation:
Guidance and manufacturer's declaration - electromagnetic emissions
The Cast Cutter REF 941 is intended for use in the electromagnetic environment specified below. The customer or the user
of the Cast Cutter REF 941 should assure that it is used in such an environment.
Compliance
Group 1
Class A
Class A
Complies
Electromagnetic environment - guidance
The Cast Cutter REF 941 uses RF energy only for its internal function.
Therefore, its RF emissions are very low and are not likely to cause any
interference in nearby electronic equipment.
The Cast Cutter REF 941 is suitable for use in all establishments other
than domestic establishments and those directly connected to the
public low-voltage power supply network that supplies buildings used for
domestic purposes.
Emissions test
RF emissions
CISPR 11
RF emissions
CISPR 11
Harmonic emissions
IEC 61000-3-2
Voltage fluctuations/
flicker emissions
IEC 61000-3-3

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Guidance and manufacturer's declaration - electromagnetic immunity
The Cast Cutter REF 941 is intended for use in the electromagnetic environment specified below. The customer or the user of the
Cast Cutter REF 941should assure that it is used in such an environment.
Immunity test
Conducted RF
IEC 61000-4-6
Radiated RF
IEC 61000-4-3
IEC 60601 test level
3 Vrms
150 kHz to 80 MHz
3 V/m
80 MHz to 2.5 GHz
Compliance level
3 Vrms
3 V/m
Electromagnetic environment - guidance
Portable and mobile RF communications equipment should
be used no closer to any part of the Cast Cutter REF
941, including cables, than the recommended separation
distance calculated from the equation applicable to the
frequency of the transmitter.
Recommended separation distance
d=1.67√P
d=1.67√P
80 MHz to 800 MHz
d=2.33√P
800 MHz to 2.5 GHz
Where P is the maximum output power rating of the
transmitter in watts (W) according to the transmitter
manufacturer and dis the recommended separation
distance in meters (m)
Interference may occur in the vicinity of equipment marked
with the following symbol:
NOTE 1: At 80 MHz and 800MHz 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.

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Guidance and manufacturer's declaration - electromagnetic immunity
The Cast Cutter REF 941 is intended for use in the electromagnetic environment specified below. The customer or the user of
the Cast Cutter REF 941 should assure that it is used in such an environment.
IEC 60601 test level
±6 kV contact
±8 kV air
±2 kV for power supply
lines
±1 kV for input/output
lines
±1 kV differential mode
±2 kV common mode
<5% UT
(>95% dip in UT)
for 0,5 cycle
40% UT
(60% dip in UT)
for 5 cycles
70% UT
(30% dip in UT)
for 25 cycles
<5% UT
(>95% dip in UT)
for 5 sec
3 A/m
NOTE: UTis the a.c. mains voltage prior to application of the test level.
Immunity test
Electrostatic discharge
(ESD)
IEC 61000-4-2
Electrical fast transient/
burst
IEC 61000-4-4
Surge
IEC 61000-4-5
Voltage dips, short
interruptions and voltage
variations on power sup-
ply input lines
IEC 61000-4-11
Power frequency
(50/60 Hz)
magnetic field
IEC 61000-4-8
Compliance level
±2, 4,6 kV contact
±2,4, 8 kV air
±2 kV for power supply
lines
±1 kV for input/output
lines
±1 kV differential mode
±2 kV common mode
95% Reduction (10ms)
60% Reduction (100ms)
30% Reduction (500ms)
95% Reduction (5s)
3 A/m
@ 50Hz
CRT 1A/m
Electromagnetic environment - guidance
Floors should be wood, concrete or ceramic
tile. If floors are covered with synthetic
material, the relative humidity should be at
least 30%.
Mains power quality should be that of a
typical commercial or hospital environment.
Mains power quality should be that of a
typical commercial or hospital environment.
Mains power quality should be that of a
typical commercial or hospital environment.
If the user of the Cast Cutter REF 941
requires continued operation during power
mains interruptions, it is recommended that
the Cast Cutter REF 941 be powered from
an uninterruptible power supply or a battery.
Power frequency magnetic fields should
be at levels characteristics of a typical
location in a typical commercial or hospital
environment.

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Recommended separation distances between portable and mobile RF communications equipment and the Cast Cutter REF 941
The Cast Cutter REF 941 is intended for use in the electromagnetic environment in which radiated RF disturbances are controlled.
The customer or the user of the Cast Cutter REF 941 can help prevent electromagnetic interference by maintaining a minimum
distance between portable and mobile RF communications equipment (transmitters) and the Cast Cutter REF 941 as recommended
below, according to the maximum output power of the communications equipment.
Rated maximum output
power of transmitter
W
150 kHz to 80 MHz
d = [ — ]√P
80 MHz to 800 MHz
d = [ — ]√P
800 MHz to 2.5 GHz
d = [ — ]√P
For transmitters rated at a maximum output power not listed above, the recommended separation distance din meters (m) can be
estimated using the equation applicable to the frequency of the transmitter, where Pis the maximum output power rating of the
transmitter in watts (W) according to the transmitter manufacturer.
NOTE 1: At 80 MHz and 800MHz, the separation distance for 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.
Separation distance according to frequency of transmitter
m
3.5
V1
3.5
E1
7
E1
0.01 0.12 0.12 0.23
0.1 0.37 0.37 0.74
1 1.17 1.17 2.33
10 3.70 3.70 7.37
100 11.70 11.70 23.30

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USA only, Stryker Instruments products are warranted to the original purchaser for a period of one year from the date of purchase
to be free from defects in material and workmanship. This warranty extends to all purchasers and is limited to the repair or
replacement of the product without charge when returned to Stryker Instruments, 4100 E. Milham, Kalamazoo, Michigan 49001-6197.
Stryker cannot accept responsibility for returns or replacements which have not been authorized.
This warranty does not cover damages caused by misuse or by failure to follow procedures outlined in this manual or as
demonstrated by Stryker Instruments representatives. This instrument is not warranted if it is used for purposes other than that of a
cast cutter.
This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
Outside the USA, contact your nearest Stryker Subsidiary.
Reorder List
Description REF
Cast Cutter, 100-120V unit...........................................................................................................................................................................940
Cast Cutter, 220-240V unit...........................................................................................................................................................................941
Ion Nitrided Blade, 2–1/2", for cutting synthetic or plaster casting material, pkg. of 1.......................................................................940-23
Stainless Steel Blade, pkg. of 4............................................................................................................................................................. 940-25
Titanium Nitrided Blade, 2–1/2", for use with synthetic casting material, pkg. of 2 ............................................................................940-35
Adaptor Hose with Cord, to connect Cast Cutter REF 940 to Stryker PlasterVac™ REF 886............................................................940-886
Adaptor Hose with Cord, to connect Cast Cutter REF 940 to Stryker PlasterVac REF 846 & 856..................................................940-855
Adaptor Hose with Cord, to connect Cast Cutter REF 940 to Stryker OrthoVac™ REF 864............................................................940-864
Limited Warranty

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