Synthes ComPact Air Drive II User manual

Instructions
for Use
Compact Air Drive II. Air-driven
Universal Power Tool System
for Traumatology, Endoprosthetics,
and the Spine.

Synthes 1
Contents
Introduction
Using the Compact Air Drive II
Care and Maintenance
Troubleshooting
Ordering Information
General Information 2
System Specifications 3
Handpiece 4
Attachments 6
General Information 22
Preparation for Cleaning and Disinfection 23
Cleaning and Disinfection 24
Lubrication 26
Inspection and Sterilization 28
29
31

2Synthes Compact Air Drive II Instructions for Use
Introduction
Intended use
The Compact Air Drive II is an air-driven power tool for use in
traumatology, endoprosthetics and spinal column surgery.
To ensure proper operation of the Compact Air Drive II, use
only Synthes original accessories.
Patient safety
The Compact Air Drive II may only be used on patients after
the medical personnel have read the instructions. Since it is
impossible to fully exclude the possibility of technical prob-
lems, always ensure that an alternative system is ready when
using the unit on patients.
Starting the system
New power tools and their accessories must undergo the
entire reprocessing process before being used. Completely
remove protective caps and films.
Compressed air units may never be operated with oxygen
(due to the explosion hazard), only with compressed air
or nitrogen.
Recommended operating pressure: 6–7 bar.
Only use Synthes original compressed air hoses.
To prevent injury, the handpiece must be locked with the
safety system during each manipulation.
Properly operating cutting tools are essential to the success
of an operation. For this reason, used tools must be checked
for wear and/or damage after each use and be replaced if
necessary. For each operation, we recommend using a new
Synthes original cutting tool.
Maintenance
The life of the equipment can be substantially extended by
following the service instructions.
For the devices to function properly, Synthes recommends
that they be serviced annually by Synthes, or by exclusive
Synthes sales outlets.
Synthes is not responsible for damage arising from improper
use or technical service rendered by unauthorized parties.
Additional information on the use and preparation of the
products can be obtained from a Synthes representative.
Particular attention should be given to the section “Care and
Maintenance“ starting on page 22.
Liability of the user
The user of the product is responsible for proper use of the
equipment during surgery.
Explanation of symbols used
This symbol provides notification of important infor-
mation. When this symbol is on a device, it refers
to important information in the accompanying docu-
ments.
This symbol indicates that the corresponding device
may not be immersed in liquids.
General Information

Synthes 3
Environmental conditions
Operation Transportation and storage
Temperature: 10 – 40°C –20 – 50°C
Relative
humidity: 30–75% 10–75%
Atmospheric
pressure: 500–1060 hPA 500–1060 hPA
System Specifications
Technical data
Continuously adjustable speed: 0–900 rpm
Weight: 780 g
Air consumption: Approx. 250 l/min
Recommended operating 6–7 bar (max. 10 bar)
pressure:
Cannulation: ⭋3.2 mm
Noise level in operating position: 72 dB(A)
Handpiece vibration: <2.5 m/s2
May not be stored or operated in explosive atmospheres. Subject to technical modifications.

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Using the Compact Air Drive II
Operation
Attachment coupling
Unlocking button for attachment coupling
Speed regulation
Reverse running selection
Softmode switch with safety function
Hose coupling
Forward/reverse running
Use the bottom trigger to gradually adjust the forward
speed up to 900 rpm.
Simultaneously pull the top trigger  to immediately switch
to reverse.
Safety system
The Compact Air Drive II has a safety system that prevents
the drive from being accidentally started.
To lock the unit, turn the softmode switch fully clockwise
to the “OFF“ position. To unlock it, turn the softmode
switch counterclockwise to the desired power level.
Adjusting the maximum power
The maximum power can be adjusted gradually by turning
the softmode switch to the appropriate marking on the
handpiece.
4Synthes Compact Air Drive II Instructions for Use
Handpiece

Synthes 5
Removing the compressed air hose
Disconnect the hose by pulling back the hose coupling
sleeve.
Connecting the compressed air hose
to the handpiece
Shove the female hose coupling onto the male hose cou-
pling until it locks into place. The coupling will lock by itself
with an audible click.

Using the Compact Air Drive II
6Synthes Compact Air Drive II Instructions for Use
Attachments
Mounting the attachments
Insert the desired attachment into the attachment coupling
of the handpiece until it engages. Do not press the
release button for the attachment coupling when mounting
the attachments.
Ensure that the attachment is correctly held in the attach-
ment coupling by pulling on it slightly.
Removing the attachments
Pressing the unlocking button releases the attachment from
the attachment coupling and shifts it slightly forward. Then
remove the attachment.
Caution
– To prevent injury, the tool must be locked with the safety
system (see page 4) during each manipulation.
– Make sure not to press the triggers (especially the top
trigger) when mounting and removing the attachments.
– When mounting and removing attachments, do not simul-
taneously pull on the attachment while pressing the
unlocking button. This can make it difficult to remove the
attachment.

Synthes 7
AO/ASIF Quick Coupling (511.750)
Attaching cutting tools:
Slide forward the ring on the attachment, and fully insert the
tool while rotating it slightly.
After the tool has been fully inserted, release the ring. Pull
on the tool to make sure that it is correctly locked in the cou-
pling.
Removing cutting tools:
First slide the ring on the attachment forward, and then
remove the tool.
Quick Coupling for DHS/DCS Triple Reamers (511.761)
Attaching cutting tools:
First slide the coupling sleeve on the attachment to the rear
in the direction of the arrow, and then insert the tool.
After the tool has been fully inserted, release the coupling
sleeve. Pull on the tool to make sure that it is correctly locked
in the coupling.
Removing cutting tools:
First slide the coupling sleeve on the attachment to the rear
in the direction of the arrow, and then remove the tool.

Using the Compact Air Drive II
8Synthes Compact Air Drive II Instructions for Use
Drill Chuck with key (511.730)
Attaching cutting tools:
Open the jaws of the chuck with the provided key (510.190)
or by hand by turning the two moveable parts against each
other to the right (clockwise).
Insert the shaft of the tool into the open chuck.
Close the Drill Chuck by rotating the moveable parts against
each other to the left. Make sure that the shaft remains in
the middle between the three jaws of the chuck. To tighten
the chuck, turn the key (510.190) to the right (clockwise).
The teeth of the key must be correctly seated in the toothed
rim of the chuck.
Removing cutting tools:
Open the chuck by turning the key (510.190) to the left,
and remove the tool.
Drill Chuck, keyless (511.731)
Attaching cutting tools:
Open the jaws by rotating the ring counter-clockwise. Insert
the tool shaft into the open chuck, and close the jaws. Make
sure that the shaft remains in the middle between the
clamps of the chuck.
Removing cutting tools:
Open the chuck jaws by turning the ring counter-clockwise,
and remove the tool.

Synthes 9
Quick Coupling for Kirschner Wires (511.791)
Inserting the Kirschner Wire:
Completely open the adjusting sleeve at the end of the at-
tachment, insert the Kirschner Wire, and close the adjusting
sleeve until it clamps the wire. Then open the adjusting
sleeve three clicks. The Kirschner Wire is automatically lightly
held in the selected position. If the wire is clamped, open the
adjusting sleeve until it is released.
Clamping the Kirschner Wire and inserting it
in the bone:
To clamp the Kirschner Wire, pull the tension lever against
the handle of the unit. The Kirschner Wire remains clamped
as long as the lever is held.
Simultaneously press the forward trigger to drill the wire into
the bone. Hold the tension lever until the Kirschner Wire is
inserted. To grasp the wire at a different place, release the
lever, move the tool with the attachment along the Kirschner
Wire to the desired length, and pull the lever against the
handle.
Removing the Kirschner Wire from the bone:
To remove the Kirschner Wire from the bone, grip it with the
tension lever and pull it out of the bone while pressing both
triggers for reverse.

10 Synthes Compact Air Drive II Instructions for Use
Using the Compact Air Drive II
Attachment for Acetabular and Medullary Reaming,
with reverse option (511.786)
This attachment allows you to use reverse running which is
blocked with attachment 511.785.
Mounting the attachment:
To enable reverse running, the attachment must be coupled
onto the drive unit in such a way that the marked arrow on
the attachment lies on the top. Reverse running can only
function in one position; this prevents unintentional activa-
tion of reverse running.
Attaching and removing cutting tools:
Use the same procedure as with the Attachment for Acetab-
ular and Medullary Reaming (511.785).
Attachment for Acetabular and Medullary Reaming
(511.785)
Attaching cutting tools:
Insert the tool into the opening of the Attachment for
Acetabular and Medullary Reaming, and press both parts
together until they lock.
Removing cutting tools:
First pull back the movable ring on the attachment, and then
remove the tool.
Reverse is automatically blocked which prevents flexible
shafts from being damaged by unintentionally actuating
reverse. If reverse is desired (for example when using
SynReam), attachment 511.786 can be used.

Synthes 11
Radiolucent Drive (511.300)
The Radiolucent Drive can be used with the Compact Air
Drive II in combination with the AO/ASIF Quick Coupling
(511.750).
Mounting the attachment:
Shove the Radiolucent Drive onto the quick coupling
(511.750) up to the stop. Rotate the drill on its axis until the
best gripping position is reached. Always hold the drill in
one hand and the drive in the other.
Removing:
Follow the same procedure in reverse.
Inserting the drill bit:
First push the moveable ring on the attachment forward, and
then insert the drill bit until the coupling piece of the drill
bit is completely engaged in the attachment coupling. Slight
rotation of the drill bit will facilitate this procedure. Then
slide back the movable ring on the attachment to secure the
drill bit. Check that the drill bit is correctly locked in the
coupling by pulling it slightly.
Removing:
Follow the same procedure in reverse.

Using the Compact Air Drive II
12 Synthes Compact Air Drive II Instructions for Use
Using the Radiolucent Drive:
Before positioning the Radiolucent Drive, align the image
intensifier until the distal locking hole of the medullary nail is
round and easily visible.
After the incision, position the Radiolucent Drive and center
the drill bit tip over the locking hole. On the monitor of the
image intensifier, you can see both the drill bit and the target
rings of the drive.
Swing the drive up and center it precisely so that the drill bit
appears as a round point and the locking hole is visible
around it. The target rings also assist centering. The locking
hole can now be drilled directly.
Caution
– Only special 3-flute spiral drill bits can be used. Your
Synthes representative will be glad to provide you with
additional information on which drill bits can be used.
– Handle the Radiolucent Drive with great care. Do not allow
contact between the drill bit and the medullary nail.
– Depending on the setting of the image intensifier, a zone
may appear in the rear of the Radiolucent Drive that is not
radiolucent. However, this does not inhibit aiming and
working with the device.
– To protect the gears, the Radiolucent Drive is equipped
with a slip clutch that disengages in case of an overload
and emits an audible rattling.
– The following procedures can cause an overload:
– Correcting the drilling angle when the cutting edges
of the drill bit are completely in the bone.
– Running into the nail with the drill bit.
– Drilling can continue after making the following
corrections:
– Correcting the drilling angle: Remove the drill bit until
the flutes are visible, and restart drilling.
– Hitting a nail: Remove the drill bit until the flutes are
visible, and re-aim the drill bit or exchange the drill bit
if necessary.

Synthes 13
Fig. 1
Fig. 2
Mounting the attachment:
Slide the Oscillating Drill Attachment from the front over the
quick coupling (511.750) up to the stop (Fig. 1). Rotate the
handpiece and Oscillating Drill Attachment in relation to
each other until the attachment locks onto the top trigger
(Fig. 2). This simultaneously keeps you from unintentionally
activating reverse.
Removing:
Follow the same procedure in reverse.
Inserting the drill bit:
First shove the sleeve on the front part of the Oscillating Drill
Attachment forward, and then completely insert the drill bit
under slight rotation.
Let the sleeve slide back, and check that the drill bit is
properly locked by pulling on it.
Removing:
Follow the same procedure in reverse.
Caution:
It is best to use a three-flute drill bit in the Oscillating Drill
Attachment. It is easier to drill into an angled surface with
such bits.
Oscillating Drill Attachment (511.200)
The Oscillating Drill Attachment (511.200) can be used on
the Compact Air Drive II together with the AO/ASIF Quick
Coupling (511.750).

Oscillating Saw Attachment (511.800)
Mounting the attachment:
Shove the attachment onto the tool. There is a noticeable
resistance. The attachment then clicks into place to show
that the coupling was successful. Once the attachment is
mounted, reverse is automatically blocked.
The attachment can be locked in eight different positions.
When the attachment needs to be rotated after it is coupled,
it must first be uncoupled, and the attachment is pulled
approx. 1 cm forward. Adjust the desired angle (45° incre-
ments), and shove the attachment back toward the tool until
it locks into place.
Removing:
Follow the same procedure in reverse.
Caution
– Do not simultaneously pull the saw attachment forward
while pressing the release button.
– When removing the saw attachment, keep the vent hole
free on the bottom of the coupling shaft.
– When mounting and removing the attachment, do not
press the top trigger. This can damage the power tool.
Changing saw blades:
1. Loosen the screw by about four turns with the key
(518.090).
2. Remove the saw blade by first pressing the saw blade
against the screw head, and then pull it out in a forward
direction.
3. Insert the new saw blade by exerting a slight pressure
against the screw head and then adjusting it to the posi-
tion required. The saw blades can be locked in different
positions.
4. Retighten the screw with the key (518.090).
Using the Compact Air Drive II
14 Synthes Compact Air Drive II Instructions for Use

Synthes 15
Adjusting the amplitude:
The deflection of the saw blade can be changed with the
Oscillating Saw Attachment (511.800). This is frequently nec-
essary when doing precision work and when very long saw
blades are used. Vibration can be minimized, and the sawing
performance can be optimized. It does not matter if the
deflection is set before you start or while you are working.
The neutral position is between the two extreme positions
and corresponds to a value of approximately 4°. If you want
a greater deflection, turn the adjusting lever toward “MAX“
(5°). When the adjuster lever is set to “MIN”, there is a
deflection of 2.5°. Maximum sawing power is obtained in
the centre position.

Using the Compact Air Drive II
16 Synthes Compact Air Drive II Instructions for Use
Oscillating Saw Attachment II (511.801)
Mount and remove the attachment in the same manner as
Oscillating Saw Attachment 511.800.
Changing saw blades:
1. Open the saw blade quick coupling by rotating the fixa-
tion knob counter-clockwise.
2. Remove the saw blade by first pressing the saw blade
against the screw head, and then pull it out in a forward
direction.
3. Insert the new saw blade by exerting a slight pressure
against the screw head and then adjusting it to the posi-
tion required. The saw blades can be locked in different
positions.
4. Lock the saw blade coupling by tightening the fixation
knob clockwise. Make sure that the fixation knob is firmly
tightened. Otherwise the screw can loosen during use
causing the saw blade to vibrate.

Synthes 17
Reciprocating Saw Attachment (511.902)
Mounting the attachment:
The attachment can be locked in eight different positions
(offset in 45° steps). Shove the Reciprocating Saw Attach-
ment onto the tool in the desired position. There is a notice-
able resistance. The attachment then clicks into place and
shows that the coupling was successful. Reverse is now
blocked.
To change the position, first release the coupling mechanism
with the release button, then use your other hand to shove
the attachment approx. 1 cm forward, rotate it into the
desired position, and shove it back until it locks on the tool.
Removing:
Release the coupling mechanism with the release button,
and then use your other hand to remove the attachment
from the machine.
Caution
– Do not simultaneously pull the saw attachment forward
while pressing the release button.
– When removing the saw attachment, keep the vent hole
free on the bottom of the coupling shaft.
– When coupling and releasing the attachment, do not press
the top trigger. This can damage the power tool.
Changing saw blades:
Turn the lock knob in the direction of the arrow until the saw
blade jumps forward approx. 1 mm. Remove the saw blade
from the coupling (the slot of the lock knob and saw blade
coupling are in the same axis). Insert the new saw blade in
the guide slot of the saw blade coupling until the lock knob
springs back into locked position with a click (the slot of the
lock knob and saw blade coupling are axially offset).
Check if the saw blade is seated tightly by pulling in a
lengthwise direction.

18 Synthes Compact Air Drive II Instructions for Use
Using the Compact Air Drive II
Top for Sternum for
Reciprocating Saw Attachment (511.904)
Mounting the attachment:
Use the Top for Sternum together with the Reciprocating
Saw Attachment (511.902). The Top for Sternum can be
placed on the Reciprocating Saw Attachment and tightened
with the provided Allen wrench. Make sure that it is
seated well.
Removing:
Follow the same procedure in reverse.
Changing saw blades:
Follow the same procedure as for Reciprocating Saw Attach-
ment (511.902). Note that only Reciprocating Saw Blade
(511.915) may be used since its length is adapted to the
length of the Top for Sternum.
Working with saw attachments
The tool must be operating when the attachment makes
contact with the bone. Do not exert excessive pressure on
the saw since it slows down sawing because the saw teeth
catch in the bone.
The best sawing performance is achieved by moving the tool
slightly back and forth in the plane of the saw blade so that
the blade can go a bit beyond the bone on both sides. Very
precise cuts can be made when the saw blade is guided
steadily. Imprecise cuts arise due to used blades, excess
pressure, or jamming the saw blade.
Instructions for handling saw blades
Synthes recommends using a new blade for each operation
to ensure that the saw blade is optimally sharp and clean.
The following risks are associated with used blades:
– Necrosis caused by excessive heat build-up
– Infection caused by residue
– Extended cutting time from poor sawing performance