Synthes ComPact Air Drive II User manual

ComPact Air Drive II
USER’S MANUAL
Original Instruments and Implants of the Association
for the Study of Internal Fixation—AO ASIF
R

ComPact Air Drive II Specifications .................. 2
Attachments ...................................................... 3
Operating Instructions...................................... 4
Quick Coupling for K-Wires........................ 6
Quick Coupling for drill bits ...................... 7
Large Quick Coupling.................................. 7
Reduction Drive Unit .................................. 8
Jacobs Chuck with Key.............................. 9
Care and Maintenance .................................... 10
Sterilization...................................................... 14
Troubleshooting.............................................. 15
Product Information........................................ 16
Page
TO ORDER:
Call your SYNTHES consultant or
SYNTHES (USA) 1- 800-523-0322
or
SYNTHES Canada 1- 800-668-1119
TABLE OF CONTENTS

2
ComPact Air Drive II Specifications
•Variable speed: 0–900 rpm
•Maximum torque: 4.0 Nm (35 in-lb)
• Operating pressure (with machine running):6 bar (90 psi)
• Air consumption: 250 lpm (liters per minute)
•Weight: 780 gm (27.5 oz)
• Fully cannulated (max. 3.2 mm)
Attachment release button
Allows easy exchange
of attachments
Attachment coupling
Accepts a wide variety
of attachments
Instant-reverse trigger
Reverses rotation to
counterclockwise direction
Variable-speed trigger
Controls rotational speed
Air control valve
Limits maximum
speed and power
Double hose connector
Transports exhaust away from
the sterile field

3
Attachments
Quick Coupling for K-wires [511.79]
• For insertion of K-wires from
0.6 mm to 3.2 mm in diameter
• Allows use of any length K-wire
Quick Coupling for drill bits [511.75]
• Accepts quick coupling drill bits
• Allows use of Oscillating Drill Attachment [511.20]
and Radiolucent Drive [511.30]
Large Quick Coupling [511.761]
• Accepts DHS®and DCS®Triple Reamers, and large
cannulated drill bits
Reduction Drive Unit [511.785]
• For intramedullary and acetabular reaming
• Reduces maximum speed to 320 rpm
• Increases maximum output torque to 11 Nm
• Automatically locks reverse trigger to prevent
damage to flexible reaming shafts
• Allows direct medullary reaming with flexible shafts
• Accepts reaming rods up to 3.2 mm in diameter
Jacobs Chuck with key [511.73]
• Accepts round shafts from 1.0 mm to 6.0 mm in
diameter, or triangular shafts up to 6.5 mm
511.79
511.75
511.761
511.785
511.73

4
Operating Instructions
ASSEMBLY/DISASSEMBLY
To connect the air hose to the
ComPact Air Drive II:
Retract the hose coupling collar. Insert the air
drive coupling stem completely into the hose
coupling. Release the hose coupling collar to
secure the connection.
To disconnect the air hose from the
ComPact Air Drive II:
Press the connectors firmly together and
simultaneously retract the hose coupling
collar until it disengages.
To install an attachment:
Insert the attachment into the air drive
coupling until the parts engage. It is not
necessary to operate the release button
for installation.
To remove an attachment:
Press the release button and remove
the attachment.

5
OPERATION
Speed Control
For forward (clockwise) rotation, press the variable-
speed trigger of the air drive. Press both triggers
for reverse (counterclockwise) rotation. Speed
correlates directly to the amount of pressure on
the variable-speed trigger and can be varied
continuously from 0 to 900 rpm.
FORWARD
(lower-trigger)
REVERSE
(both triggers)
Air Control
Valve
IMPORTANT
• Use only dry, filtered compressed air or nitrogen
to power the ComPact Air Drive II. Never operate
air powered machines with oxygen; it creates a
danger of fire and explosion.
• Recommended operating pressure, with the
instrument running, is 90 psi (6 bars).
• Be sure that all attachments and instruments
are inserted securely before operating the
air drive.
• Inspect instruments for wear and/or damage
after each use. Do not use dull, damaged or
corroded drill bits or other instruments.
Air Control Valve
The ComPact Air Drive II air control valve controls
the regulation of maximum speed and power.
Turning the air control valve clockwise will
increase power; turning counterclockwise will
decrease power.
IMPORTANT
To prevent injuries, the air control valve
should always be turned to the “off” position
when inserting or removing instruments
from the attachments.

6
Operating Instructions (continued)
Quick Coupling for K-wires [511.79]
For insertion of K-wires from 0.6 mm to
3.2 mm diameter.
See page 4 for installation and removal
of attachments.
IMPORTANT
To prevent injuries, the air control valve
should always be turned to the “off” position
when inserting or removing K-wires.
To insert the K-wire into the Quick
Coupling for K-wires:
Set the adjustment sleeve dial to the K-wire
diameter. Insert the K-wire into the front
opening and set to the desired working depth.
Note: The K-wire is “presqueezed” upon
insertion into the coupling to prevent slippage
during handling. Pulling back on the lever
grasps the K-wire securely for insertion
into bone.
To insert a K-wire into bone:
Grasp the K-wire by pulling the lever against
the handpiece, and press the lower (forward)
trigger.
To remove a K-wire from bone:
Slide the drive unit and coupling over the
K-wire. Grasp the wire by squeezing the lever
toward the handpiece and press both triggers
simultaneously (reverse) to remove the wire
from the bone.
Sleeve
Dial
511.79
Lever

7
Quick Coupling for Drill Bits [511.75]
• Accepts quick coupling drill bits and screw-
driver shafts
• Allows use of Oscillating Drill Attachment [511.20]
and Radiolucent Drive [511.30]
Large Quick Coupling [511.761]
Accepts DHS®and DCS®Triple Reamers, and
large cannulated drill bits
IMPORTANT
To prevent injuries, the air control valve
should always be turned to the “off” position
when inserting or removing instruments
from the Quick Couplings.
To insert an instrument into the
Large Quick Coupling:
Retract the collar of the Large Quick Coupling
and insert the instrument shaft completely with
a slight rotation. When the shaft is fully inserted,
release the collar. Pull on the instrument slightly
to ensure that it is held securely.
To insert an instrument into the
Quick Coupling for Drill Bits:
Push the collar of the Quick Coupling forward
and insert the instrument shaft completely with
a slight rotation. When the shaft is fully inserted,
release the collar. Pull on the instrument slightly
to ensure that it is held securely.
511.75
511.761
To remove the instrument:
Push the collar of the Quick Coupling forward
to release the instrument.
To remove the instrument:
Retract the collar of the Large Quick Coupling
to release the instrument.

8
Operating Instructions (continued)
Reduction Drive Unit [511.785]
• For intramedullary and acetabular reaming
• Allows intramedullary reaming with flexible
shafts and reaming rods
• Automatic locking of reverse trigger prevents
damage to flexible shafts
See page 4 for installation and removal
of attachments.
IMPORTANT
To prevent injuries, the air control valve
should always be turned to the “off” position
when inserting or removing instruments
from the Reduction Drive Unit.
To insert an instrument into the
Reduction Drive Unit:
Insert the instrument shaft into the opening
until it engages.
511.785
To remove the instrument:
Retract the collar of the quick coupling to
release the instrument.

9
IMPORTANT
• To prevent injury, the air control valve
should always be turned to the “off” position
when inserting or removing an instrument.
• Always remove the key from the chuck
before operating the air drive.
Jacobs Chuck with Key [511.73]
Accommodates instruments, K-wires and Steinmann
pins with round shafts from 1.0 mm to 6.0 mm, or
triangular shafts up to 6.5 mm.
See page 4 for installation and removal of
attachments.
To insert an instrument:
Open the chuck jaws by turning the key
counterclockwise, or by manually turning the
parts as shown. Insert the instrument shaft
into the opened chuck.
511.73
To remove an instrument:
Turn the key counterclockwise to open the
jaws. Remove the instrument.
Close the chuck manually by rotating the collar,
keeping the shaft centered in the jaws. Tighten
the chuck by turning the key clockwise.

10
IMPORTANT
• Before cleaning and sterilization, remove
attachments, instruments and hose from
the air drive unit.
• Clean and lubricate the air drive, attach ments
and air hose immediately after each use.
• Clean the drive unit, attachments and air
hose by hand; never immerse or clean in an
automatic washer or ultrasonic cleaner.
• Use a mild, neutral pH cleaning solution to
clean the air drive and accessories.
CLEANING
Care and Maintenance
1
2
Before cleaning, turn the air control valve to the
“off ” position. Manipulate all other moving parts
under running water to loosen and remove debris.
Open and close chucks, and move quick couplings
back and forth.
Manually remove blood and debris from
the air drive and attachments under
running water. Use a mild cleaning
solution and a soft brush or cloth.
Do not allow water to enter the air inlet
of the drive unit.
Clean cannulations of the air drive and
attachments with the cleaning brush
[519.40].
Do not insert cleaning brush into
the air inlet. The Quick Coupling for
K-wires [511.79] must be fully open to its
maximum diameter of 3.2 mm before
inserting the brush.

11
3
4
5
Retract and clean quick coupling hose
end with a soft brush and mild
cleaning solution.
Do not allow water to enter the
air inlet.
Clean hose with a mild cleaning solution
and a soft brush or cloth.
Keep hose ends out of water.
Dry all instrumentation with a soft cloth.

12
Open air control valve before lubrication.
Apply approximately five drops of
Autoclavable Oil into the air intake of
the drive unit. Lubricate both triggers.
1
2
3
Care and Maintenance (continued)
Lubricate the ComPact Air Drive II and attachments
after every cleaning and before sterilization.
Use SYNTHES Autoclavable Oil [519.97].
LUBRICATING
Connect the air drive to the double
air hose.
Run the air drive for 20 seconds in
both directions.

13
4
5
Lubricate all moving parts of the
attachments with one to two drops
of oil. Operate the parts to distribute
the oil.Wipe off excess oil.
Lubricate the quick coupling hose
end with one to two drops of oil.

14
Sterilization
To sterilize air powered equipment and
air hoses:
• If the handpiece is new, remove the plastic
stopper in the nitrogen inlet.
• Disassemble all parts including hoses,
attachments, adaptors and instruments.
• All air powered equipment should be steam
sterilized in accordance with the following
guidelines:
To minimize hose deformation
during autoclaving:
• Place absorbent muslin between
handpieces and hoses.
• Do not place weight on the hose.
Temperature Pressure Minimum
Exposure Time
IMPORTANT
• Do not accelerate the cooling process. In emergencies, a
partially cooled saw or drill can be brought to room
temperature by cycling filtered compressed nitrogen or
air through it.
• Hot air and ethylene oxide gas (ETO) sterilization are not
recommended. Hot air can damage air hoses, and steam
sterilization is a safer alternative than ETO sterilization.
IMPORTANT: Times represent exposure times only and not total cycle times.
Wrapped
Gravity displacement
Prevacuum
Unwrapped (Flash)
Gravity displacement
Prevacuum
132–135°C
270– 275°F
132–135°C
270– 275°F
132–135°C
270– 275°F
132–135°C
270– 275°F
28–32 psi (2 bar)
28–32 psi (2 bar)
28–32 psi (2 bar)
28–32 psi (2 bar)
22 minutes
8 minutes
8 minutes
6 minutes

15
Troubleshooting
PROBLEM PROBABLE CAUSE SOLUTION
Machine does not start Safety system may be activated
Rotor may jam if machine is not
used for a long time
Slide air control valve to the “on” position
Mount quick coupling, then rotate chuck
manually, without pressing trigger
Machine lacks power Operating pressure is too low
Air inlet is blocked
Air control valve may not be
completely open
Air hose is too long
Adjust operating pressure to 90 psi
(6 bar) on regulator
Clean air inlet: remove solid particles
with pickups
Important: Do not use sharp tools.
Tu rn air control valve to
the “off ” position
Slide the air control valve to the “on”
position
Overall hose length should not exceed
26 feet (8 meters)
Machine keeps on running after
trigger is released
Trigger is jammed by residues Immediately turn air control valve to the
“off” position
Operate trigger several times, clean and
oil according to instructions
Important: Use only SYNTHES
Autoclavable Oil
Attachments cannot be coupled
to machine
Coupling is blocked by residue Remove solid particles with pickups
Important: Do not use sharp tools.
Tu rn air control valve to the
“off ” position
Cannot remove attachments
from drive unit
Release inhibited by pulling on
attachment while pressing the
release button
Press release button before attempting to
remove attachment
Cannot attach instrument or
difficulty attaching instrument
Instrument excessively worn,
especially insertion part
Replace instrument
K-wire completely inserted into
coupling, cannot be advanced
K-wire inserted incorrectly
into rear of machine
Disconnect Quick Coupling, hold drive
unit with opening down and shake
out K-wire
Important:
Tu rn air control valve to the
“off ” position
If suggested solutions are unsuccessful, call the Synthes Service Department
at 1-800-288-6698 for servicing information.
Annual servicing by qualified SYNTHES personnel is recommended.

16
ComPact Air Drive II Set [150.16]
Set Contents
304.010 Graphic Case for ComPact Air Drive II
Attachments
511.73 Jacobs Chuck with key
511.75 Quick Coupling for drill bits
511.761 Large Quick Coupling
511.785 Reduction Drive Unit
511.79 Quick coupling for K-wires
Also with set:
519.51S Double Air Hose, 3 meter
length with Schrader stem
Also Available
519.97 Autoclavable Oil
519.98 Spare Container with
Autoclavable Oil
519. 40 Cleaning Brush
Double Air Hoses,
with SYNTHES stem:
519.50 2 meter length
519.51 3 meter length
519.53 5 meter length
Double Air Hoses,
with Schrader stem:
519.50S 2 meter length
519.53S 5 meter length
511.701 ComPact Air Drive II

◊
Also available sterile-packed. Add ‘S’ to catalog number.
* Available sterile only.
Also Available
511.20 Oscillating Drill Attachment
511.30 Radiolucent Drive
511.731 Keyless Jacobs Chuck
511.782 Hudson Adaptor
511.783 Modified Trinkle Adaptor
511.784 Trinkle Adaptor
511.80 Oscillating Saw Attachment
511.801 Oscillating Saw Attachment II
511.902 Reciprocating Saw Attachment
511.904 Sternum Top, for use with 511.902
Saw Blades for Oscillating Saw Attachment II
◊
CALIBRATED CUTTING
WIDTH LENGTH THICKNESS
519.100 27 mm 50 mm 0.6 mm
519.103 10 mm 25 mm 0.6 mm
519.104 10 mm 50 mm 0.6 mm
519.105 20 mm 50 mm 0.6 mm
519.106 19 mm 70 mm 1.0 mm
519.113 18 mm 70 mm 1.2 mm
519.150 14 mm 50 mm 0.6 mm
519.170 27 mm 70 mm 0.8 mm
519.190 50 mm 70 mm 0.8 mm
519.200 27 mm 70 mm 1.0 mm
519.210 27 mm 70 mm 1.2 mm
519.230 6 mm 25 mm 0.6 mm
519.250 14 mm 25 mm 0.6 mm
Aggressive Tooth Saw Blades*
CALIBRATED CUTTING
WIDTH LENGTH THICKNESS
519.107S 19 mm 95 mm 0.9 mm
519.108S 25 mm 95 mm 0.9 mm
519.109S 25 mm 60 mm 0.9 mm
519.114S 19 mm 95 mm 1.25 mm
519.115S 25 mm 95 mm 1.25 mm
519.116S 19 mm 95 mm 1.4 mm
519.117S 25 mm 95 mm 1.4 mm
519.118S 12.5 mm 90 mm 0.9 mm
Saw Blades for Reciprocating Saw Attachment
◊
CUTTING
LENGTH THICKNESS
511.905 80 mm 1.1 mm
511.907 55 mm 1.1 mm
511.909 55 mm 0.9 mm
511.912 68 mm 1.1 mm
511.915 42 mm 0.8 mm
Oscillating
Drill Attachment
511.20
Radiolucent Drive
511.30
Oscillating Saw Attachment
511.80
Hudson Adaptor
511.782
Modified
Trinkle Adaptor
511.783
Trinkle Adaptor
511.784
Reciprocating Saw Attachment
511.902
Keyless
Jacobs Chuck
511.731
511.905
511.907
511.909
511.912
519.100
519.104
519.250
519.108S
Oscillating Saw Attachment II
511.801

Original Instruments and Implants of the Association
for the Study of Internal Fixation— AO ASIF
R
©SYNTHES (USA) 1997 DHS, DCS, SYNTHES and ASIF are registered trademarks of SYNTHES (USA) and SYNTHES AG Chur. Printed in U.S.A. GP0741-C 4/03 J1633-C
SYNTHES (CANADA) LTD.
111 Brunel Road
Suite 110
Mississauga, Ontario L4Z1X3
Telephone: [phone]
Fax: [phone]
To order: 1-800-668-1119
SYNTHES (USA)
1690 Russell Road
Paoli, PA 19301-1262
Telephone: [phone]
Fax: [phone]
To order: 1-800-523-0322
ComPact Air Drive II Set
[150.16]