Synthes Air Power Line II User manual

Instructions
for Use
Air Power Line II. Power tools for
endoprosthetics and traumatology.

Synthes 1
Contents
Introduction
Air Reamer/Drill
Air Oscillator
Air Reciprocator
General information 3
Startup of the Air Power Line system 5
Working with the Air Power Line system 6
Power Tool 7
Attachments for the Air Reamer/Drill 8
Power Tool 16
Attaching the saw blades 17
Positioning the saw head 18
Power Tool 19
Attaching the saw blades 20
Positioning the saw head 21

Contents
Care and Maintenance
Troubleshooting
Ordering Information
General information 22
Preparing for disinfection and cleaning 23
Disinfection and cleaning 24
Lubrication 26
Inspection and sterilization 27
28
30
2 Synthes Air Power Line II Instructions for Use

Synthes 3
Introduction
Use
The Air Power Line is a pneumatically-operated tool system
used for endoprosthetics and large bone surgery. To ensure
proper operation of the Air Power Line, use only Synthes
original accessories.
Patient safety
The Air Power Line may only be used on patients after the
medical personnel have read the instructions. Since it is im-
possible to fully exclude the possibility of technical problems,
always ensure that an alternative system is ready when using
a power tool on patients.
Use
New power tools and their accessories must undergo the
entire reprocessing process before being used. Completely
remove protective caps and film.
Compressed air units may never be operated with oxygen
(due to the explosion hazard), only with compressed air or ni-
trogen.
Recommended operating pressure: 6–7 bar (max. 10 bar).
Only use Synthes original compressed air hoses.
To prevent injury, the power tools must be locked with the
safety system during each manipulation.
High torque of the powerful Reamer/Drill (511.606) must
always be observed.
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 saw blade.
Servicing
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 their exclu-
sive 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 for reprocessing of
the products can be obtained from the Synthes representa-
tive.
Please pay special attention to the chapter “Care and Main-
tenance” starting on page 22.
Responsibility of the user
The user of the product is responsible for proper use the
equipment during surgery.
Explanation of symbols
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 symbols indicates that the corresponding unit
may not be immersed in liquids.
Warranty
The warranty for machines and accessories does not cover
damage of any kind resulting from improper use, servicing or
repairs carried out by unauthorized sites, or use of acces-
sories by third parties.
Disposal
Please return devices and attachments no longer in use to
your local Synthes representative for disposal.
General information

4 Synthes Air Power Line II Instructions for Use
Introduction
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
May not be stored or operated in explosive atmospheres.

Synthes 5
Connecting the compressed air hose to the power tool
Attach the hose coupling over the air inlet nipple on the unit
up to the stop. The coupling will lock by itself with an
audible click.
Removing the compressed air hose
Pull back the grip ring on the hose coupling until the connec-
tion releases.
Startup of the
Air Power Line system

6 Synthes Air Power Line II Instructions for Use
Operating the trigger
The trigger smoothly regulates the speed of the air
reamer/drill (511.606) and the frequency of the air oscillator
(511.610) and the air reciprocator (511.615).
Safety system
Air Power Line power tools have a safety system that pre-
vents unintentional operation.
To lock the trigger, pull it forward according to the marking
on the handle and then turn it. To unlock the trigger, twist it
in the opposite direction and then push it back.
Introduction
Working with
the Air Power Line system






Synthes 7
Attachment coupling
Unlocking ring for attachment coupling
Trigger and safety device
Air inlet
Knob for forward and reverse
Reverse operation of the Air Reamer/Drill
The Air Reamer/Drill is equipped with a knob for forward and
backward .
By turning the knob in the indicated direction, the tool
switches from forward to reverse or vice versa.
Caution
– Do not switch the direction of rotation while the tool is
operating.
– Use reverse only with tools that are approved for such use.
Otherwise the tool may break and cause damage.
Technical data
Rpm, without attachment: 0–340 rpm
Weight: 1,100 g
Air consumption at 6 bar: max. 380 l/min
Recommended operating pressure: 6–7 bar (max. 10 bar)
Cannulation: 4.0 mm
Noise level in operating position: 82 dB(A)
Handle vibration: < 2.5 m/s2
Air Reamer/Drill
Subject to technical modifications.
Power tool

8 Synthes Air Power Line II Instructions for Use
Air Reamer/Drill
Attachments for the Air Reamer/Drill
Please observe the safety instructions and warnings on the
relevant pages when working with attachments. Only use
original Synthes attachments and tools. Damage that arises
from using attachments and tools by other manufacturers
is not covered by the warranty.
Mounting the attachments
Insert the attachment into the front of the attachment cou-
pling and turn until the positioning pins lock into the grooves
of the unlocking ring. Applying slight pressure, turn the at-
tachment clockwise until it has completely locked into posi-
tion. Check that it is fitted properly by lightly pulling
the attachment.
Removing the attachments
Turn the unlocking ring for the attachment coupling 
(see page 7) clockwise and remove the attachment.

Synthes 9
Trinkle Quick Coupling, modified (530.793)
(Speed: 0–930 rpm)
Trinkle Quick Coupling, modified (530.783)
(Speed: 0–340 rpm)
Hudson Quick Coupling (530.792)
(Speed: 0–930 rpm)
Trinkle Quick Coupling (530.784)
(Speed: 0–340 rpm)
Hudson Quick Coupling (530.782)
(Speed: 0–340 rpm)
AO/ASIF Quick Coupling for Reamer (530.780)
(Speed: 0–340 rpm)
Quick Coupling for DHS/DCS Triple Reamers (530.760)
(Speed: 0–930 rpm)
AO/ASIF Quick Coupling (530.750)
(Speed: 0–930 rpm)
Trinkle Quick Coupling (530.794)
(Speed: 0–930 rpm)

10 Synthes Air Power Line II Instructions for Use
Air Reamer/Drill
Inserting the tools in the attachments
(on page 9)
Attaching cutting tools
Pull the unlocking sleeve on the attachment backwards (for-
wards for the DHS/DCS Quick Coupling, 530.760) and com-
pletely insert the tool (e.g. drill bit) by lightly turning it.
Once the tool is completely locked in place, release the un-
locking sleeve. Turn slightly to ensure that the tool is properly
locked into the coupling.
For the AO/ASIF Quick Coupling (530.750/530.780) the tool
can be inserted without moving the unlocking sleeve
(“click-in”).
Removing cutting tools
Pull the unlocking sleeve on the attachment backwards
(forwards for the DHS/DCS Quick Coupling, 530.760) and
remove the tool.
Caution:
Properly operating 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 should be replaced
if necessary.

Synthes 11



Quick Coupling for Guide Pins 1.6 to 4.0 mm
(510.790)
(Speed: 0–930 1/min)
Load the guide pin and insert into the bone
1. Adjust the adjusting sleeve  to fit the diameter of the
guide pin to be used. Slightly press the adjusting sleeve
axially against the tool and rotate the sleeve.
2. Apply a slight amount of pressure to insert the guide pin
from the front or back into the cannulation . The guide
pin is held automatically.
3. Adjust the working length by pulling on the guide pin.
4. To fit the guide pin pull the tension lever  against the
tool. Only pull the tension lever against the tool as much
as necessary. The clamping force can be varied by pulling
and releasing the clamping lever.
5. Insert the guide pin into the bone. Apply the clamping
force as long as the guide pin is advanced.
6. To regrip the guide pin, reduce the clamping force and
move the tool to the desired length. Reclamp the guide
pin by pulling on the tension lever.
The guide pin is removed from the bone analogue as
described above.

12 Synthes Air Power Line II Instructions for Use
Air Reamer/Drill
Loading tools into the chuck
Drill chuck with key (530.730, 530.732)
Open the clamps of the drill chuck with the key provided
(510.190): Insert the key into the suitable shaft and turn
anticlockwise. Insert the shaft of the tool into the centre of
the opened chuck.
Close the chuck in reverse order.
Ensure that the shaft of the tool is fitted between the centre
of the three clamps of the chuck. Turn the key clockwise to
tighten. The teeth of the key must be properly seated in the
gear of the drill chuck. The teeth of the chuck and of the key
must not be worn.
Drill Chuck, keyless (530.731)
Open the clamps manually be holding the retaining ring and
turning the securing ring clockwise. Insert the shaft of the
tool into the centre of the opened chuck. Lock and tighten
the chuck by holding the retaining ring and turning the
securing ring clockwise. Ensure that the shaft of the tool is
loaded between the centre of the three clamps of the chuck.
Caution:
Do not allow the tools fitted in the keyless Drill Chuck to
rotate backwards, as the Drill Chuck can otherwise open.
Use the Drill Chuck with Key for reverse mode (530.730,
530.732)
Drill Chuck, keyless (530.731)
(Speed: 0–930 rpm)
Drill Chuck with key (530.730)
(Speed: 0–930 rpm)
Drill Chuck with key (530.732)
(Speed: 0–340 rpm)

Synthes 13
Removing cutting tools
Drill Chuck with key (530.730, 530.732)
Release the chuck by turning the key (510.190) anticlockwise
and remove the tool. The teeth of the chuck and of the key
must not be worn.
Universal Drill Chuck, Keyless (530.731)
Hold the Drill Chuck on the retaining ring and release the
securing ring by turning anticlockwise. Remove the tool from
the Drill Chuck.

Coupling the Radiolucent Drive to the power tool
Attach the Adapter for Radiolucent Drive (530.741) to the
tool (for information please refer to page 8, mounting
the attachments). Push the Radiolucent Drive as far as it will
go over the quick coupling and the adapter, and rotate it
into the desired working position. Support the drive with
your free hand.
For removal, follow the same procedure in reverse.
Inserting the drill
Pull the ring on the attachment forward, and push the drill
into the coupling as far as it can go while rotating it slightly.
Push the ring on the attachment back to fix the drill. Check
if the drill is seated correctly by gently pulling on it.
For removal, follow the same procedure in reverse.
Adapter for Radiolucent Drive (530.741)
Radiolucent Drive (511.300)
14 Synthes Air Power Line II Instructions for Use

Synthes 15
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 centring. The locking
hole can now be drilled directly.
Caution
– Grip the coupled Radiolucent Drive tightly when the power
tool is held downward.
– 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 may 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
visble, and re-aim the drill bit or exchange the drill bit
if necessary.





16 Synthes Air Power Line II Instructions for Use
Air Oscillator
Locking knob for the saw blade quick coupling
Sliding sleeve for positioning the saw head
Trigger and safety device
Air inlet
Technical data
Continuously adjustable frequency: 0–14000 1/min
Weight: 1,200 g
Air consumption at 6 bar: max. 380 l/min
Recommended operating pressure: 6–7 bar (max. 10 bar)
Saw blade deflection: 4.5°
Noise level in operating position: 83.1 dB(A)
Handle vibration: < 2.5 m/s2
Subject to technical modifications.
Power Tool

Synthes 17
Only use original Synthes saw blades. This are optimally
tailored to the tool. Imitation products can reduce the life of
the saw blade coupling.
Mounting the saw blades
Open the quick coupling for saw blades by turning the lock-
ing knob (Fig. page 16) counter clockwise. Use a slight
amount of pressure to slide the saw blade against the screw
head and turn it to the desired position. Lock the saw blade
coupling by tightening the locking knob clockwise.
Note:
Make sure that the locking knob for the saw blade quick
coupling is firmly tightened. Otherwise the screw can loosen
during use causing the saw blade to vibrate.
Removing the saw blade
Open the quick coupling for saw blades by turning the
locking knob (Fig. page 16) counter clockwise, and
remove the saw blade.
Attaching the saw blades

18 Synthes Air Power Line II Instructions for Use
The saw head can be locked in eight operating positions
(8 45°).
To choose the operating working position, pull the sliding
sleeve backwards and rotate the saw head into the required
position. Release the sliding sleeve. It will lock automatically
as soon as the correct position is reached.
Air Oscillator
Positioning the saw head