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
2 Synthes 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/s
2
May not be stored or operated in explosive atmospheres. Subject to technical modifications.
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.
4 Synthes 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
6 Synthes 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
8 Synthes 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
Synthes 19
Torque Limiter 1.5 Nm (511.770)
and Torque Limiter 4.0 Nm (511.771)
Mounting and removing a screwdriver shaft:
Insert the screwdriver shaft while rotating it slightly until it
locks into place. To remove it, pull back the unlocking ring,
and pull out the screwdriver shaft.
Using the Torque Limiter:
Pick up a screw from the corresponding locked plating
system with the screwdriver shaft, and insert it in the desired
plate hole. To insert the screw, start the power tool slowly,
increase the speed and then reduce it again before the screw
is fully tightened. The torque is automatically limited to
1.5 or 4.0 Nm. When this limit is reached, you will hear a dis-
tinct clicking. Stop the tool immediately, and pull the tool
away from the screw.
Follow the surgical technique of the respective locked plating
system.
Caution:
The Torque Limiter must be annually serviced and
recalibrated by Synthes. Note the information on the test
certificate in the packaging. The user is responsible for
following the calibration schedule.
Using the Compact Air Drive II
20 Synthes Compact Air Drive II Instructions for Use
Angular Drive Unit for Medullary Reaming (510.200)
Mounting the attachment:
Use the Angular Drive Unit for Medullary Reaming together
with the Attachment for Acetabular and Medullary Reaming
(511.785 or 511.786). Before mounting the drive, remove its
locking screw by turning it counter-clockwise. Then shove
the drive up to the stop over the Attachment for Acetabular
and Medullary Reaming that is coupled to the Compact Air
Drive II. Rotate the drive unit to achieve the optimum grip,
and lock it in place by tightening the locking screw clock-
wise.
Removing:
Follow the same procedure in reverse.
Attaching and removing cutting tools:
Use the same procedure as with the Attachment for Aceta-
bular and Medullary Reaming ( 511.785 or 511.786).
Synthes 21Synthes 21
511.782 Hudson Adapter
511.783 Trinkle Adapter, modified (Zimmer adapter)
511.784 Trinkle Adapter
511.787 Küntscher Adapter
511.788 Harris Adapter
Adapters for using tools by other manufacturers
Mounting the adapters:
Use the adapters together with the Attachment for
Acetabular and Medullary Reaming (511.785 or 511.786).
Insert the adapter into the opening of the Attachment for
Acetabular and Medullary Reaming (511.785 or 511.786),
and press both parts together until they lock.
Removing:
First pull back the movable ring on the attachment, and
then remove the adapter.
Attaching cutting tools:
First move the coupling sleeve on the adapter toward the
rear, and then completely insert the tool.
After the tool has been fully inserted, release the coupling
sleeve. Check that the tool is properly locked in the adapter
by gently pulling on it.
Removing cutting tools:
First shove the coupling sleeve on the adapter toward the
rear, and then remove the tool.
Care and Maintenance
22 Synthes Compact Air Drive II Instructions for Use
Regular care and maintenance according to the following
instructions (fulfilling DIN EN ISO 17664) can substantially
increase the reliability and life of the system components.
Synthes recommends annual servicing and inspection by the
original manufacturer or its exclusive sales outlets. The
manufacturer assumes no warranty for damages arising from
improper use or unauthorized servicing.
If not stated otherwise, the following reprocessing steps
apply to the entire Compact Air Drive II product line. Deter-
gents used on the products will make contact with the
following materials: Stainless steel, aluminum, plastic, and
rubber seals.
Caution
– Cannulations, unlocking sleeves and other narrow sites
require special attention during cleaning.
– Detergents with a pH above 11.0 can reduce the life of the
products.
– Lubricating regularly with Synthes special oil, especially
when mechanical cleaning is performed, will reduce wear
and can substantially extend the life of the product.
Restriction regarding reprocessing
Frequent reprocessing does not have a great effect on the
life of the unit and attachments. The expiration of the prod-
uct’s service life is normally determined by wear and damage
from use and can be determined in a timely manner through
annual servicing. Synthes always recommends that cutting
tools such as saw blades be only used once to ensure opti-
mum patient treatment.
General Information
Synthes 23
Preparation for Cleaning and Disinfection
In the operating room
Remove surface soiling with a disposable cloth or paper
towel.
Storage and transport
No special requirements. Reprocess an instrument directly
after it is used so that blood does not dry on it.
Preparation for cleaning
– Reprocessing must be carried out immediately after each
use.
– Before disinfection and cleaning, all attachments and
instruments must be removed from the machine.
– The unit and attachments may not be immersed.
– Make sure that no cleaning solution enters the machine’s
air inlet.
– Do not use pointed objects for cleaning.
– When cleaning the unit, do not insert objects into the inlet
and outlet holes for the air connector since this would
damage the microfilter.
24 Synthes Compact Air Drive II Instructions for Use
Care and Maintenance
Manual cleaning and disinfection
1. Wipe or spray the outside of the Air Hoses, machine and
accessories with disinfectant and let the disinfectant
work according to the instructions of the disinfectant’s
manufacturer.
2. Remove all residues from the disinfected machine and
accessories under running water using a soft brush or
cloth.
3. Clean cannulations of the drive unit, attachments and
tools with the provided cleaning brush (519.400).
4. Coupling sleeves, sliding sleeves and similar difficult-to-
access locations require special attention.
5. Rinse the unit and accessories with clear water and then
dry with an absorbent cloth.
Cleaning and Disinfection
Synthes 25
Caution
– For automated cleaning, also consult the brochure
“Synthes Power Tools – Machine Washing Recommen-
dations” (036.000.101).
– Power Tools (especially seals and bearings) are exposed to
greater stress in machine washing than when they are
cleaned manually. For this reason, power tools must be
regularly sent to be serviced (at least once per year) when
they are machine washed.
– Other cleaning and disinfecting methods are possible.
Have an expert check the effectiveness under local condi-
tions.
– Other detergents and disinfectants are possible. Clarify the
material compatibility and effectiveness beforehand with
the detergent or disinfectant manufacturer.
Automated cleaning and disinfection
(Validated with Miele G 7735 CD, program: Vario TD;
detergent: Neodisher Mediclean)
1. Plug the air inlet of the drive unit with the seal nipple
(519.596).
2. Seal the air hoses with the Synthes coupling by joining
the inlet and outlet.
3. Use sealing nipples (519.591, 519.596 or 519.592) to
close air hoses that have Dräger and BOC/Schrader cou-
plings.
4. Manually preclean critical sites such as cannulations,
unlocking sleeves and other difficult-to-access locations.
5. Place all articles in the washing tray in a way that an
effective washing/disinfection can be performed. Ensure
that the water can flow off any surface.
6. Prewash with cold water.
7. Wash with detergent according to the instructions of the
detergent manufacturer.
8. Rinse with tap water and then with cold demineralized
water.
9. Thermally disinfect with demineralized water at 92°.
10. Dry with hot air at 90°.
11. Upon removing the instruments, remove the seal nipple
and inspect the cannulations, coupling sleeves, etc.
for visible soiling. If necessary, repeat the cycle or clean
manually.
26 Synthes Compact Air Drive II Instructions for Use
Care and Maintenance
Lubrication
Lubricating the Power Tool
– After each use, apply around 5 drops of the Synthes
special oil (oil dispenser 519.970) into the air inlet of the
cleaned power tool.
– Connect the handpiece to a single hose, or to a double
hose using the adapter for oiling (519.790).
– Wrap gauze or a cloth around the hose coupling to absorb
the exiting oil.
– Run the handpiece for approximately 20 seconds, and
change the direction of rotation several times.
– When the exiting oil is visibly dirty, the process has to be
repeated.
Synthes 27
Lubricating the attachments
After each use, lubricate all moving parts of the attachments
with 1–2 drops of Synthes special oil (519.970). Distribute
the oil by moving the parts, and remove excess oil with a
cloth.
Caution
– To ensure a long service life and reduce repairs, the power
tool and all attachments must be lubricated after each use.
Exception: The Radiolucent Drive (511.300) may not be
lubricated.
– The power tool and accessories may only be lubricated
with Synthes special oil (519.970). The composition of the
vapor-permeable and biocompatible oil is optimized for
the specific requirements of the power tool. Lubricants
with other compositions can cause the power tool to jam
and be toxic.
– Only lubricate the power tool and attachments when
clean.
– Compressed air hoses should never contact oil. When
lubricating, never use a double hose without the adapter
for oiling (519.790) since leaking oil could otherwise
damage the hose.
28 Synthes Compact Air Drive II Instructions for Use
Care and Maintenance
Inspection and function test
– Visually inspect for damage and wear.
– Check the handpiece controls for smooth operation and
function.
– Check the coupling and unlocking sleeves of the hand-
piece and attachments for smooth operation, and check
for function together with instruments such as cutting
tools.
Packaging
– We recommend the Synthes Vario Case (689.200) or steril-
izing trays in combination with double-layer sterile paper.
– Sterile containers can also be used. Please follow the man-
ufacturer’s instructions.
– Pack the hoses separately since contact with hot metal can
damage the plastic. Do not join the hose ends for sterili-
zation and remove any sealing nipples.
Sterilization
(Validated with AD Linden 3/3/6 DECE)
For sterilization, we recommend a fractionated prevacuum
method with the following parameters:
– Temperature: 134°C
– Plateau time: 5 minutes
– Programs with a longer plateau time are also possible.
– After sterilization, the handpiece may only be used when it
has cooled to room temperature. Cooling may not be ac-
celerated. Only in emergencies may a largely cooled power
tool be connected to the compressed air and fully cooled
by being purged with air.
Inspection and Sterilization
Caution
– The following maximum values may not be exceeded:
143°C over a maximum of 22 minutes. Higher values can
damage the sterilized products.
– Hot air sterilization, ethylene oxide and formaldehyde
sterilization are not suitable for reasons of material incom-
patibility.
– Other sterilization methods are possible. Have an expert
check the effectiveness of all sterilization methods under
local conditions.
Storage
No special requirements (environmental conditions: see
page 3). Follow the instructions of the sterile paper and
sterile container manufacturers.
Contact Manufacturer
Please consult a local Synthes representative if you need any
additional information.
Synthes 29
Lock the power tool. Mount quick
coupling (511.750) or drill chuck
(511.730) and manually turn without
pulling the trigger.
Set operating pressure on pressure
regulator to 6–7 bar.
Exchange microfilter in the central air
supply.
Remove particles from the air inlet
with tweezers. Do not use sharp
objects for this.
Check that the entire length of the
hose does not exceed 8 m.
Check wall and power tool hose
couplings for leaks.
Have someone check the central air
system.
Let the tool run at maximum speed and
turn the softmode switch on and off
several times.
Press trigger several times; clean and
oil according to instructions. Use only
Synthes Special Oil (Oil Dispenser
519.970).
Lock the power tool. Remove particles
with tweezers. Do not use sharp
objects for this.
Send attachments for repair to
your Synthes representative.
Compressed air motor is blocked from
not operating for a long time.
Operating pressure is too low.
Microfilter is blocked.
Air inlet is blocked.
Hose is too long.
Hose couplings are defective.
Central air system is blocked.
Softmode switch is blocked.
The trigger is blocked by deposits
of blood, etc.
The locking pin on the attachment
coupling is blocked.
The connection geometry at the
attachments is faulty.
Problem Possible causes Remedy
Tool does not start.
Tool does not have enough power.
Power tool continues to operate
after releasing the trigger.
Attachments cannot be coupled
to the tool.
Troubleshooting
Despite pressing the release button, the
attachments cannot be removed from
the tool.
Tool is difficult to couple or cannot be
coupled.
The Kirschner wire is completely inside
the drill and cannot be moved forward.
Bone and tool heat up during surgery.
Oscillating saw attachment vibrates
too much.
Problem Possible causes Remedy
The attachment became jammed by
simultaneously pressing the release
button and pulling on the attachment.
Coupling geometry of the tool has
changed due to wear.
The Kirschner wire was inserted from
the rear.
The cutting tool is blunt.
The saw blade has come loose.
Press the release button again without
pulling on the attachment.
Exchange the tool, or send it to your
local Synthes service center.
Lock the power tool. Remove the quick
coupling for the Kirschner wires
(511.791), hold the drive shaft opening
facing downward, and shake the
Kirschner wire out.
Replace the tool.
Tighten the fixation knob for the saw
blade quick coupling more firmly (for
saw attachment 511.801), or tighten
the connection with the key (for saw
attachment 511.800).
30 Synthes Compact Air Drive II Instructions for Use
If the recommended solutions do not work, send the power
tool to your Synthes service center.
For further technical questions or information on our
services, please contact your Synthes representative.
Troubleshooting
Synthes 31
* Can also be used to close the air intake of compressed air-operated drive units
during washing.
Ordering Information
Air Hoses
Double Air Hoses, for Wall Coupling
Synthes Dräger BOC/Schrader
Length 3 m 519.510 519.610 519.511
Length 5 m 519.530 519.630 519.531
Double Spiral Air Hoses, for Wall Coupling,
working length variable up to 2 m
Synthes Dräger BOC/Schrader
519.550 519.650 519.551
Oscillating Saw Blades
Art. No. Art. No. Usable length Thickness of cut Width
non-sterile sterile in mm in mm in mm
519.230 519.230S 25 0.60 6
519.103 519.103S 25 0.60 10
519.250 519.250S 25 0.60 14
519.104 519.104S 49 0.60 10
519.150 519.150S 49 0.60 14
519.105 519.105S 49 0.60 20
519.100 519.100S 49 0.60 27
519.109 519.109S 60 0.90 25
519.170 519.170S 69 0.80 27
519.190 519.190S 69 0.80 50
519.106 519.106S 69 1.00 18
519.200 519.200S 69 1.00 27
519.113 519.113S 69 1.20 18
519.210 519.210S 69 1.20 27
519.118 519.118S 91 0.90 12.5
519.107 519.107S 95 0.90 19
519.108 519.108S 95 0.90 25
519.114 519.114S 95 1.25 19
519.115 519.115S 95 1.25 25
519.116 519.116S 95 1.40 19
519.117 519.117S 95 1.40 25
Reciprocating Saw Blades
Art. No. Art. No. Usable length Thickness of
non-sterile sterile in mm cut in mm
511.905 511.905S 80 1.05
511.907 511.907S 55 1.05
511.909 511.909S 55 0.85
511.912 511.912S 68 toothed on both sides 1.10
511.915 511.915S 40 for top for sternum 1.10
Drive units
511.701 Compact
™
Air Drive II
Attachments
310.900 Chuck with mini quick coupling
510.200 Right angled drive for medullary reaming
511.200 Oscillating drill attachment
511.300 Radiolucent drive
511.730 Chuck with key
511.731 Drill chuck, keyless
511.750 AO/ASIF quick coupling
511.761 Quick coupling for DHS/DCS
®
triple reamers
511.770 Torque limiter, 1.5 Nm
511.771 Torque limiter, 4.0 Nm
511.782 Hudson adapter
511.783 Trinkle adapter, modified (Zimmer adapter)
511.784 Trinkle adapter
511.785 Attachment for acetabular and medullary reaming
511.786 Attachment for acetabular and medullary reaming,
with optional reverse
511.787 Küntscher adapter
511.788 Harris adapter
511.791 Quick Coupling for Kirschner Wires ⭋ 0.6–3.2 mm
511.800 Oscillating saw attachment, with variable deflection,
with key No. 518.090
511.801 Oscillating saw attachment, with quick coupling
511.902 Reciprocating saw attachment
511.904 Top for sternum for reciprocating saw attachment
Accessories
510.190 Spare key, for No. 511.730
518.090 Key, for fixing of saw blades
519.400 Cleaning brush
519.591 Seal nipple for BOC/Schrader double air hoses with
st. steel coupling, silver
519.592 Seal nipple for BOC/Schrader double air hoses
with aluminum coupling, beige
519.596 Seal nipple for Dräger double air hoses*
519.790 Lubrication adapter
519.970 Oil dispenser with Synthes special oil
689.200 Vario Case
™
for Compact Air Drive, without lid,
without contents
689.507 Lid (stainless steel), size 1/1, for Vario Case
32 Synthes Compact Air Drive II Instructions for Use
Drill bits, 3-flute, for Radiolucent Drive
Art. No. Art. No. Diameter Usable
non-sterile sterile in mm length in mm
511.411 511.411S 2.0 with centering tip 122
511.412 511.412S 2.5 with centering tip 122
511.413 511.413S 2.7 with centering tip 122
511.414 511.414S 3.2 with centering tip 122
511.415 511.415S 3.5 with centering tip 122
511.416 511.416S 3.6 with centering tip 122
511.417 511.417S 4.0 with centering tip 122
511.418 511.418S 4.5 with centering tip 122
511.431 511.431S 3.2 with centering tip 80
511.432 511.432S 4.0 with centering tip 80
Ordering Information
036.000.064 SE_048033 AA 40050023 © Synthes 2006 Subject to modifications
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