Instructions
for Use
Air Pen Drive. Compact drive with
specific attachments for a
wide spectrum of applications.
Contents
Introduction
Air Pen Drive System
Attachments
General Information 3
Technical Data 4
Air Pen Drive 5
Angular Coupling 6
Hand Switch 7
Foot Switch 8
General Information 9
Drill Attachments 10
Screw Attachments 12
Kirschner Wire Attachment 12
Saw Attachments 13
Burr Attachments 15
Perforator 16
Craniotome Attachment 17
Irrigation 18
Synthes 1
Contents
Cutting Tools
Care and Maintenance
Troubleshooting
Ordering Information
Saw Blades 19
Burrs and Drill Bits 25
General Information 34
Preparation for Cleaning and Disinfection 35
Cleaning and Disinfection 36
Maintenance 38
Inspection and Sterilization 41
42
44
2 Synthes Air Pen Drive Instructions for Use
Introduction
Intended use
The Air Pen Drive is an air-driven system to be used for the
treatment in general traumatology, as well as for surgeries in
the areas of the hand, foot, spine, maxillofacial and neuro-
surgery. Only use Synthes accessories to guarantee opera-
tional reliability of the Air Pen Drive.
Patient safety
The Air Pen Drive is only to be used for patient treatment
after careful consultation of the instructions for use. It is rec-
ommended to have an alternative system ready to use during
application, as technical problems can never be completely
ruled out.
Starting the system
Before first use, new power tools and their accessories/at-
tachments have to run through the complete reprocessing
process. Protection caps and foils have to be completely
removed during preparation.
Never use oxygen to run air-powered systems (danger of
explosion!); only use compressed air or compressed nitrogen.
Recommended operating pressure: 6–8 bar (max 12 bar)
Only use original Synthes hoses for compressed air.
To avoid injuries the blocking mechanism of the machine has
to be activated before every manipulation.
Efficiently working cutting tools are the basis for successful
surgeries. Therefore, it is mandatory to check used tools after
every application for wear and/or damage and to replace
them if necessary. We recommend using new Synthes cut-
ting tools for every surgery.
Maintenance
Compliance with the maintenance specifications can consid-
erably extend the service life span of the Air Pen Drive. To
ensure proper operation of the machine, Synthes recom-
mends regular maintenance by the original manufacturer or
its exclusive sales agencies.
For further information on the use and maintenance of the
product, please contact your local Synthes representative.
Please observe the chapter on Care and Maintenance.
Transport
The original packaging is recommended to use for shipments
of the system. If the original packaging is not available any-
more, please contact your Synthes affiliate.
Warranty
The manufacturer assumes no warranty for damages arising
from improper use or unauthorized servicing.
Liability of the user
The user is liable for the surgical application.
Scope of delivery
The main components in the APD System are the handpiece,
Hand Switch, Foot Switch, Air Hose as well as attachments
and accessories. An overview of all components belonging to
the APD System can be found in the chapter “Ordering Infor-
mation”.
For using the APD System the following components are a
must:
– Air Pen Drive 60,000 rpm (05.001.080)
– Hand Switch (05.001.082) or Foot Switch (05.001.081,
also a Double Air Hose from Synthes is necessary to con-
nect the Foot Switch e.g. 519.510)
– Double Air Hose, for Air Pen Drive (05.001.083 or
05.001.084)
– At least one attachment belonging to the system and cut-
ting tool fitting to the attachment
For an optimal function of the system only Synthes cutting
Tools shall be used.
For sterilization and storage two system specific Vario Cases
are recommended and available.
For care and maintenance special tools are available, such as
cleaning brushes, Synthes Special Oil for EPD and APD, Main-
tenance Spray and Maintenance Unit.
Explanation of symbols used
This symbol indicates important information. On a
device, it refers to important information in the
enclosed documents.
This symbol indicates that the corresponding device
may not be immersed in liquids.
Synthes 3
General Information
4 Synthes Air Pen Drive Instructions for Use
Environmental conditions
Operation Transportation and storage
Temperature 10 – 40°C –20 – 50°C
50 – 104°F –4 – 122°F
Relative 30–75% 10–75%
humidity
Atmospheric 500–1060 hPA 500–1060 hPA
pressure 0.5–1.06 bar 0.5–1.06 bar
Duty cycle
Intermittent operation X
min on
Y
min off
Cycles
with 6.5 bar
Drilling Attachments 5 min 3 min unlimited
Burr Attachments unlimited – unlimited
Craniotome Attachment 1 min 30 s 5 cycles
Perforation 5 min 3 min unlimited
Reciprocating 3 min 2 min unlimited
Saw Attachment
Oscillating 1 min 2 min unlimited
Saw Attachment
Sagittal 1 min 2 min unlimited
Saw Attachment
Intermittent operation X
min on
Y
min off
Cycles
with12 bar*
Burr Attachment 15 min 10 min 2
Craniotome Attachment 1 min 30 s 5 cycles
Perforator 3 min 5 min unlimited
Technical specifications
Pen
Weight: 169 g / 5.96 oz
Length: 144 mm / 5.7 in
Recommended 6–8 bar
Pressure: For maximum 10 minutes (continuous
operation) it is possible to run the Air Pen
Drive up to 12 bar with the following
attachments: 05.001.045–05.001.050,
05.001.054, 05.001.059, 05.001.055.
Continuously 0–60.000 rpm at 6.5 bar
variable speed: 0–80.000 rpm at 12 bar (only with
05.001.045–05.001.050, 05.001.054,
05.001.059, 05.001.055)
Foot Switch
Dimensions: 267 mm⳯160 mm⳯47 mm
(bar included 151 mm)
10.5 in⳯6.3 in⳯1.9 in
(bar included 5.9 in)
Caution
– The Air Pen Drive must never be operated with oxygen,
due to danger of explosion. The Air Pen Drive should also
not be stored or operated in an explosive atmosphere.
– Dirt inside e.g. adapters, air hoses, angular coupling and
pen can cause loss of power.
Technical Data
* For maximum 10 minutes.
Introduction
Mounting the air hose on the handpiece
The Air Hose 05.001.083 is coupled by fitting the pins on
the hose coupling into the grooves on the coupling for hoses
on the handpiece and turning the hose coupling clockwise.
To remove the air hose simply turn the hose coupling piece
and pull it off the handpiece.
Adjusting the handpiece
Adjustment sleeve
Release sleeve for attachment
Coupling for hoses
LOCK position
Hand Switch position
Foot Switch position
Lock slide for adjustment sleeve
Caution:
The air hoses have to be connected properly and should
never be squeezed with sharp objects or obstructed by any
loads. Non-respect might lead to bursting of the outer hose!
Lock position Foot switch positionHand switch position
Air Pen Drive System
Air Pen Drive
Synthes 5
Adjustment sleeve
To avoid an unintentional change of the operating mode
the lock slide for adjustment sleeve
locks the adjustment
sleeve automatically. To be able to move the adjustment
sleeve the lock slide has to be pushed backwards. After hav-
ing reached the desired position release the lock slide and
the adjustment sleeve is locked in the desired position.
By turning the adjustment sleeve into the hand switch posi-
tion , the handpiece can be used with the Hand Switch.
In the foot switch position only the Foot Switch shall be
used! If the foot switch position is set and no Foot Switch
is attached the handpiece will run with full speed.
Either a Hand Switch or a Foot Switch can be used for speed
control.
The LOCK position is used for safety switch-off when
changing attachments and tools. This prevents accidental
start-up of the unit while performing these activities.
For instructions on mounting the attachments see the chap-
ter “Attachments”.
6 Synthes Air Pen Drive Instructions for Use
Air Pen Drive System
The Angular Coupling (05.001.085) can be connected to the
Air Pen Drive (05.001.080) and the Air Hose (05.001.083)
and is used to guide the air hose away from the handpiece in
a 45° angle. It allows 360° rotation.
Mounting the Angular Coupling
The Angular Coupling is coupled to the handpiece by fitting
the pins into the grooves on the coupling for hoses on the
handpiece and turning the Angular Coupling clockwise. The
Air Hose is then connected to the Angular Coupling by
fitting the pins on the Air Hose coupling into the grooves of
the Angular Coupling by turning it clockwise. To disassemble
it turn the parts counter-clockwise and pull the Air Hose
off the Angular Coupling, and then the Angular Coupling off
the handpiece.
Angular Coupling (05.001.085)
Synthes 7
Removing
To remove the Hand Switch, grasp the lever and pull it away
upwards.
Operation
The adjustment sleeve on the pen must be set on the hand
switch position for working with the Hand Switch.
The length of the Hand Switch can be individually adjusted
with the pull-out finger rest
. The speed can be continu-
ously adjusted by operating the Hand Switch. The Hand
Switch can be deactivated (LOCK position) or activated (ON
position) with the locking switch
.
Caution:
The angled sections of the handpiece and the Hand Switch
must run parallel with the Hand Switch mounted (see arrow
in picture above).
Always remove the Hand Switch before sterilization.
Hand Switch (05.001.082)
Positioning arrow
Pull-out finger rest
Positioning arrow
Guide groove
Locking switch
Mounting the Hand Switch on the handpiece
Position the Hand Switch on the handpiece so that both
positioning arrows
of the Hand Switch cover the position-
ing arrows
over the guide grooves
of the pen. Then
press downward vertically until the Hand Switch clicks into
position
8 Synthes Air Pen Drive Instructions for Use
Pedal
Irrigation ON/OFF button
Plug for Double Air Hose
Plug for Irrigation Control Unit
Plug for Air Pen Drive Hose
Connecting the Foot Switch
Connect a standard Synthes Double Air Hose (519.510
or 519.530) to the male plug for the Double Air Hose on the
Foot Switch
and connect it to the air outlet socket. Then
connect the Double Air Hose for Air Pen Drive (05.001.083)
to the female plug for Double Air Hoses
. To remove
the air hoses simply slide the female hose-coupling pieces in
direction of the arrow.
For assembling the Irrigation Control Unit
and Irrigation
Tube, see page 18.
Operation
The adjustment sleeve on the pen must be set on the Foot
Switch position for working with the Foot Switch.
The speed can be continuously adjusted with the pedal
.
Briefly pressing the irrigation button
activates or deacti-
vates the irrigation. If the irrigation button
is activated,
the irrigation fluid will flow when the pedal
is pressed.
Caution:
Never keep the adjustment sleeve in the Foot Switch
position , if no Foot Switch is connected! This will make
the pen run constantly and can be very dangerous for
patient and OR staff.
Foot Switch (05.001.081)
Air Pen Drive System
Synthes 9
Mounting the attachments on the handpiece
The attachments can be connected in 8 different positions
(45° increments). To mount, turn the release sleeve for the
attachments clockwise (see arrow on the release sleeve) until
it engages. The release sleeve protrudes slightly from the
black section of the handpiece toward the front. Insert the
attachment into the attachment coupling from the front and
press it lightly against the handpiece. The attachment auto-
matically engages. If the release sleeve accidentally closes,
turn the attachment clockwise while applying slight pressure
against the handpiece until it engages without holding
the release sleeve in place, or repeat the entire connection
process. Check secure holding of the attachment on the
handpiece by pulling on the attachment.
Removing the attachments from the handpiece
Turn the release sleeve for attachments (see page 5) clock-
wise until it disengages. Hold the attachment upward while
doing so. Then remove the attachment.
Attachments and accessories
For easier change of burrs, without having the Burr Attach-
ment or Cranio tome Attachment connected to the hand-
piece, the Handhold for Change of Instruments (05.001.074)
can be used.
Caution:
Only use Synthes saw blades, burrs and rasps while working
with the Air Pen Drive attachments. The use of other tools
voids the device warranty.
Attachments
General Information
Release sleeve
10 Synthes Air Pen Drive Instructions for Use
Attachments
Drill Attachment (05.001.030–05.001.032,
05.001.042–05.001.044, 05.001.110)
Speed: approx.1,800 rpm at 6.5 bar
The Air Pen Drive System includes straight and 45° Drill
Attachments with Mini Quick Coupling, J-Latch Coupling
and AO Coupling, as well as a straight Drill Attachment with
Hexagonal Coupling.
Mounting and removing tools
Lock unit. Pull back the release sleeve and insert/remove
the tool.
Release sleeve
Drill Attachments
Release sleeve
Drill Attachment 45°, cannulated, with Jacobs Chuck
(05.001.120)
Speed drill attachments: approx. 1,800 rpm at 6.5 bar
The cannulation of 1.6 mm permits the use of this attach-
ment for drilling and reaming over K-wires (e.g. for cannu-
lated screws and for cup & cone technique).
Mounting and removing tools
Lock unit. Open the chuck with the key provided (310.932)
or by hand by turning the two moving parts clockwise with
respect to each other. Insert/remove the tool. Close the
chuck by turning the moving parts counterclockwise and
tighten it by turning the key clockwise.
Synthes 11
Oscillating Drill Attachment (05.001.033)
Frequency: approx. 3,200 osc./min at 6.5 bar
The oscillating drilling movement of the Oscillating Drill
Attachment prevents tissue and nerves from wrapping
around the drill. This can considerably improve the operating
results.
Mounting and removing tools
With the Oscillating Drill Attachment, tools with a Mini Quick
coupling can be clamped. To do this, lock the unit, pull back
the release sleeve
and insert/remove the tool.
Release sleeve
Drill Attachment 90°, short (05.001.035) and long
(05.001.036) with Mini Quick Coupling
Speed: approx. 1,800 rpm at 6.5 bar
Due to its very small angled head, the 90° Drill Attachment,
enables good visibility during operations with narrow access
(e.g. intraoral, shoulder etc.).
Mounting and removing tools
Lock unit. Move the slide
to the side following the arrow
on the slide and insert/remove the tool. To secure the tool,
push the slide back again.
Slide
12 Synthes Air Pen Drive Instructions for Use
Attachments
Kirschner Wire Attachment (05.001.037)
Speed: approx. 2,700 rpm at 6.5 bar
With the Quick Coupling for Kirschner Wires, Kirschner
Wires of any length with a diameter of 0.6–1.6 mm
(0.02–0.06 in) can be tensioned. The tensioning lever
can be rotated by 300°, permitting individual adjustment
suitable for left and right-handed users).
Mounting and removing Kirschner Wires
Lock unit. To insert and remove Kirschner Wires, press the
tensioning lever
. After the lever is released, the Kirschner
Wire is automatically tensioned. To regrasp, press the
tensioning lever, pull back the unit along the Kirschner Wire
and then release the tensioning lever again.
Screw Attachments (05.001.034, 05.001.028,
05.001.029)
Speed: approx. 400 rpm at 6.5 bar
Mounting and removing tools
Lock unit. Pull back the release sleeve and insert/remove the
tool.
Caution
– Only use the attachment with 6.5 bar to avoid higher
speed than 400 rpm.
– Always use an appropriate torque limiting attachment
while putting locking screws into a locking plate.
– The APD contains no reverse mode for removing screws.
Release sleeve
Tensioning lever
Screw Attachments
Kirschner Wire Attachment
Synthes 13
Sagittal Saw Attachment (05.001.039)
Frequency: approx. 22,000 osc./min at 6.5 bar
Changing saw blades
1. Lock unit.
2. Press the clamping button
, lift the saw blade
and remove it.
3. Push a new saw blade into the saw blade coupling and
move it into the desired position. The saw blade can
be locked in 5 different positions (45° increments) for
optimum positioning.
4. Release the clamping button.
Caution
– Saw blades cannot be resharpened.
– Only use Synthes saw blades. The use of other saw blades
voids the device warranty.
Clamping button for saw blades
Working with saw attachments
Allow the unit to start up before placing it on the bone.
Avoid heavy pressure on the saw blade so that the cutting
process is not slowed and the saw teeth do not bind up
in the bone. The best sawing performance is achieved by
moving the unit slightly to and fro on the plane of the saw
blade. Imprecise cuts indicate worn saw blades, excessive
pressure or jamming of the saw blade due to tilting.
Information on handling saw blades
Synthes recommends using a new saw blade for each sur-
gery, as only then can it be ensured that the saw blade is
always optimally sharpened and clean. Used saw blades pres-
ent the following risks:
– Necrosis due to excess heat
– Infections due to residues
– Longer cutting time due to reduced sawing performance
Saw Attachments
14 Synthes Air Pen Drive Instructions for Use
Attachments
Reciprocating Saw Attachment (05.001.040)
Frequency: 18,000 osc./min at 6.5 bar
Both Synthes reciprocating saw blades and Synthes rasps can
be used with the Reciprocating Saw Attachment.
Replacing saw blades
1. Lock unit.
2. Turn the release sleeve for saw blades
clockwise until it
engages and remove the saw blade.
3. Insert a new saw blade until slight resistance can be felt.
Turn the saw blade with slight pressure until it automati-
cally engages.
Oscillating Saw Attachment (05.001.038)
Frequency: 16,000 osc./min at 6.5 bar
The Oscillating saw attachment is particularly well suited for
crescentic and angled saw blades.
Changing saw blades
1. Lock unit.
2. Pull back the release sleeve for saw blades
and remove
the saw blades from the mounting opening
.
3. Push a new saw blade into the mounting opening
and
move it into the desired position.
4. Release the release sleeve for saw blades.
Mounting and removing the Guide for
Kirschner Wires (05.001.121)
Secure the Guide for Kirschner Wires on the Oscillating Saw,
by pushing the Guide as far as possible over the attachment
from the front, so that it engages in the shape of the Oscil-
lating Saw. Then mount the attachment on the handpiece.
Release sleeve for saw blades
Mounting opening for saw blades
Kirschner Wire ⭋ 1.6 mm
Release sleeve for saw blades
Synthes 15
Burr Attachments
(05.001.045–05.001.050, 05.001.055, 05.001.063)
Gear ratio: 1:1
The system includes straight and angled Burr Attachments
in 3 lengths each (S, M, L). The related burrs are also marked
with S, M and L. Angled XL and XXL Burr Attachments
are available, for these attachments the L burrs shall be used.
Changing burrs
1. Lock unit.
2. Turn the release sleeve for burrs
until it engages in the
UNLOCK position and remove the tool.
3. Insert the new tool as far as possible, turn it slightly until
it locks in place and then turn the release sleeve for burrs
into the LOCK position until it engages. The burr is cor-
rectly clamped when the marking S, M or L on the burr
shank is no longer visible.
Information on handling burrs
– Synthes recommends using a new burr for each surgery,
as only then can it be ensured that the burr is always
optimally sharpened and clean. Used tools present the fol-
lowing risks:
– Necrosis due to excess heat
– Infections due to residues
– Longer cutting time due to reduced burr performance
Caution
– Burrs must be cooled with irrigation liquid to prevent heat
necrosis. For this purpose, use either the foot switch with
the irrigation flow control unit or irrigate manually.
– The attachments may only be used with the burrs intended
for this purpose or one size above (see marking S, M and L
on burr and attachment).
– Synthes recommends wearing protective goggles when
working with burrs.
– When the Burr Attachments are not attached to the hand-
piece during tool change, use the Handhold (05.001.074)
for easier change of burrs.
Release sleeve for burrs
Burr Attachments
16 Synthes Air Pen Drive Instructions for Use
Attachments
Release sleeve for Trepan Burrs
Locking pin
Locking groove
Protective Sleeve
05.001.096–05.001.097
Perforator
05.001.054
Trepan Burr
03.000.350–351
Perforator
Fig. 1 Fig. 2
Caution
– If conditions such as adherent dura, intracranial
pressure or other underlying abnormalities are pres-
ent in the area of the penetration, the perforator
may cut the dura. Caution must be observed when
perforating thin skull areas such as temporal bone,
infants, children, elderly, or diseased bone since
skull consistencies and thicknesses can vary and the
dura could be cut. Only use the perforator
05.001.054, the trepan burrs 03.000.350–
03.000.351 and the protective sleeves 05.001.096–
097 on bones with a thickness of 3 mm or above.
– It is recommended to cool the trepan burr during
trepanation (Use the irrigation nozzle 05.001.076).
– Check function before each use of the perforator.
– The user is liable for the surgical application.
– Synthes recommends using new cutting tools for
every surgery.
Perforator (05.001.054)
Gear reduction: 97:1
The perforator is used with the related trepan burrs
(03.000.350–351) including the protective sleeves
(05.001.096–097) to open a cranium with a thickness
of 3 mm or above. The handpiece has to be in the
FWD position. Hold the perforator perpendicular
to the skull at point of penetration and always apply
constant pressure when the trepan burr is engaged in
the bone. As soon as the cranium is cut through, the
trepan burr automatically disengages.
Changing trepan burrs
1. Turn the release sleeve for trepan burrs
until the
locking pin
disengages from the locking groove
. (Position ).
2. Pull off the trepan burr together with the protec-
tive sleeve.
3. Insert a new trepan burr into the protective sleeve
and make sure that the pins on the trepan burr
engage properly in the grooves in the protective
sleeve.
4. Place the new trepan burr together with the pro-
tective sleeve on the perforator.
5. Turn the release sleeve for trepan burrs
until the
locking pin
engages in the locking groove
.
(Position ).
Craniotome Attachment
Craniotome Attachment (05.001.059)
and Dura Guards (05.001.051–05.001.053)
Gear ratio: 1:1
The system includes a Cranitome Attachment and Dura
Guards in 3 lengths (S, M, L). The related burrs are also
marked with S, M and L.
Changing burrs
1. Lock the handpiece.
2. Turn the release sleeve for burrs
until it engages in
the UNLOCK position.
3. Pull off the Dura Guard over the burr and remove the burr.
4. Insert the new burr as far as possible turning it slightly.
The burr is correctly inserted when the Dura Guard can be
properly fitted.
5. Push the Dura Guard over the burr and turn the release
sleeve into the LOCK position until it engages to clamp
the burr and the Dura Guard.
6. Check that Dura Duard is well engaged and that Cranial
Burr can be turned freely.
Caution
– Only use the Craniotomes with the related Cranial Burrs.
– Cranial Burrs must be cooled with irrigation liquid to avoid
heat necrosis. For this purpose, attach the Irrigation Tube
(05.001.069.01S and 05.001.069.05S) to the nozzle built
into the Dura Guard.
– Only use Synthes Cranial Burrs. The use of other burrs
voids the device warranty.
– Avoid all side load on burr and Dura Guard, as they may
otherwise break.
– When the Craniotome Attachment is not attached to the
handpiece during tool change, use the Handhold,
(05.001.074), for easier change of the burr and Dura
Guard.
Release sleeve for burrs and Dura Guard
Craniotome Attachment
05.001.059
Cranial Burr
03.000.124S–03.000.126S
Dura Guard
05.001.051–05.001.053
Synthes 17
18 Synthes Air Pen Drive Instructions for Use
12
34
Irrigation Control Unit (05.001.090)
and Irrigation Tube Set (05.001.069.01S and
05.001.069.05S)
Preparing the Irrigation Control Unit.
1. Connect the Irrigation Control Unit to the Foot Switch, by
pushing the end of the Air Tube into the plug for the Irri-
gation Control Unit (see page 7, Position no. 4). Remove
the hand pump of the pressure collar and connect the
pressure collar to the Irrigation Control Unit. See picture 1.
2. Charge pressure collar with an irrigation fluid bag. See
picture 1.
Inserting Irrigation Tube
1. Remove the sterile Irrigation Tube from the sterile pack-
age. See picture 2.
2. Secure the Irrigation Nozzles on the attachment used, by
pushing the Irrigation Nozzles for the Burr Attachments,
Drill Attachments, Oscillating Saw and Reciprocating Saw
as far as necessary over the attachment from the front.
Push the Irrigation Nozzle for the Sagittal Saw and the
Perforator onto the attachment from the rear (from the
attachment coupling side) before mounting the attach-
ment on the handpiece.
3. First fit the Irrigation Tube on the Irrigation Nozzle used
as in picture 3, and then turn it around the Air Hose and
secure it with e.g. Hose Holder 519.598 in the unsterile
area. Premounted clips should not be used; those are in-
tended for use together with the Electric Pen Drive cable.
4. Route the Irrigation Tube end into the non-sterile area
and press the Irrigation Tube in the grooves of the Irriga-
tion Control Unit in accordance with the marking.
See picture 4.
5. Remove the protective cap from the cannula and connect
cannula to Irrigation Bag. When doing so, make sure that
the connection nipple of the cannula is not touched by
non- sterile persons. See picture 5.
Picture 1
Picture 2 Picture 3
Picture 4
Picture 5
Irrigation
Attachments
Synthes 19
Cutting Tools
Sagittal Saw Blades
The following saw blades for the Sagittal Saw Attachment
(05.001.039) are available from stock. All saw blades are
sterile packed.
Art. No. Usable Blade Width Cut Thickness
Length (mm) (mm) (mm)
03.000.314S 18 2.5 0.38
03.000.300S 18 4.0 0.38
03.000.301S 15 6.0 0.38
03.000.302S 31 6.0 0.38
03.000.303S 22 8.0 0.38
03.000.304S 15 10.0 0.38
03.000.305S 31 10.0 0.38
03.000.306S 22 12.0 0.38
03.000.307S 15 16.0 0.38
03.000.308S 27 6.0 0.60
03.000.309S 27 10.0 0.60
03.000.310S 27 14.0 0.60
03.000.315S 43 20.0 0.60
Saw Blades
20 Synthes Air Pen Drive Instructions for Use
Cutting Tools
Reciprocating Saw Blades
The following saw blades for the Reciprocating Saw Attach-
ment (05.001.040) are available from stock. All saw blades
are sterile packed.
Art. No. Cutting Edge Blade Height Cut Design,
Length (mm) Thickness Special Application
(mm) (mm)
03.000.320S 13.0 6.4/2.9 0.60
03.000.321S 20.0 6.4/2.9 0.60
03.000.322S 7.0 4.0 0.60
03.000.323S 14.0 6.4 0.60
03.000.324S 14.5 4.0 0.60
03.000.325S 25.0 5.5 0.60 For rhinoplasty
03.000.326S 27.0 6.4 0.60
03.000.327S 27.0 6.4/2.9 0.60
03.000.328S 33.5 6.4 0.60
03.000.329S 34.5 5.0/2.5 0.60 Crescent-shaped,
for vertical osteotomy
03.000.330S 33.5 6.4 0.60 Downward offset
03.000.331S 33.5 6.4 0.60 Right offset
03.000.332S 33.5 6.4 0.60 Left offset
Note: After they are removed from their packages, the Re-
ciprocating Saw Blades can be put in the Support for
Cutting Tools (68.000.007) for easy intraoperative removal.
Synthes 21
Synthes 21
Art. No. Cutting Edge Blade Height Cut Design,
Length (mm) Thickness Special Application
(mm) (mm)
03.000.334S 20.0 6.4/2.9 0.60 LeFort I Osteotomy,
Rhinoplasty
03.000.335S 27.0 6.4/2.9 0.60 LeFort I Osteotomy,
Rhinoplasty
Note: After they are removed from their packages, the Re-
ciprocating Saw Blades can be put in the Support for
Cutting Tools (68.000.007) for easy intraoperative removal.
Elongated Reciprocating Saw Blades
The following saw blades for the Reciprocating Saw Attach-
ment (05.001.040) are available from stock. All saw blades
are sterile packed.
Note: After they are removed from their packages, the Re-
ciprocating Saw Blades can be put in the Support for
Cutting Tools (68.000.007) for easy intraoperative removal.
Art. No. Cutting Edge Blade Height Cut Design,
Length (mm) Thickness Special Application
(mm) (mm)
03.000.336S 13.0 3.20 0.40 intra-dental
03.000.337S 20.0 3.16 0.40 intra-dental
Thin Reciprocating Saw Blades
The following saw blades for the Reciprocating Saw Attach-
ment (05.001.040) are available from stock. All saw blades
are sterile packed.
22 Synthes Air Pen Drive Instructions for Use
Cutting Tools
Art. No. Cutting Edge Blade Height Cut Design,
Length (mm) Thickness Special Application
(mm) (mm)
03.000.338S 9.20 7.40 0.50 Left – BSSO
03.000.339S 9.20 7.40 0.50 Right – BSSO
I.B.O. Saw Blades
The following saw blades for the Reciprocating Saw Attach-
ment (05.001.040) are available from stock. All saw blades
are sterile packed.
Synthes 23
Synthes 23
Art. No. Usable Blade Height Cut Thick- Design,
length (mm) (mm) ness (mm) Special Application
03.000.360S 11 5 Cross-grinding,
for Rhinoplasty
03.000.361S 14 7 Cross-grinding,
for Rhinoplasty
03.000.362S 11 5 Straight-grinding,
for Rhinoplasty
03.000.363S 14 7 Straight-grinding,
for Rhinoplasty
03.000.364S 19 4.5 4.5 Interphalangeal joint
replacement, proximal
03.000.365S 19 6 6 Interphalangeal joint
replacement, distal
Rasps and broaches
The following cutting tools for the Reciprocating Saw
Attachment (05.001.040) are available from stock.
All cutting tools are sterile packed.
24 Synthes Air Pen Drive Instructions for Use
Crescentic Blades Art. No. Usable Blade Width Cut Thickness Diameter
Length (mm) (mm) (mm) (mm)
03.000.311S 26.5 13.3 0.60 18
03.000.312S 25 16.3 0.60 22
03.000.313S 30 17.9 0.60 18
03.000.316S 30 21.9 0.60 22
105° Angled Blades Art. No. Usable Blade Width Cut Thickness Usable Shank
intra-oral Length (mm) (mm) (mm) Length (mm)
03.000.340S 7 11.5 0.38 70
03.000.341S 12 11.5 0.38 70
03.000.342S 12 9.5 0.38 70
03.000.343S 12 4.5 0.38 70
Saw blades for Oscillating Saw Attachment
The following saw blades for the Oscillating Saw Attachment
(05.001.038) are available from stock.
Cutting Tools
Synthes 25
Synthes 25
Burrs for Burr Attachments 05.001.045–050, 05.001.055,
05.001.063
The following burrs with an EPD/APD Coupling are available
from stock. All burrs are provided sterile packed.
Round burrs Max. diameter Attachment Attachment Attachment
03.000.XXXS (mm) Type S Type M Type L–XXL
1.0 000 001 002
1.5 003 004 005
2.0 230 231 232
2.5 006 007 008
3.0 009 010 011
4.0 012 013 014
5.0 015 016 017
6.5 018 019 020
8.0 021 022 023
Round burrs, diamond-coated Max. diameter Attachment Attachment Attachment
03.000.XXXS (mm) Type S Type M Type L–XXL
1.0 030 031 032
1.5 033 034 035
2.0 036 037 038
2.5 039 040 041
3.0 042 043 044
3.5 045 046 047
4.0 048 049 050
5.0 051 052 053
6.0 054 055 056
Burrs and Drill Bits
Note: See table for end digits.
26 Synthes Air Pen Drive Instructions for Use
Cutting Tools
Acorn burrs Max. diameter Head Attachment Attachment Attachment
03.000.XXXS (mm) Length Type S Type M Type L–XXL
(mm)
5.0 6.7 233 234 235
6.0 8.0 060 061 062
7.5 9.5 063 064 065
9.0 11.4 066 067 068
Egg-shaped burrs Max. diameter Head Attachment Attachment Attachment
03.000.XXXS (mm) Length Type S Type M Type L–XXL
(mm)
4.0 8.0 070 071 072
5.5 10.0 073 074 075
Pear-shaped burrs Max. diameter Head Attachment Attachment Attachment
03.000.XXXS (mm) Length Type S Type M Type L–XXL
(mm)
4.0 6.9 236 237 238
5.0 8.3 076 077 078
6.0 9.7 079 080 081
Barrel-shaped burrs Max. diameter Head Attachment Attachment Attachment
03.000.XXXS (mm) Length Type S Type M Type L–XXL
(mm)
4.0 9.0 239 240 241
5.0 10.0 082 083 084
6.0 11.0 242 243 244
Synthes 27
Synthes 27
Fissure burrs, tapered Diameter Head Attachment Attachment Attachment
Carbide (mm) Length Type S Type M Type L–XXL
03.000.XXXS (mm)
1.0–1.6 4.5 085 086 087
1.6–2.3 5.2 088 089 090
2.1–2.6 6.8 091 092 093
Fissure burrs, cylindrical Max. diameter Head Attachment Attachment Attachment
Carbide (mm) Length Type S Type M Type L–XXL
03.000.XXXS (mm)
1.6 4.3 094 095 096
3.0 16.0 097 098 099
Inverted cone burrs Max. diameter Head Attachment Attachment Attachment
03.000.XXXS (mm) Length Type S Type M Type L–XXL
(mm)
6.5 6.1 100 101 102
Drum burrs Max. diameter Head Attachment Attachment Attachment
03.000.XXXS (mm) Length Type S Type M Type L–XXL
(mm)
4.7 7.9 245 246 247
6.0 7.9 103 104 105
9.1 7.9 106 107 108
28 Synthes Air Pen Drive Instructions for Use
Cutting Tools
Circular burrs Diameter Head Attachment Attachment Attachment
diamond-coated (mm) Length Type S Type M Type L–XXL
03.000.XXXS (mm)
25.0 0.7 109 110 111
Lindemann burr Diameter Head Attachment Attachment Attachment
03.000.XXXS (mm) Length Type S Type M Type L–XXL
(mm)
1.8–2.3 20.2 112 113 114
Swanson burrs Max. diameter Head Attachment Attachment Attachment
03.000.XXXS (mm) Length Type S Type M Type L–XXL
(mm)
2.0 6.3 115 116 117
3.0 9.7 118 119 120
4.0 12.7 121 122 123
5.0 15.8 160 161 162
Pin-shaped burrs Diameter Head Attachment Attachment Attachment
03.000.XXXS (mm) Length Type S Type M Type L–XXL
(mm)
1.1–1.4 6.0 127 128 129
1.5–2.1 12.0 130 131 132
3.0 19.5 248 249 250
Synthes 29
Neuro burrs Max. diameter Head Attachment Attachment Attachment
03.000.XXXS (mm) Length Type S Type M Type L–XXL
(mm)
1.7 2.3 133 134 135
2.2 3.7 136 137 138
2.9 3.8 139 140 141
Drill bits Max. diameter Attachment Attachment
03.000.XXXS (mm) Type S Type M
1.0 142 143
1.1 144 145
1.3 146 147
1.5 148 149
2.0 150 151
2.5 152 153
Wire pass drills Max. diameter Head Attachment Attachment
03.000.XXXS (mm) Length Type S Type M
(mm)
1.1 5.0 154 155
1.5 7.0 156 157
2.0 7.0 158 159
30 Synthes Air Pen Drive Instructions for Use
Cutting Tools
Cranial burrs Diameter Usable Dura Guard Dura Guard Dura Guard
03.000.XXXS (mm) Head Length Type S Type M Type L
(mm)
1.2–1.8 11 124
1.3–2.2 16 125
1.7–3.0 25 126
Burrs for Craniotome Attachment (05.001.059)
and Dura Guards (05.001.051–053)
The following burrs with an EPD/APD Coupling are available.
All burrs are provided sterile packed.
Trepan burrs Diameter Protection Sleeve Protection Sleeve
03.000.XXX (mm) 05.001.096 05.001.097
03.000.XXXS 05.001.096S 05.001.097S
7 350
12 351
Burrs for Perforator (05.001.054)
The following burrs are available.
The Trepan burrs and Protection Sleeves are available
unsterile and sterile packed.
Note: See table for end digits.
Note: After they are removed from their packages,
the burrs can be put in the Support for Cutting Tools
(68.000.007) for easy intraoperative removal.
Synthes 31
Burrs with Mini Quick and J-Latch Coupling
The following burrs with a Mini Quick ( ) and J-Latch
Coupling ( ) are available from stock. All burrs are
provided sterile packed.
Note: See table for end digits.
Round burrs Max. diameter Overall Overall
03.000.XXXS (mm) Length Length
28 mm 45 mm
3.0 170 171 Mini-Quick
200 201 J-Latch
5.0 172 Mini-Quick
202 J-Latch
Egg-shaped burrs Max. diameter Head Overall Overall
03.000.XXXS (mm) Length Length Length
(mm) 28 mm 45 mm
7.0 11.0 173 174 Mini-Quick
203 204 J-Latch
8.0 4.8 175 176 Mini-Quick
205 206 J-Latch
Pear-shaped burrs Max. diameter Head Overall Overall Overall
03.000.XXXS (mm) Length Length Length Length
(mm) 23/24 mm 28 mm 45 mm
5.0 8.3 183 184 185 Mini-Quick
213 214 215 J-Latch
6.0 9.7 186 187 188 Mini-Quick
216 217 218 J-Latch
32 Synthes Air Pen Drive Instructions for Use
Cutting Tools
Note: After they are removed from their packages, the burrs
can be put in the Support for Cutting Tools 68.000.007 for
easy intraoperative removal.
Bud burrs Max. diameter Head Overall Overall Overall
03.000.XXXS (mm) Length Length Length Length
(mm) 23/24 mm 28 mm 45 mm
5.0 8.3 177 178 179 Mini-Quick
207 208 209 J-Latch
6.0 9.7 180 181 182 Mini-Quick
210 211 212 J-Latch
Fissure burrs, tapered Max. diameter Head Overall Overall
03.000.XXXS (mm) Length Length Length
(mm) 28 mm 45 mm
1.0–2.1 11.3 189 190 Mini-Quick
219 220 J-Latch
1.6–3.2 12.0 191 192 Mini-Quick
221 222 J-Latch
Circular burrs Max. diameter Overall
03.000.XXXS (mm) Length
28 mm
8.0 193 Mini-Quick
223 J-Latch
10.0 194 Mini-Quick
224 J-Latch
12.0 195 Mini-Quick
225 J-Latch
15.0 196 Mini-Quick
226 J-Latch
Lindemann burrs Diameter Head Overall
03.000.XXXS (mm) Length Length
(mm) 53 mm
2.0–2.3 35 197 Mini-Quick
227 J-Latch
Synthes 33
Drill Bits with Stop, Diameter Usable Usable Usable Usable Usable
with Mini Quick Coupling (mm) Length Length Length Length Length
These drill bits are available 4 mm 6 mm 8 mm 12 mm 18 mm
unsterile and sterile packed.
1 370 371 372 384
03.000.XXX 1.1 373 374 375 376
03.000.XXXS 1.5 377 378 379
1.8 380 381 382
2.0 383
34 Synthes Air Pen Drive Instructions for Use
Regular care and maintenance according to the specifications
of the instructions for use (DIN EN ISO 17664) can consider-
ably increase the reliability and service life of the system com-
ponents. For this purpose, Synthes recommends annual
maintenance and inspection by the original manufacturer
or its exclusive sales offices. The manufacturer shall assume
no responsibility for damage resulting from improper opera-
tion or unauthorized maintenance.
The following processing methods are valid – unless other-
wise stated – for the entire Synthes Air Pen Drive Assort-
ment. The detergent will be in contact with the following
materials belonging to the system: stainless steel, aluminium,
plastic and rubber.
Warning Notice
– Pay extra attention to cannulations, release sleeve, and
other narrow parts.
– Detergents with a pH-value over 11.0 can shorten the lifes-
pan of the system components.
– Regular oiling of the system components with the Synthes
Maintenance Unit (05.001.099), the Maintenance Spray
(05.001.098) or Synthes Oil (05.001.095) is essential. It
reduces wear and increases the lifespan – especially when
machine washing is used for the products.
Restrictions regarding reprocessing
Frequent reprocessing has little impact on the machine and
attachments. The service life of a product is normally decided
by wear and tear from using the product, but can be identi-
fied soon enough during the annual service. For cutting tools
Synthes recommends the use of a new cutting tool for each
procedure.
Disposal of waste
Follow the national regulations regarding disposal of waste.
Your local Synthes representative is willing to take old or de-
fect power tools back.
Care and Maintenance
General Information
Air in-take
Hose couplings
Release sleeve
Air in-take
In the operating room
Surface contamination is to be removed with a disposable
cloth or paper cloth.
Storage and transport
No special requests, although it is recommended to reprocess
instruments as soon as possible after use.
Preparation for cleaning
– Cleaning must immediately be carried out after each use.
– The handpiece and attachments may not be immersed or
cleaned in an ultrasonic bath.
– Make sure that no cleaning solution enters the air inlet
of the handpiece as well as the inside of the hose. See
pictures
–
.
– Do not use pointed objects for cleaning.
– When cleaning the handpiece, do not insert objects into
the air inlet and outlet holes since this would damage the
micro filter.
– The Irrigation Control Unit and the Foot Switch may only
be wiped off with an absorbent cloth.
– Before cleaning and disinfection, all attachments and in-
struments have to be removed from the handpiece.
– Make sure that the release sleeve is free from residues and
can move properly. See picture
.
Preparation for Cleaning and Disinfection
Synthes 35
05.001.091
Care and Maintenance
36 Synthes Air Pen Drive Instructions for Use
Manual cleaning and disinfection
1. Separate all system components (handpiece, hand
switch, angled coupling, hoses, attachments, tools) from
each other.
2. Wipe off the Irrigation Control Unit with an absorbent
cloth soaked in disinfectant; do not immerse the Irriga-
tion Control Unit.
3. Wipe off the Foot Switch with an absorbent cloth
soaked in disinfectant. Make sure that no water gets
into the air in-take or air out-let holes. Also make sure
that no water enters the hole in the bottom plate. Do
not immerse the Foot Switch.
4. Plug the air in-/outlet of the drive unit with the Protective
Cap (05.001.086), by inserting the pins of the cap into
the groves of the coupling for hoses and turning the cap
clockwise. See picture
. Make sure that the surfaces,
which the Protective Cap will cover, are not contami-
nated.
5. Before connecting both sides of the Air Hose
(05.001.083, 05.001.084) with the Seal Nipple
(05.001.091), see picture
, make sure that the sur-
faces, which the Seal Nipple will cover, are not contami-
nated. If they are, first wipe off or spray these surfaces
with disinfectant according to the manufacturers in-
structions, and then put the Seal Nipple on. Make sure
that no solution enters the hose.
6. Remove coarse residues on the handpiece and the
attachments with a pair of tweezers and/or a cloth. Pay
extra attention to the Sagital and Oscillating Saw At-
tachments and make sure that all residues are removed
on and in the saw blade couplings.
7. Wipe off or spray the handpiece, attachments and ac-
cessory parts with disinfectant and allow the agent to
take effect according to the manufacturer’s instructions.
8. Remove all residues from the disinfected drive unit (use
Protective Cap 05.001.086 to avoid that water enters
the air intake or outlet of the pen), attachments and ac-
cessory parts under running cold water with a soft brush
or cloth. When doing so, turn the release sleeve for at-
tachments of the drive unit in the direction of the arrow
to open it.
9. Open the coupling for sawblades of the Sagital Saw
Attachment by pressing the clamping button and clean
the inside of the coupling with a soft brush.
See Nipple for Double Air Hose for Air Pen Drive
Pen with Protectiv Cap
10. Clean the cannulations of the Quick Coupling for
Kirschner Wires (05.001.037), Drill Attachment 45°, can-
nulated, with Jacobs Chuck (05.001.120) and the Guide
for Kirschner Wires for Oscillating Saw Attachment
(05.001.121) with the supplied cleaning brush. Flush the
inner lumen of irrigation nozzles with a syringe using
cold tap water.
11. Wipe the unit and accessories with an absorbent cloth
to dry them.
12. The adapters for Schrader-/Synthes Coupling and
Dräger-/Synthes Coupling also have to be cleaned when
needed, to assure full performance of the system.
Cleaning and Disinfection
05.001.086
Automated cleaning and disinfection
(Validated with Miele G 7735 CD, Program Vario TD;
Detergent: Neodisher Midizym, DECONNEX 23 Neutraclean,
DECONNEX 23 Neutrazym)
1. Do not machine wash the Irrigation Control Unit and the
Foot Switch. See Manual Cleaning and Disinfection on
previous page (point 2 and 3).
2. Plug the air inlet of the drive unit with the protective cap
(05.001.086). See picture
on previous page. Make
sure that the surfaces, which the Protective Cap will
cover, are not contaminated.
3. Before connecting both sides of the Air Hoses
(05.001.083, 05.001.084) with the Seal Nipple
(05.001.091), make sure that the surfaces, which the
Seal Nipple will cover, are not contaminated. If they are,
first wipe off or spray these surfaces with disinfectant
according to the manufacturers instructions, and then
put the Seal Nipple on. Make sure that no solution en-
ters the hose. See picture
on previous page.
4. Manually clean critical sites such as cannulations, un-
locking sleeves, lumen of irrigation nozzles and other
difficult-to-reach locations as described on previous
page, points 8 and 9.
5. Position the devices in the washing machine so that
dead zones do not arise and the water can properly
drain.
6. Pre-rinse with cold water.
7. Wash with detergents 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 the Protective Cap and inspect the cannulations,
coupling sleeves, etc. for visible soiling. If necessary, re-
peat the cycle or clean manually.
Caution
For automated cleaning, also consult the brochure “Power
Tools-Machine washing recommendations” (036.000.101)
– Drive units (especially seals and bearings) are exposed to
greater stress during machine washing than when they are
cleaned manually. For this reason, drive units must be reg-
ularly sent for service (at least once per year) when they
are machine washed.
– The use of other cleaning and disinfecting methods is
possible. Have an expert check the effectiveness under
local conditions.
– The use of other detergents and disinfectants is possible.
Clarify the material compatibility and effectiveness before-
hand with the detergent or disinfectant manufacturer.
Synthes 37
Care and Maintenance
38 Synthes Air Pen Drive Instructions for Use
Maintenance – with the Synthes Maintenance Unit
Synthes recommends the use of the Synthes Maintenance
Unit (05.001.099) developed for oiling of handpiece and at-
tachments. With the Maintenance Unit an optimal mainte-
nance of the system over the entire service life can be en-
sured. The operation of the Maintenance Unit is explained in
the related instructions for use (036.000.098).
For attaching the Air Pen Drive to the Maintenance Unit, the
Adapter for Maintenance Unit for Air Pen Drive 05.001.089,
has to be used. The pen must be on position foot switch dur-
ing oiling.
It is recommended to apply Synthes Special Oil 05.001.095
for Electric and Air Pen Drive after each use or when needed,
on movable parts on the handpiece as described in the
captet entitled “Maintenance – manually”.
Caution:
The Air Pen Drive has to be oiled through the air in-/outlet,
not through the front.
Maintenance Unit,
05.001.099
Adapter for Maintenance
Unit, for Air Pen Drive
05.001.089
Maintenance
Maintenance – manually
Oiling the handpiece – with Maintenance Spray
05.001.098
1. Perform maintenance on the handpiece following every
use with the Synthes Maintenance Spray (05.001.098)
and Oiling Adapter for Air Pen Drive (05.001.092). The
pen must be on foot switch position.
2. Push the spray over the air in-take part and briefly actuate
it once (approx. 1 sec.). When doing so, wrap the adapter
for Air Pen Drive (05.001.092) with a cloth to catch excess
oil, or hold it over a washbasin. Always spray away from
the body.
3. Remove the excess oil with a cloth after spraying.
It is recommended to apply Synthes Special Oil 05.001.095
for Electric and Air Pen Drive after each use or when needed,
on movable parts on the handpiece as described on the next
page.
Oiling the attachments
1. Perform maintenance on the attachments following every
use with the Synthes Maintenance Spray (05.001.098)
and oiling Adapter for Attachments for Maintenance
Spray (05.001.102).
2. Push the spray over the attachment coupling and briefly
actuate it once (approx. 1 sec.). When doing so, wrap the
attachments with a cloth to catch excess oil, or hold over
a washbasin. Always spray away from the body.
3. Remove the excess oil with a cloth after spraying.
Synthes 39
Maintenance of movable parts on handpiece
and Foot Switch – with Synthes special oil (05.001.095)
Apply Synthes special oil 05.001.095 for Electric and Air Pen
Drive after each use or when needed, on movable parts on
the handpiece and the Foot Switch.
Oiling movable parts of the handpiece
Apply one drop of oil in the slots between the adjustment
sleeve
and the basic body, one drop of oil in the slots
behind the release sleeve
and move the sleeves. To oil the
valve
of the handpiece first set the handpiece on Hand
Switch position. Then drop one drop of oil on the valve and
connect the Hand Switch to the handpiece. Operate the
Hand Switch by moving it up and down. Make sure that the
valve opens and closes and that oil get into the valve. If
necessary, repeat the oiling procedure. Finish by wiping off
excess oil from the handpiece.
Oiling movable parts of the Foot Switch
If the connections for air hoses and irrigation do not move
smoothly please drop 2 drops of Synthes special oil
05.001.095 on each connection and move them to spread
the oil.
Caution:
Only use the Synthes Maintenance Spray (05.001.098)
or/and Synthes Electric and Air Pen Drive Oil (05.001.095).
Their biocompatible composition matches the requirements
for power tools in the operating room. Lubricants with other
compositions may lead to sticking and could have a toxic
effect.
40 Synthes Air Pen Drive Instructions for Use
Care and Maintenance
Inspection and function check
1. Carry out a visual inspection to see if the products are
damaged or worn out.
2. Check function and movement of the operating elements
(adjustment sleeve and release sleeve of the pen as well as
couplings of the attachments).
3. Synthes recommends replacing all cutting tools after each
use.
Packaging
– Pay attention that the handpieces are properly held in
place in the basket and cannot move during transport,
sterilization and storage, as shocks could damage them.
– We recommend the use of Synthes Vario Case
(68.000.020 or 68.000.030) or sterilization baskets in com-
bination with double layers of sterile paper.
– Use of containers for sterilization is also possible. Please
see the instructions from the chosen manufacturer.
– Remove the Seal Nipple for Double Air Hose for Air Pen
Drive (05.001.091) and the Protective Cap (05.001.086)
from the Air Pen Drive before sterilization.
Sterilization
(Validated with AD Linden 3/3/6 DECE).
We recommend a sterilization program including a pre -
vacuum method with the following parameters:
– Temperature: 134°C
– Plateau time: 5 minutes
– Programmes with longer plateau times are also possible.
– After sterilization, the handpiece should only be used
again when it has cooled down to room temperature. The
cooling process must not be accelerated.
Inspection and Sterilization
Synthes 41
Caution
– The following sterilization parameters must not be
exceeded:
– Temperature 143°C (289.4°F) during a maximum of
22 minutes. Higher values will damage the products.
– The Foot Switch and the Irrigation Control Unit must not
be sterilized.
– The handpiece, the attachments and other accessories
(hose,tools, hand switch etc.) must not be assembled
during sterilization.
– Remove the Hand Switch for sterilization. If this is not
done, the function of the Hand Switch can be damaged!
– Do not use the following sterilization methods, because
of incompability with materials:
– Ethylene oxide sterilization
– Formaldehyde sterilization
– Hot-air sterilization (see above, max. temperature)
– Other sterilization methods are possible. Have a trained
expert check the effectiveness of all sterilization methods
under local conditions.
Storage
– Pay attention that the handpieces are properly held in
place in the basket and cannot move during transport and
storage, as shocks could damage them.
– Please note the instructions from the manufacturer of
sterile paper and sterile containers.
Contact Manufacturer
Please contact your local Synthes representative.
For information on the reprocessing of Synthes cutting tools please see the
brochure “Reprocessing of Cutting Tools” (036.000.499)
Troubleshooting
Problem
Pen does not start up.
Drive has not enough power.
Possible causes
Adjustment sleeve on pen is set to LOCK
position.
Release sleeve for burr on burr attach-
ment set to UNLOCK position.
Hand Switch turned 180°.
Hand Switch cannot work because Foot
Switch is shutting off air supply.
Adjustment sleeve is in the position
HAND or LOCK while trying to work with
the Foot Switch.
Safety switch on Hand Switch is in LOCK
position.
Operating pressure too low.
Micro filter blocked.
Air inlet is blocked.
Hose is too long.
Hose couplings defective.
Central air supply
tubes are obstructed.
Remedy
Set adjustment sleeve to HAND or FOOT
switch position.
Set release sleeve on burr attachment
to LOCK position.
Turn Hand Switch 180° and fit as
described in the chapter Hand Switch.
Remove Foot Switch and connect the
hand piece directly to the air power sup-
ply or use the Foot Switch.
Set adjustment sleeve to position FOOT.
Set safety switch to ON position.
Set operating pressure on pressure
regulator to 6–8 bar.
Exchange micro filter in the central air
supply.
Remove solid objects from the air inlet
with tweezers. Important: Do not use
piercing objects to do this. Lock the drive
when removing objects.
Check that the entire length of hose
does not exceed 8 m.
Check wall and drive hose couplings for
tightness.
Check central air supply.
42 Synthes Air Pen Drive Instructions for Use
If the recommended remedies are unsuccessful,
please contact your Synthes service center.
Problem
Pen runs at full speed all the time.
Attachments cannot be coupled to unit.
Attachment or tool (saw blade, drill, burr
etc.), cannot be coupled or only with
difficulty.
Tool (saw blade, drill, burr etc.) cannot be
coupled or only with difficulty.
Bones and tool heat up due to working
process.
Possible causes
Adjustment sleeve is in the position
FOOT without having a foot switch
attached.
Attachment coupling is blocked by
deposits.
Movable parts have not been
maintained.
Shaft geometry of tool damaged.
Cutting edges of tool are dull.
No irrigation has been used.
Remedy
Set adjustment sleeve in position HAND
or LOCK.
Remove solid objects with a pair of
tweezers. Attention: When removing
objects, set unit to OFF.
Oil the movable parts.
Replace tool or send to your Synthes
service office.
Replace tool.
Use irrigation.
Synthes 43
Ordering Information
44 Synthes Air Pen Drive Instructions for Use
Handpiece
05.001.080 Air Pen Drive 60,000 rpm
Foot Switch
05.001.081 Foot Switch, for Air Pen Drive
Hand Switch
05.001.082 Hand Switch, for Air Pen Drive
Hose and accessories
05.001.083 Double Air Hose, length 3 m, for Air Pen Drive
05.001.084 Double Air Hose, length 5 m, for Air Pen Drive
05.001.085 Angular Coupling, for Air Pen Drive
05.001.090 Irrigation Control Unit, for Air Pen Drive
05.001.091 Seal Nipple for Double Air Hose, for Air Pen Drive
05.001.086 Protective Cap, for Air Pen Drive
05.001.087 Adapter for Schrader/Synthes Coupling
05.001.088 Adapter for Dräger/Synthes Coupling
Attachments for 05.001.080
05.001.030 Drill Attachment with Mini Quick Coupling
05.001.031 Drill Attachment with J-Latch Coupling
05.001.032 AO/ASIF Drill Attachment
05.001.110 Drill Attachment, with Hexagonal Coupling
05.001.033 Oscillating Drill Attachment 45°, with Mini Quick Coupling
05.001.042 Drill Attachment 45°, with Mini Quick Coupling
05.001.043 Drill Attachment 45°, with J-Latch Coupling
05.001.044 AO/ASIF Drill Attachment 45°
05.001.120 Drill Attachment 45°, cannulated with Jacobs Chuck
05.001.035 Drill Attachment 90°, short, with Mini Quick Coupling
05.001.036 Drill Attachment 90°, long, with Mini Quick Coupling
05.001.028 Screw Attachment, with AO Coupling
05.001.029 Screw Attachment, with Hex Coupling
05.001.034 Screw Attachment, with Mini Quick Coupling
05.001.037 Kirschner Wire Attachment
05.001.038 Oscillating Saw Attachment
05.001.039 Sagittal Saw Attachment
05.001.040 Reciprocating Saw Attachment
05.001.045 Burr Attachment, S
05.001.046 Burr Attachment, M
05.001.047 Burr Attachment, L
05.001.048 Burr Attachment, S, angled
05.001.049 Burr Attachment, M, angled
05.001.050 Burr Attachment, L, angled
05.001.063 Burr Attachment, XL, angled
05.001.055 Burr Attachment, XXL, angled
05.001.059 Craniotome Attachment, for Electric Pen Drive
05.001.051 Dura Guard, S, for Craniotome Attachment No. 05.001.059
05.001.052 Dura Guard, M, for Craniotome Attachment No. 05.001.059
05.001.053 Dura Guard, L, for Craniotome Attachment No. 05.001.059
05.001.054 Perforator
05.001.096/S Protection Sleeve for Trepan Burr ⭋ 7.0 mm
05.001.097/S Protection Sleeve for Trepan diameter 12 mm
03.000.350/S Trepan Burr ⭋ 7.0 mm
03.000.351/S Trepan Burr ⭋ 12.0 mm
Accessories
05.001.121 Guide for Kirschner Wire, for Oscillating Saw
05.001.066 Irrigation Nozzle, short, for Nos. 05.001.045 and 05.001.048
05.001.067 Irrigation Nozzle, medium, for Nos. 05.001.046 and 05.001.049
05.001.068 Irrigation Nozzle, long, for Nos. 05.001.047 and 05.001.050
05.001.065 Irrigation Nozzle, for No. 05.001.063,
05.001.122 Irrigation Nozzle, for No. 05.001.055
05.001.111 Irrigation nozzle, for drilling attachment, for Nos. 05.001.030,
05.001.031, 05.001.032 and 05.001.110
05.001.070 Irrigation Nozzle, for Sagittal Saw Attachment No. 05.001.039
05.001.071 Irrigation Nozzle, for Reciprocating Saw Attachment
No. 05.001.040
05.001.076 Irrigation Nozzle, for Perforator 05.001.054
05.001.069.01S Irrigation Tube Set, sterile, single packed
05.001.069.05S Irrigation Tube Set, sterile, pack of 5 units
05.001.098 Synthes
®
‚ Maintenance Spray, 400 ml
05.001.098.06 Synthes
®
‚ Maintenance Spray, 400 ml (6 units)
05.001.099 Maintenance Unit, for Electric Pen Drive
05.001.094 Maintenance kit with oil and filter
05.001.095 Oil Dispenser with Synthes
®
Special Oil, 50 ml
05.001.092 Adapter for oiling Air Pen Drive,
for Maintenance Spray 05.001.098
05.001.102 Adapter for oiling Attachments for EPD/APD,
for Maintenance Spray 05.001.098
05.001.089 Adapter for Maintenance Unit No. 05.001.099, for Air Pen Drive
05.001.064 Adapter for Maintenance Unit, for Nos. 05.001.055 and
05.001.063, for EPD and APD
05.001.074 Handle for Change of Instruments, for attachments
68.000.007 Support for Cutting Tools with shaft ⭋ 2.3 and 3.2 mm
05.001.075 Cleaning Brush for 05.001.037
519.598 Hose Holder
310.932 Spare Key, for Nos. 310.930, 532.016 and 05.001.120
Cases
68.000.020 Vario Case
™
, size 1/1, height 67mm for Air Pen Drive
68.000.030 Vario Case
™
, size 1/1, height 88 mm for Air Pen Drive
68.000.004 Insert, size 1/2, for Basic Instruments, for Vario Case
™
No. 68.000.000
68.000.005 Insert, size 1/4, for Spine, for Vario Case
™
No. 68.000.000
68.000.006 Insert, size 1/4, for Neuro, for Vario Case
™
No. 68.000.000
689.507 Lid (stainless steel), size 1/1, for Vario Case
™
Cutting Tools
For ordering informations for the Electric Pen Drive Cutting Tools refer to the Flyer
Cutting Tools for EPD/APD (036.000.054)
0123
036.000.503 SE_036268 AC 41080001 © Synthes 2008 Subject to modifications
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