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Section 9: General Repairs

Repair Instructions

2016 Bambi MAX Service Manual

–

Models 4453-7590

(Version D)

46

We Engineer Solutions

Section 9: General Repairs

Repair Instructions

Suspension Line Replacement

A suspension line should be replaced whenever it displays
noticeable kinking or fraying. Factory replacement lines come pre-
swaged with connection links to make replacing quick and easy.

To remove the connecting link (connecting the suspension line to the M-strap), follow these procedures.

Locate a metal bar with a 5/16" hole (or drill a 5/16" hole into any
metal bar). If you are unable to locate a metal bar, a wooden block
will work, however, make sure to drill the hole into the end grain.

Tools required. Pin locked in place.

Center holding sleeve.

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Summary of Contents for BAMBI MAX BBX4453

Page 1: ...2016 VERSION D BAMBI MAX 4453 7590 MODELS SERVICE MANUAL Photo courtesy of Dan Sweet ...

Page 2: ... D Issue Date January 2017 PLEASE READ BEFORE USING SEI INDUSTRIES LTD 7400 Wilson Avenue Delta B C Canada V4G 1H3 Phone 604 946 3131 Fax 604 940 9566 E Mail seisales sei ind com Website www sei ind com USA Patent 9 265 977 Australia Patent AU2012201273 Canada Patent Pending COPYRIGHT 2016 SEI INDUSTRIES LTD ALL RIGHTS RESERVED ...

Page 3: ... 11 System Description 11 Electrical Requirements 12 Flying with the PowerFill System 12 Filling the Bambi MAX Bucket with the PowerFill System 12 Using Foam 13 Sacksafoam Foam Injection System 14 Compatible Bambi MAX Sacksafoam Models 15 Bambi Mobility Sled 15 Section 4 Making Adjustments 16 Adjusting Components 16 Valve Adjustment 16 Section 5 Packing and Storage 18 Packing and Storing 18 Packin...

Page 4: ...aps and Top Chains Repair Criteria 44 Control Head Repair Criteria 45 Section 9 General Repairs 46 Repair Instructions 46 Suspension Line Replacement 46 M Strap Replacement 47 Removing Old M Straps 48 Installing New M Straps Short 49 Installing New M Straps Long 51 Bottom Loop Repairs 53 Bucket Patching 53 IDS Hub Spokes Replacement 54 IDS Detailed Drawing 55 Load Test on the Hook 55 Bambi MAX She...

Page 5: ... MAX Head Model 4453 77 Bambi MAX Head Models 5566 7590 77 Bucket Shell Models 4453 78 Bucket Shell Models 5566 79 Bucket Shell Models 6578 7590 80 Rigging Models 4453 81 Rigging Models 5566 7590 82 IDS System Model 4453 83 IDS System Model 4453 continued 84 IDS System Model 5566 85 IDS System Model 5566 continued 86 IDS System Models 6578 7590 87 IDS System Models 6578 7590 continued 88 Ballast S...

Page 6: ...s Ltd offers complete parts supply and repair services for the Bambi MAX For a repair facility in your area please contact SEI For maintenance and repair purposes parts diagrams and descriptions are provided in this manual When ordering parts please provide the model and serial number of your Bambi MAX There are several other models of buckets available from SEI Industries These include Bambi MAX ...

Page 7: ...through the opening in the base ring System Description Movement of the valve tube is controlled by an actuator and drive cable system The actuator is mounted on the top plate and consists of a drive motor reduction gearing and a cable drum The cable drum can be rotated clockwise or counter clockwise depending on the direction of the motor One end of the drive cable is attached to the cable drum T...

Page 8: ...he lift bar via the deflector sheaves closing the valve It is normal for there to be slackness on the non tension side of the cable Operation of the valve motor is regulated by a controller located in a waterproof enclosure on the top of the valve assembly The controller receives power and a control signal from the aircraft via a three conductor cable The control signal is provided in the aircraft...

Page 9: ...ft the valve motor rotates clockwise and opens the valve When the open sensor is triggered by the cam the motor turns off and the valve remains in the open position as long as the open signal is present When the operator releases the push button the open signal is removed The motor rotates clockwise and closes the valve When the closed sensor is triggered by the cam the motor turns off and the tub...

Page 10: ...protection device activates When activated the device isolates the motor from the power source but does not remove power from the rest of the controller The controller and valve will remain locked in whatever state they were at the time the motor protection device was activated To reset the motor protection turn off power to the circuit using the aircraft s circuit breaker Wait for approximately 1...

Page 11: ...ocked position to assure that the ballast is always facing forward in flight Caution The Bambi MAX may not be suitable for a direct hook up to the cargo hook The actual hook up will be different for various aircraft and operators must comply with all instructions and bulletins supplied by the aircraft manufacturer It is the operator s responsibility to ensure that the Bambi MAX is correctly fitted...

Page 12: ...into the pilot s control column through a 50 amp relay as per US interagency regulations This system can also be used to control a heli torch etc 3 Crew control remote power supply This configuration allows a crew member or a pilot to control the dumping of the bucket using a battery pack to supply the power to the remote switch This also eliminates the high cost of pre wiring the aircraft Using L...

Page 13: ...ed to the outside of a longline the flight characteristics can change In our experience it may take some time and a few trial flights to determine the length between attachment points of the conduit to the longline Longline Wire Details For Valve and PowerFill Checking Suspension Cable Length Length Valve PowerFill Feet Meters Wire Recommended Plugs Wire Recommended Plugs 0 100 23 30 16 3 SOW NEMA...

Page 14: ...et This measurement should be less than the maximum total length of the dimension taken from the helicopter Lengths are accurate to within 1 Overall lengths with standard rigging Specifications subject to change Bambi Max Model Overall Length PowerFill Lengths Feet Meters Feet Meters BBX4453 21 3 6 47 21 9 6 62 BBX5566 21 5 6 53 21 11 6 68 BBX6578 21 8 6 60 22 2 6 75 BBX7590 27 9 8 46 28 3 8 61 Im...

Page 15: ...le and hub restrainer cables should be slack as they should not bear any load Their function is to position the hub and spoke mechanism to hold the bucket open The main parts of the IDS are illustrated in this manual for maintenance purposes To deploy the IDS on the ground reach into the bucket grasp the hub of the IDS and pull outward fully until the two restraining cables from the hub to the low...

Page 16: ...of the valve plate The pump assemblies and motors are then attached to the screens on the top of the valve plate When the bucket is immersed in water to the level of the top plate of the valve the pumps will draw water through the screens and discharge into the bucket through one way flapper valves The pump motors are controlled by solid state relays in a watertight control enclosure located betwe...

Page 17: ... Failure to do so may prevent the pumps from priming Frothing of the water or slow fill rate indicates the pump is not submerged enough to maintain prime It may not be pos sible to fill from water sources less than 18 46cm deep Opening the valve also allows the water level in the bucket to equalize with the external water source level thereby minimizing the filling time 2 Close the valve 3 Press a...

Page 18: ...ump off Important Note The filter screens are designed to filter out objects large enough to damage the pump impellers and to prevent weeds and debris from clogging the pump intakes If operating the pumps in extremely dirty or swampy water sources more frequent inspections of the pump impellers and filter screens may be required to maintain optimal function Important Note The pumps can be run dry ...

Page 19: ...he pilot through a control unit which is mounted in the cockpit Sacksafoam I contains the foam reservoir directly installed inside the bucket The Sacksafoam II is a self contained unit that can be stowed onboard the helicopter This system is completely housed in a foam resistant case With the Sacksafoam II the pilot still controls the foam dispensing through the control unit The Sacksafoam III is ...

Page 20: ...piece Bambi Mobility Cart allows one person to move a bucket from one location to another Easy to steer and brake the three wheeled cart comes equipped with tow bar and foam filled all terrain 16 tires Roll on winch and go Model Bambi Bucket Reservoir USG Capacity Liters Sacksafoam I 004339 BBX2024 BBX4453 30 114 004240 BBX5566 BBXHL5000 60 228 Sacksafoam II 004344 BBX1518 BBX4453 25 95 Sacksafoam...

Page 21: ... valve is adjusted too low the motor protection circuit may be activated Determine the current state of valve adjustment as follows Power up the bucket circuit to allow the valve to move to the closed position If the indicator lamp flashes green or the cable drum sensor cam oscillates when the valve is closed then the valve is adjusted too low Actuate the bucket dump switch and hold to keep the va...

Page 22: ...just the valve downwards by rotating the sensor cam clockwise so that your reference line moves approximately 1 16 1 mm Tighten one set screw After adjustment power up the bucket circuit The valve should move to the closed position The indicator light should have a steady yellow color The cable drum sensor cam should not oscillate Actuate the bucket dump switch and hold The valve should move to th...

Page 23: ...olutions Section 5 Packing and Storage Packing and Storing Packing the Bucket 1 Open the valve 1 2 inches 2 Collapse the IDS by pushing the hub into the bucket Important Note Always leave the valve open 1 to 2 inches as this prevents the bottom seal from collapsing during long periods of storage leading to longer seal life ...

Page 24: ... Solutions 3 Grab the control head and pull the suspension lines taut Tape the lines together in two bunches 4 Insert the operations manual into the storage bag 5 Gather the suspension lines into a coil and stow inside the bucket Place the control head outside of the bucket to prevent the possibility of the lines tangling ...

Page 25: ...Storing 2016 Bambi MAX Service Manual Models 4453 7590 Version D 20 We Engineer Solutions 6 Place the head on top of the collapsed bucket 7 Roll the bucket into a bundle and wrap with straps supplied 8 Rotate shell until head is under the shell ...

Page 26: ...nd Storing 2016 Bambi MAX Service Manual Models 4453 7590 Version D 21 We Engineer Solutions 9 Take the carrying bag and drape it over the bucket 10 Roll the bucket over and insert the manual 11 Close with zipper and store with label showing ...

Page 27: ...ensure the longevity of your Bambi MAX 1 Do not pile heavy objects on the Bambi MAX in storage This may result in creases in the neoprene seal in the dump valve which may cause leakage 2 Wash the bucket and allow it to dry prior to storing it 3 Do not store a wet bucket This will result in the growth of mildew and the corrosion of aluminium and steel parts 4 Store the bucket indoors in an unfolded...

Page 28: ...alve down Circuit Breaker Trips Off White Valve adjusted too low Adjust valve up Flashing Green Motor protector activated Power cycle to reset Adjust valve up No open signal Check aircraft longline wiring Yellow Controller failure Contact service center Green Damaged drive cable Replace drive cable Valve Closed Won t Open Red Controller sensor failure Contact service center Flashing Green Motor pr...

Page 29: ...the red lead into the round socket of the helicopter wiring harness The multimeter should read approx 28V Actuate the bucket dump switch The multimeter should still read 28V Move the red lead to the wide socket of the helicopter wiring harness The multimeter should read 0V Actuate the bucket dump switch The multimeter should now read 28V If a longline is being used re connect the longline into the...

Page 30: ...cedures Weekly Inspections In addition to the daily pre flight inspections as outlined in the operations manual follow the weekly inspection procedure for times when the bucket is in continuous use Weekly Inspection Checklist 1 Check all parts of the system for visible damage or defects 2 Check for excessive movement in linkage 3 Check top and bottom valve seals ...

Page 31: ...of force Once tightened try to move the linkage from side to side There should be no movement Valve Removal Whenever any valve maintenance such as seal changes or maintenance on the valve cycling has to be done we recommend that you remove the valve from the Bambi MAX shell To remove the valve follow the steps listed below Tools required ratchet and 9 16 socket side cutter 1 Make sure that the bal...

Page 32: ...s 4453 7590 Version D 27 We Engineer Solutions 2 Next detach one spoke from the shell this spoke should be in the 5 o clock location 3 Push the spoke into the bucket and attach to the opposite spoke 4 Now remove the four bolts holding the valve to the bottom plate Note location of arrows for bolts ...

Page 33: ... Valve Installation The following steps will allow one person to easily install the valve 1 Making sure the ballast is still at the bottom roll the valve through the opening Leaving the control cable at the top of the shell roll the valve to the base of the shell 2 Place the valve inside the valve guard then rotate the valve until the control box is in the position shown in the picture below ...

Page 34: ... may be necessary to line up the standoffs to the bottom plate holes When lining up the holes always move the standoff to the nearest bottom plate hole 4 Next string the control line Before unrolling the coil of cable pass it through the center of the IDS hub 5 Check to ensure that you have at least 6 of slack in the control cable before attaching the cable to the head with the four tie wraps Note...

Page 35: ...r plywood To remove the valve please refer to the valve removal section in the maintenance section of this manual Once the valve has been removed follow the directions below Bottom Seal Replacement Tools required Ratchet 1 4 drive extension short socket 5 16 or slot screwdriver 1 To make the valve more stable open the valve until the top of the tube is level with the top of the motor and cut the p...

Page 36: ...is picture 4 Remove the seal and clean any debris from the bottom of the tube and groove 5 Install the replacement seal and move the clamp into position Make sure that two of the tensioner clamps are located between the lift bar bolts 6 Tighten the tensioner clamps Make sure to tighten each clamp equally as this will eliminate a problem of the clamp releasing as one of the tensioners is not engage...

Page 37: ...ons at the same time To remove the valve please refer to the valve removal section in the maintenance section of this manual Tools required Allen key 1 8 1 To replace the top seal with the valve still in the bucket first detach the control cable from the head and the IDS deployment cable and hub Coil the cable up and place it inside the top of the shell 2 Remove all the Allen head bolts from the t...

Page 38: ...ring and pass the coiled control cable through the middle of the ring 4 Take the ring and old seal out of the shell Place the ring on a level surface with all bolts inserted into the ring 5 Slip the new seal over the bolts and return the ring with seal to the shell Pass the control cable through the ring making sure to pass the cable through from the seal side ...

Page 39: ...s they are going into plastic Do not over tighten as you would in metal 8 String the control line and before unrolling the coil of cable pass it through the center of the IDS hub Once all the cable is outside the bucket with no slack push it 6 back into the bucket Now using tie wraps attach the cable to the deployment cable eye on the hub Use at least two tie wraps 9 Reattach the control cable to ...

Page 40: ...n wire which should go to the green screw black wire to brass screw and white wire to silver screw Removing the existing cable The drive cable can be replaced with the valve in the bucket but if you are doing other maintenance work on the valve it will be easier to change the cable outside the bucket 1 Cut the cable below the lift bar 2 Remove the cable retainer from the lift bar 3 Remove the cabl...

Page 41: ...talling the new cable 1 Examine the new drive cable to determine the shorter end 2 Insert the short end of the drive cable into the cable retainer then insert the long end of the cable through the hole in the lift bar 3 Secure the cable retainer to the lift bar 4 Trim the short end of the drive cable and insert the cable through the cable bushing ...

Page 42: ...e about a 1 3 of the way and cut the power The cable anchor should be close to the position shown in this picture Now feed the cable through the cable anchor pull it snug but do not tighten 6 Install a 3 8 spacer plate between the sheave bar and lift bar Place a heavy weight on the lift bar to hold it down 7 Turn on the power The valve will close Pull the cable tight and secure with cable anchor s...

Page 43: ...er from the lift bar install the cable over the five sheaves and trim the end of the cable Now pass the cable to the inside of the carrier cross bolt through the cable bushing in the top plate 10 Turn on the power and open the valve to its full open position Install the cable through the second cable anchor and then pull the cable tight and secure with cable anchor screws Install a piece of 1 8 x ...

Page 44: ...ment flashing light issues Changing the Guide Bushings To change the guide bushings follow the steps listed below 1 Open the valve about half way 2 Remove the two bolts holding the old bushings in place and remove the old bushings 3 Place the new bushing into position 4 Insert the bolts attach the nuts and tighten 5 Run the valve up and down If any slowing of the valve movement or jamming is notic...

Page 45: ...in personal injury or damage to equipment These defects can compromise the following functions of the Bambi Bucket structural integrity flight stability water re lease and flight safety Category 2 Operational All defects in this category should be repaired before the next operational day or approximately eight hours of flight time The defects do not compromise the safety of the bucket but may lead...

Page 46: ... or missing bottom webbing protective wear strips Five or more broken battens Wear abrasions and cuts to the bucket shell fabric isolated to one side of the material that do not cut through Wear abrasions and cuts to the webbing loops strips and top loop knots that involve less than 25 of the fabric strands on any portion of the affected webbing Wear and abrasions to webbing protective strips Up t...

Page 47: ...s due to twisting known as bird caging Evidence of heat damage Abrasion wear comprising of more than 1 3 of the original diameter of the outside indi vidual strands Any visible reduction in outside diameter due to overload Cracked or broken end fittings some elongation of cable eyes is acceptable Wear broken strands kinks and twisting in cable that do not exceed the limits defined in Category 2 de...

Page 48: ...r more bent spokes bends in excess of 20 degrees broken One broken or cracked spoke bracket on IDS hub One broken or missing spoke One broken or missing clevis pin or shell bracket Up to two bent spokes Wear on IDS hub Dents abrasions and wear on spokes Clevis pin and shell bracket wear Category 1 Safety Cease operations and repair immediately Category 2 Operational Repair before next days operati...

Page 49: ...fabric strands broken Visibly worn top chains Bent gouged worn or cracked shackles and shackle pins Damage to an M strap that does not exceed 25 of the fabric Minor wear impact marks or corrosion on chains Minor wear impact marks or corrosion on shackles Category 1 Safety Cease operations and repair immediately Category 2 Operational Repair before next days operation or eight hours flight time Cat...

Page 50: ...0 Version D 45 We Engineer Solutions Control Head Repair Criteria Any visible crack or break on the head Visibly bent shackles Broken or missing safety wire on shackle pins Broken or exposed electrical conductors Broken or missing break away plug Category 1 Safety Cease operations and repair immediately ...

Page 51: ...e kinking or fraying Factory replacement lines come pre swaged with connection links to make replacing quick and easy To remove the connecting link connecting the suspension line to the M strap follow these procedures Locate a metal bar with a 5 16 hole or drill a 5 16 hole into any metal bar If you are unable to locate a metal bar a wooden block will work however make sure to drill the hole into ...

Page 52: ...eplace M straps if they become noticeably worn M straps may be repaired if frayed by melting the fray with a lighter to stop the fray from spreading The length of the M strap is critical to the proper functioning of the Bambi MAX and we recommend that you replace worn straps with factory supplied equipment There are two types of straps long webbing and short webbing Long webbing are used for the d...

Page 53: ... We Engineer Solutions Removing Old M Straps 1 Using needle nose pliers insert the tip under the top webbing layer 2 Fully insert the pliers at the far left hand side of the top layer 3 Holding the pliers tight turn your hand clockwise Repeat the operation until the knot is loose enough to remove the strap ...

Page 54: ...ual Models 4453 7590 Version D 49 We Engineer Solutions Installing New M Straps Short Once the old straps have been removed the new strap installation can begin 1 Rotate the strap until the joint is centered 2 Pass the strap through the loop 3 Twist the loop eye 180 degrees ...

Page 55: ...9 General Repairs Repair Instructions 2016 Bambi MAX Service Manual Models 4453 7590 Version D 50 We Engineer Solutions 4 Rotate the eye to the opposite side 5 Pull strap end through the eye 6 Pull strap tight ...

Page 56: ...ice Manual Models 4453 7590 Version D 51 We Engineer Solutions Installing New M Straps Long Once the old straps have been removed the new strap installation can begin 1 Locate the center of the strap 2 Pass the strap through the loop 3 Twist the loop eye 180 degrees ...

Page 57: ...General Repairs Repair Instructions 2016 Bambi MAX Service Manual Models 4453 7590 Version D 52 We Engineer Solutions 4 Rotate the eye to the opposite side 5 Pull strap end through the eye 6 Pull the strap tight ...

Page 58: ...is The suspension line attaches to the top of each M strap set Bottom Loop Repairs If the bottom loops which hold the chain become worn the frays can be melted with a lighter to prevent them from spreading If the bottom loops require replacement they should receive an overlay of heavy duty wear resistant webbing Bucket Patching Please see Bucket Repairs in this section ...

Page 59: ...elow the ballast and the other is directly opposite 6 o clock position No wear strips are required for the restrainer cable brackets 4 With the ballast oriented at the 6 o clock position rotate the IDS assembly so that the deployment cable faces upward and it s at the 3 o clock position 5 Attach the two spokes at either side of the 12 o clock position using the stainless steel clevis pins Complete...

Page 60: ... side and repeat the above steps 3 These two spokes are across from each other Note Newer bucket spoke bolt holes are in the same location See parts section for detailed parts listings IDS Detailed Drawing Load Test on the Hook Deployment cable adjustment can only be properly assessed on the hook of the helicopter or otherwise suspended with a full load of water For this test with retrofits the de...

Page 61: ... clean and scrubbed to a matte finish before applying the patch Repairs are attempted during wet or cold weather The glue and patch are not properly placed creating air bubbles between the glue and the patch The patch is not weighed down for 24 hours The bucket is used before the glue has set Important Note Try a test repair before attempting to repair the bucket This will verify your technique wi...

Page 62: ...y white appearance on the surface The use of a solvent to clean the surface prior to cementing can also reduce temperatures below the dew point To overcome the high humidity problem raise the temperature of the patch area This can be accomplished with a warm air fan Warning Glue vapours are highly explosive Explosive vapours may occur causing fire and or injury Keep away from all sparks flame ligh...

Page 63: ...ith a patch when the bucket can be set aside for 24 hours 1 Select the largest clamp that will just slip through the hole in the item The size of cut or hole will determine the size of the sealing clamp to use For a cut or hole up to 2 5 cm use a 3 7 6 cm clamp supplied For a cut or hole up to 4 10 cm use a 5 12 7 cm clamp supplied For a cut or hole up to 6 15 cm use a 7 5 19 cm clamp special orde...

Page 64: ...ersion D 59 We Engineer Solutions 3 Pull the bolt up through the hole Turn it until the clamp lines up with the hole 4 Place the top of the clamp over the bolt Caution Tightening the nut with tools may break the bolt away from the lower clamp Overtightening can also deform the clamp and cause leaks ...

Page 65: ...weight bag with water prior to beginning repairs 2 Clean the area to be repaired with an abrasive pad dampened with solvent Remove all traces of masking tape if previously used If possible place a piece of masking tape on the back side of the item being repaired 3 Paint the damaged area with glue Use a thick coat of glue overlapping the edges of the repair by 1 25 mm Be sure that the edges are wel...

Page 66: ...h to be rolled once it is in place 2 Scrub the damaged area with an abrasive pad dampened with solvent isopropyl rubbing alcohol is recommended Scrub vigorously to remove the cured surface The area should be clean and dry with a dull matte finish 3 Wipe with a rag dampened with solvent to remove any residue from cleaning Check to see if the area is totally clean and all coated surfaces and edges a...

Page 67: ... sides is that it will be painted with glue on the outside later Applying the Patch 1 Apply the Dura Seal glue to the patch and damaged area Wait 30 minutes at 75F or 22C for some of the solvent to evaporate from the glue The glue should become thicker but still be quite wet If it has been allowed to dry too long give both sides another thin coat If the glue has dried too long it will be difficult...

Page 68: ... sheet over the patch followed by a weight bag for 12 hours at room temperature Remove the weight bag and leave to dry for 24 hours 4 If the patch will be subjected to abrasion after 24 hours paint over the patch with glue Painting the patch also provides protection from ultra violet light and weather Allow the bond to harden for 24 hours at room temperature before using the item ...

Page 69: ...ler One hot air gun Steinel HL 1800 E or equivalent 120 V 1500 W 800 to 1100 deg F 450 litres per min One wide surface nozzle Isopropyl alcohol Scissors Warning It is extremely dangerous to use a hot air gun in the presence of flammable fumes such as gasoline or paint thinner There is a high risk of explosion and or burns Warning Injury especially to hands and fingers can occur when using a hot ai...

Page 70: ... OVERHEAT OR BLACKEN THE FABRIC 3 Starting from the centre of the patch held down by the roller concentrate the heat flow equally to patch and fabric Apply a light pressure with the roller when the fabric starts melting This can be seen as small bubbles DO NOT OVERHEAT 4 Roll the patch down to fuse it to the fabric moving roller and gun simultaneously Repeat on the unfused portion of the patch Let...

Page 71: ...the responsibility of the dealer and end user to ensure that the importation of glue is allowed in the country of use PART NUMBER DESCRIPTION QTY 011161 BAG TOOL 1 003661 FABRIC REPAIR MANUAL 1 003608 BAG WEIGHT 1 003064 PAD ABBRASIVE 2 003071 ROLLER SEAM 1 1 003074 SCISSORS 1 004502 CLAMP REPAIR SMALL 2 HOLE 1 003856 PATCH FABRIC 32OZ BAMBI 3 PART NUMBER DESCRIPTION QTY 003090 ADHESIVE DURA SEAL ...

Page 72: ...0 4620 2100 220 100 BBX5566 550 660 2500 5790 2630 290 130 BBX6578 650 780 3000 6830 3100 330 150 BBX7590 750 900 3400 7850 3560 350 160 Bambi Max Model Capacity Gross Weight Empty Weight IMP Gal USG Gal Liters lb kg lb kg BBX4453PF 440 530 2000 4720 2140 320 140 BBX5566PF 550 660 2500 5890 2670 390 180 BBX6578PF 650 780 3000 6930 3140 430 190 BBX7590PF 750 900 3400 7950 3600 450 200 Caution The s...

Page 73: ...e 25 Shell Assembly Models 4453 5566 ITEM MODEL PART NUMBER DESCRIPTION QTY 1 008229 TAPE BUTYL 440 3 16 X 3 8 15 2 007139 RING BASE 25 4453MX 5566MX 1 3 007142 RING CLAMP 25 4453MX 5566MX 1 4 006887 GUARD VALVE 25 4453MX 5566MX 1 5 000394 BOLT HX 3 8 16 x 2 SS 16 6 001846 WASHER FLAT 0 39 x 1 00 x 0 125 SS 24 7 BBX4453 BBX5566 001665 NUT HX NYLOCK 3 8 16 SS 16 ...

Page 74: ...ell Assembly Models 6578 7590 ITEM MODEL PART NUMBER DESCRIPTION QTY 1 008229 TAPE BUTYL 440 3 16 X 3 8 15 2 007140 RING BASE 25 6578MX 7590MX 1 3 007143 RING CLAMP 25 6578MX 7590MX 1 4 006888 GUARD VALVE 25 6578MX 7590MX 1 5 000394 BOLT HX 3 8 16 x 2 SS 20 6 001846 WASHER FLAT 0 39 x 1 00 x 0 125 SS 32 7 BBX6578 BBX7590 001665 NUT HX NYLOCK 3 8 16 SS 20 ...

Page 75: ...ns Bambi MAX Valve 25 Installation ITEM MODEL PART NUMBER DESCRIPTION QTY 1 BBX4453 BBX7590 002299 VALVE 25 ASSEMBLY 4453MX 7590MX 1 2 007340 PLATE BLANK PUMP 4453MX 7590MX 2 3 005755 GASKET PUMP 2 4 000391 BOLT HX 3 8 16 X 1 SS 4 5 005773 SCREW SC 1 4 20 X 1 1 2 SS 6 6 001853 WASHER LOCK SPLIT 3 8 SS 4 7 001662 NUT HX 1 4 20 SS 6 ...

Page 76: ...421 SEAL VALVE BTM 25 4453MX 7590MX 1 3 011527 CLAMP GEAR 12 1 2 SS 2 4 010737 RINGS SEAL SUPPORT 25 1 5 005770 RINGS SEAL SUPPORT 25 1 6 006332 SEAL VALVE TOP 25 4453MX 7590MX 1 7 007337 RING SEAL TOP 25 4453MX 7590MX 1 8 000009 BOLT HEX 1 4 28 X 29 32 CAD 4 9 000416 SCREW SC 6 32 X 1 1 4 SS 12 10 000496 SCREW PNPH 10 24 X 7 8 SS 9 11 001833 WASHER FLAT 028 X 0 69 X 0 036 SS 4 12 001660 NUT HEX N...

Page 77: ...7590 Version D 72 We Engineer Solutions Bambi MAX Valve 25 Actuator and Controller ITEM MODEL PART NUMBER DESCRIPTION QTY 1 000211 ACTUATOR ASSEMBLY 4453MX HL9800MX 1 2 000206 IVC ASSEMBLY 1518MX HL9800MX 1 3 001606 SCREW 10 24 x 3 4 HXSL SS 6 4 BBX4453 BBX7590 001848 WASHER LOCK SPLIT 10 SS 6 ...

Page 78: ...R CABLE 1518MX HL9800MX 2 4 000219 HUB MOTOR 4453MX HL9800MX 1 5 000224 PLUG DESICCANT ASSY 1 6 006335 O RING BUNA N 020 50A 1 7 012312 O RING BUNA N 044 70A 1 8 000500 GLAND CABLE NIBR M16 1P68 1 9 000280 BOLT HX 10 32 X 25 32 CAD 2 10 010735 SCREW SET CUP NYLON 10 32 X 1 4 SS 1 11 000063 SCREW SC M4 X 0 7 X 14 SS 1 12 000920 SCREW SC 6 32 X 1 4 SS 4 13 000408 SCREW SC 6 32 X 3 8 SS 2 14 000414 S...

Page 79: ...ABLE 2 3 000227 BAR SHEAVE 25 4453MX 7590MX 1 4 001617 SHEAVE CABLE 5 5 000232 ROD GUIDE 4453MX HL9800MX 2 6 000230 ROD SUPPORT 4453MX HL9800MX 2 7 007107 SPRING DISC 0 650 x 0 855 x 0 060 SS 4 8 005988 RING RETAINER EXT 1 4 PLT 2 9 005214 RING RETAINER EXT 5 8 SS 2 10 000012 BOLT HX 10 32 x 1 1732 CAD 5 11 000391 BOLT HX 3 8 16 x 1 SS 3 12 002241 SCREW FSC 10 32 x 1 1 2 SS 4 13 001853 WASHER LOCK...

Page 80: ...000234 BAR LIFT 25 4453MX 7590MX 1 2 008661 ARM LINKAGE LONG 4453MX HL9800MX 8 3 008663 ARM CARRIER LONG 4453MX HL9800MX 2 4 008664 SPACER SOLID CARRIER 2 5 008874 SPACER TUBE CARRIER 2 6 008665 BLOCK PIVOT 2 7 001755 BOLT HX 10 32 x 2 25 32 CAD 2 8 001771 BOLT HX 10 32 x 3 29 32 CAD 4 9 000449 SCREW FSC 10 24 x 1 2 SS 4 10 002269 WASHER FLAT 0 20 x 0 57 x 0 40 PTFE 16 11 BBX4453 BBX7590 001685 NU...

Page 81: ...EM MODEL PART NUMBER DESCRIPTION QTY 1 000234 BAR LIFT 25 4453MX 7590MX 1 2 000236 BUSHING GUIDE 16 2 3 001619 RETAINER CABLE 1 4 001615 CABLE DRIVE ASSEMBLY 1 5 000012 BOLT HX 10 32 x 1 17 32 CAD 4 6 001606 SCREW 10 24 X 3 4 HXSL SS 2 7 001848 WASHER LOCK SPLIT 10 SS 2 8 001843 WASHER FLAT 0 20 x 0 50 x 0 6 SS 4 9 BBX4453 BBX7590 001685 NUT HX NYLOCK 10 32 SS 4 ...

Page 82: ...ead Model 4453 Bambi MAX Head Models 5566 7590 ITEM PART NUMBER DESCRIPTION QTY 1 007272 HEAD SMALL 1518MX 4453MX 1 2 001794 SHACKLE ANCHOR SCREW 3 8 GLV 2 3 001795 SHACKLE ANCHOR SCREW 1 2 GLV 1 ITEM PART NUMBER DESCRIPTION QTY 1 007273 HEAD MEDIUM 5566MX 7590MX 1 2 001796 SHACKLE ANCHOR SCREW 5 8 GLV 2 3 001790 SHACKLE ANCHOR SCREW 3 4 GLV 1 ...

Page 83: ... MAX 4453 1 2 005428 BATTEN ASSY 51 16 3 005270 STRIP WEAR 16 X 2 3 8 16 4 000450 SCREW 10 24 X 5 8 FHPH SS 16 5 000496 SCREW 10 24 X 7 8 PNPH SS 16 6 001856 WASHER FLAT 10 X 1 SS 28 7 001855 WASHER FLAT 10 X 3 4 SS 16 8 001833 WASHER FLAT 10 X 11 16 SS 16 9 001660 NUT HX NYLOCK 10 24 SS 16 10 001661 NUT HX JAM NYLOCK JAM 10 24 SS 16 11 001788 SHACKLE ANCHOR SCREW 1 4 GLV 1 12 BBX4453 003846 CHAIN...

Page 84: ... MAX 5566 1 2 005430 BATTEN ASSY 54 16 3 005687 STRIP WEAR 16 X 2 3 4 16 4 000371 BOLT HX 1 4 20 x 1 1 4 SS 16 5 000495 SCREW 10 24 X 3 4 PNPH SS 16 6 001855 WASHER FLAT 10 X 3 4 SS 32 7 001857 WASHER FLAT 1 4X 1 1 2 SS 28 8 001828 WASHER 7 32 x 1 1 2 x 1 8 NEO 16 9 001660 NUT HX NYLOCK 10 24 SS 16 10 001662 NUT HX NYLOCK 1 4 20 SS 16 11 001788 SHACKLE ANCHOR SCREW 1 4 GLV 1 12 BBX5566 003846 CHAI...

Page 85: ...6578 005433 BATTEN ASSY 56 20 BBX7590 005436 BATTEN ASSY 61 1 2 3 BBX6578 005687 STRIP WEAR 16 X 2 3 4 20 BBX7590 4 ALL 000371 BOLT HX 1 4 20 X 1 1 4 SS 20 5 000495 SCREW 10 24 X 3 4 PNPH SS 20 6 001855 WASHER FLAT 3 16 X 3 4 SS 40 7 001857 WASHER FLAT 1 4 X 1 1 2 SS 40 8 001828 WASHER 7 32 x 1 1 2 x 1 8 NEO 20 9 001660 NUT HX NYLOCK 10 24 SS 20 10 001662 NUT HX NYLOCK 1 4 20 SS 20 11 001789 SHACK...

Page 86: ...ging Models 4453 6 1 3 2 4 5 7 ITEM MODEL PART NUMBER DESCRIPTION QTY 1 005471 M STRAP LOOP 22 1 4 6 2 005472 M STRAP STRAIGHT 46 1 2 5 3 005549 CABLE SUSPENSION PAIR 4 4 005526 CHAIN TOP 18 1 2 2 5 005527 CHAIN TOP 20 1 2 6 6 001794 SHACKLE ANCHOR 3 8 SCREW GALV 2 7 004057 LINK CONNECTING 9 32 PLT 8 8 BBX4453 005317 CABLE DEPLOYMENT 1 ...

Page 87: ...9857 BBX6578 009858 BBX7590 009859 CABLE SUSPENSION LINE PAIR 4 BBX6578 009862 3 BBX7590 009863 CABLE SUSPENSION LINE SINGLE 2 BBX5566 005526 CHAIN TOP 18 1 2 BBX6578 4 BBX7590 005528 CHAIN TOP 19 1 2 2 BBX5566 005527 CHAIN TOP 20 1 2 BBX6578 5 BBX7590 005529 CHAIN TOP 20 3 4 6 6 001789 SHACKLE ANCHOR 5 16 SCREW GLV 5 7 004057 LINK CONNECTOR 9 32 PLT 10 8 006710 LINK CONNECTING 3 8 PLT 6 9 005483 ...

Page 88: ...Section 10 Specifications and Parts Parts Listings 2016 Bambi MAX Service Manual Models 4453 7590 Version D 83 We Engineer Solutions IDS System Model 4453 ...

Page 89: ...KET 8 5 005307 BRACKET RESTRAINER 2 6 005300 CABLE RESTRAINER HUB 2 7 005317 CABLE IDS DEPLOYMENT 1 8 000496 SCREW 10 24X7 8 PNPH SS 8 9 000497 SCREW 10 24X1 PNPH SS 12 10 001856 WASHER FLAT 10X1 FND SS 20 11 001833 WASHER FLAT 1 4X11 16 SS 2 12 001824 WASHER 3 16X1 1 8 NEO 2 13 000068 WASHER FLAT 5 16X3 4 SS 16 14 001826 WASHER FLAT 5 16X1 1 8NEO 16 15 001660 NUT HX NYLOCK 10 24 SS 20 16 001697 P...

Page 90: ...Section 10 Specifications and Parts Parts Listings 2016 Bambi MAX Service Manual Models 4453 7590 Version D 85 We Engineer Solutions IDS System Model 5566 ...

Page 91: ...CKET RESTRAINER 2 6 005301 CABLE RESTRAINER HUB 2 7 005317 CABLE IDS DEPLOYMENT 1 8 005483 PROTECTOR M STRAP 8 9 000371 BOLT HX 1 4 20 X 1 1 4 SS 20 10 001833 WASHER FLAT 1 4 X 11 16 SS 2 11 001857 WASHER FLAT 1 4 X 1 1 2 SS 20 12 000068 WASHER FLAT 5 16 X 3 4 SS 16 13 001826 WASHER FLAT 5 16 X 1 X 1 8 NEO 16 14 001828 WASHER FLAT 1 4 X 1 1 2 X 1 8 NEO 4 15 001662 NUT HX NYLOCK 1 4 20 SS 20 16 001...

Page 92: ...Section 10 Specifications and Parts Parts Listings 2016 Bambi MAX Service Manual Models 4453 7590 Version D 87 We Engineer Solutions IDS System Models 6578 7590 ...

Page 93: ...ABLE ASSY 2 6578 005320 7 7590 005321 IDS DEPLOYMENT CABLE 1 8 ALL 005483 PROTECTOR M STRAP 10 9 ALL 000371 BOLT HEX 1 4 20 X 1 1 4 SS 34 10 ALL 000390 BOLT HEX 5 16 18 X 2 SS 10 11 ALL 000314 BOLT HEX 5 18 24 X 2 11 32 CAD 10 12 ALL 001833 WASHER FLAT 1 4 X 11 16 SS 2 13 ALL 001857 WASHER FLAT 1 4 X 1 1 2 FND SS 34 14 ALL 001840 WASHER FLAT 5 16 X 9 16 AN SS 20 15 ALL 000068 WASHER FLAT 5 16 X 3 ...

Page 94: ...ystems Models 4453 7590 ITEM MODEL PART NUMBER DESCRIPTION QTY 1 005455 BALLAST BAR 16 LB GALV 3 2 005499 BACKING PLATE LG SS 3 3 005494 PATCH WEAR BALLAST 3 4 007111 SPACER BALLAST BAR 6 5 000380 BOLT HX 1 4 20 X 2 1 4 SS 6 6 001834 WASHER FLAT 1 4 X 3 4 X 1 8 SS 6 7 001857 WASHER FLAT 1 4 X 1 1 2 SS 12 8 ALL 001662 NUT HX NYLOCK 1 4 20 SS 6 ...

Page 95: ...owerFill MAX Pump Assembly Models 4453 7590 ITEM PART NUMBER DESCRIPTION QTY 1 007243 DRIVE PUMP PFX ASSEMBLY 2 PUMP 1 2 007327 PUMP PFX ASSSEMBLY 2 3 005755 GASKET PUMP 2 4 007995 O RING BUNA N 011 50A 4 5 011151 O RING BUNA N 031 65A 2 6 001866 STATOSEAL 5 16 PLT 4 7 005773 SCREW SC 1 4 20 X 1 1 2 SS 6 8 000386 BOLT HX 5 16 18 X 1 4 ...

Page 96: ...NUMBER DESCRIPTION QTY 1 006816 VALVE FLAPPER PFX 1 2 006829 DISC FLAPPER INNER PFX 1 3 006827 DISC FLAPPER OUTER PFX 1 4 006699 RETAINER FLAPPER PFX 1 5 005734 IMPELLER CAST SS 4 3 1 6 000553 BOLT SHL 1 4 X 1 4 X 1032 HX SS 2 7 000533 BOLT HEX 1 4 28 X 3 4 SS 1 8 000494 SCREW 10 24 X 5 8 PNPH SS 2 9 001852 WASHER LOCK SPLIT 1 4 SS 1 10 001855 WASHER FLAT 10 X 3 4 FND SS 2 11 001660 NUT HX 10 24 S...

Page 97: ...gs 2016 Bambi MAX Service Manual Models 4453 7590 Version D 92 We Engineer Solutions PowerFill MAX Screens Models 4453 7590 ITEM PART NUMBER DESCRIPTION QTY 1 007379 SCREEN PUMP PFX ASSEMBLY 2 2 005755 GASKET PUMP 2 3 011530 SCREW SC 1 4 20 X 1 SS 6 ...

Page 98: ...lutions PowerFill MAX Standoff Models 4453 5566 ITEM PART NUMBER DESCRIPTION QTY 1 008709 RING STANDOFF 25 X 16 PFX 8 2 008710 SPACER STANDOFF PFX 10 3 008699 BLOCK MUDPAD PFX 4453MXP 5566MXP 4 4 000392 BOLT HX 3 8 16 X 1 1 2 SS 8 5 012091 BOLT HX 3 8 16 X 8 SS 8 6 001863 WASHER FLAT 3 8 SS 24 7 001665 NUT HX NYL 3 8 16 SS 16 ...

Page 99: ...utions PowerFill MAX Standoff Models 6578 7590 ITEM PART NUMBER DESCRIPTION QTY 1 012024 RING STANDOFF 25 X 16 PFX 1 2 008710 SPACER STANDOFF PFX 10 3 008700 BLOCK MUDPAD PFX 6578MXP 7590MXP 5 4 000392 BOLT HX 3 8 16 X 1 1 2 SS 10 5 012091 BOLT HX 3 8 16 X 8 SS 10 6 001863 WASHER FLAT 3 8 SS 26 7 001665 NUT HX NYL 3 8 16 SS 20 ...

Page 100: ...ry Bags Troubleshooter Kit PART NUMBER DESCRIPTION 005603 CARRY BAG BBX4473 005604 CARRY BAG BBX5566 BBX6578 005605 CARRY BAG BBX7590 PART NUMBER DESCRIPTION QTY 001615 CABLE DRIVE ASSEMBLY 1 000236 BUSHING GUIDE 2 002328 CLAMP HOSE 1 2 SS 5 FT 002332 TENSIONER CLAMP HOSE 1 2 SS 4 006421 SEAL VALVE BOTTOM 25 1 006332 SEAL VALVE TOP 25 1 ...

Page 101: ... must be returned to the company for inspection with all transportation and duty charges prepaid g The warranty does not extend to any product that has been accidentally damaged abraded altered punctured abused misused or used for a purpose which has not been approved by the company h This warranty does not apply to any accessories used with the product that are not supplied by the company and any...

Page 102: ...Appendix Drawings 2016 Bambi MAX Service Manual Models 4453 7590 Version D 97 We Engineer Solutions Appendix Drawings Pilot Controls ...

Page 103: ...Appendix Drawings 2016 Bambi MAX Service Manual Models 4453 7590 Version D 98 We Engineer Solutions Pilot Controls US Interagency ...

Page 104: ...Appendix Drawings 2016 Bambi MAX Service Manual Models 4453 7590 Version D 99 We Engineer Solutions Crew Controls using remote power supply ...

Page 105: ...Appendix Drawings 2016 Bambi MAX Service Manual Models 4453 7590 Version D 100 We Engineer Solutions PowerFill MAX Wiring ...

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