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Bambi MAX Service Manual (HL Series)

1. 38 cj 38 Category 2 Operational 38 CACO OLY 2 d 38 20 0 38 Bucket Shell Repair Criteria cies 39 Gables Repair m 40 IDS Hub Repair Criteria ccccccceccccseececceseeeeceeecesaeeeeeseeeeeseseesseeeeessseesseeeeessseeesaaeees 41 M Straps Top Chains Repair Criteria 42 Control Head Repair Criteria 43 Section 9 General Repairs 44 miseriis I ROTE mr 44 Suspension Line Replacement 4 44 uei Ezi ee n gm 45 Removing Old M SIraps eese eren estara aa oa ra rar EAS Rude 46 Installing New M Straps Short sees eene 47 Installing New M Straps Long 49 Bottom Loop esses esses eene n ann hase n snas rss a sar saa nana 51 ille i al 51 IDS Hub Spokes Replacement 52 B
2. 69 Bambi MAX Valve 28 Actualor 70 Bambi MAX Valve 28 Actuator 2 71 Bambi MAX Valve 28 Sheave Bar and Guide Hods 72 Bambi MAX Valve 28 Lift Bar and Linkage 73 Bambi Valve 28 Lift 74 Bambi Head Model 4000 5000 cesses 75 Bambi Head Models HL 7600 9800 75 Bucket Shell Models HL4000 9800 76 Rigging Models 4000 9800 _ 77 IDS System Model HL4000 9800 79 IDS System Model HL4000 9800 continued 80 Ballast Systems Models HL4000 9800 81 M E 82 T OUDICSNOOVCl M E 82 Section 11 Warranty 83 Appendix Drawings 84 6 CONTOS 84 Pilot Controls US Interagency sessi essen rennen nnns 85 Crew Controls using remote power supply 86 af We Engineer
3. 12 DNC Ol ERROR 13 Section 4 Making Adjustments 14 Adj st ng 9 91401019 4 11 14 FIO USO m 14 Section 5 Packing and Storage 16 PACKING Um 16 Packing the Bucket 16 reise Te BITO MAN qe 20 Section 6 Troubleshooting and Maintenance 21 Trouble hooting 21 Valve 1TOUDICSIOOUNG ETE 21 Checking Aircraft Longline Wiring sees seen 22 Maintenance Procedures 23 Weekly 23 Weekly Inspection Checklist nnn 23 af We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A z z m Section 7 Valve Maintenance 24 MAX Valve Repair and Replacement essen 24 LK JGC AOI SUMO M 24 WAIVE TICINOVAN n 24 22117128 4 2 112116 26 Bambi MAX Seal Replacement 28 Drive Cable Replacement do Changing the Guide Bushings sse isses eese enne nnn rna 37 Section 8 Repair Quick Guide 38 Overview of Repair Categories
4. Caution Tightening the nut with tools may break the bolt away from the lower clamp Overtightening can also deform the clamp and cause leaks a amm m amen We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 version A 57 Section 9 General Repairs Temporary Repairs Using Glue Temporary Repairs Using Glue Important Note Allow repair to harden for 24 hours at room temperature before using the item Applying the Glue Small scrapes damaged fabric coating or pinholes which are not leaking can be repaired with glue only They do not require a patch A small scrape is defined as damage to the outer fabric coating only A pinhole is defined as a small puncture that is not leaking However damage to the base fabric must be repaired with a patch 1 the 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 well coated A damaged coating should be given two coats of glue Apply the second coat within four hours of the first toat 2 uus Clean and apply masking tape on the backside of the tear Squeeze glue around the te
5. Pu 53 Load Test on the HOOK C E n 53 BaMmDLMAX ea 54 gizo laucP 54 Repairing in High Humidity a E eE EEE A ETE 55 Making Temporary Repairs with Sealing Clamps 56 Temporary Repairs Using Glue 58 ADODO TE CIO E 58 Gluing with Patches o ccccsseccccccsseeccecssneecccsseesecsesseeecesssseeeeesseeseeessuanecessaaeeseesaas 59 CUO NOF aise sh 60 Applying the Patch E 60 FOLAT CUT PONI Mmmm 62 ne 10 5 63 MARTE 64 NI 64 Seele M 64 S We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A Section 10 Specifications and Parts 65 Capacity and Weight Specifications 65 mcos He E 66 Bambi MAX Valve 28 Shell Assembly Models HL4000 9800 66 Bambi MAX Valve 28 Installation esses seen 67 Bambi MAX Valve 28 Seals 68 Bambi MAX Valve 28 Actuator and Controller
6. 061 5 YWAN 9 310143234 S0193NNO2 ze diL vZ BZ01 S YOLOSNNOD 14 SL L vZ 3101 SN 310v143238 HOI93NNOO BZ tZGb 2S AMVINJNON ISdS HOLMS LO 99LFZSM WOS 11545 vos 3wv3sg UNOHO 289 G CLOZZSH 4J4v348 LINDHID 192 NOILvOIJIO3dS NOlLdilJ42S3G0 WIU SINIJINOGNOD QJUN3AWOO33S m O T NOILISOd 340 JHL ONY N3dO Q3xVIA HOLIMS ANLOATION JHL NO GSLNNOW HOLIMS NOLLYNLOV F SNOILINYLSN S YSYNLIVINNVW 14 HLIM 3ONVOHOOOV NI INO SWNIWH3L Q3dWIHO ONY STVNIWH31L 5 SONNOHD TV E WALSAS JHL 1 34 Ol SLYNOSOY 51 ALIOVdVD YOLVYANAD JHL SHNSNA OL SISATYNY QvOT1 14 50 TWLLINSSS3 HO A9N393W3 0350 SI Snhg8 14 ANY OL 5 5 SWYE JHL LOSANNOD LON 2 1 ONY SLEEPY 51 HLIM 3ONVOHOOOV NI INOA Addis H3MOd 14 OL NOLLDJNNOO 2 5 1201 318V9l1ddV 39ONVOHOOOV NI T3NNOSH3d GJ TANO A8 38 OL SNOILWTIVLSNI TIY SNOILOYNLSNI NOLIVTTV LSNI Q30N3NINOO38 383HL SALON sng SS3 NON JOA 8z 2014 Bambi MAX Service Manual Models HL4000 9800 version A 85 ons i Solut gineer SEF WeEn INDUSTRIES Parts Listings ings Draw Appendix Crew
7. Remember to re attach the tripline to the dump valve passing the line through the hub Also attach the IDS deployment cable to the control head small adjustment chain Attach the two restrainer cables ll n un We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 version A 52 Section 9 General Repairs Repair Instructions If the IDS is too tight adjust two of the spokes as follows 1 Cut off the spoke just above the existing hole on one end only Then redrill a new hole centred the same distance from the new end of the spoke as the other spokes This will likely produce a good fit 2 Ifthe IDS is still too tight remove another spoke on the opposite 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 deployment cable is attached to the middle link of the adjustment chain Check tension in the deployment cable Under full load the deployment cable should feel relaxed but not slack The hub should be free to move up or down about 1 2 13 mm HT sb af Il ll We Engineer Solutions 2014 Bambi MAX Service Manual Models
8. SEAL SUPPORT 28 BBXHL4000 SEAL VALVE TOP 28 HL4000MX iiid HL9800MX si n ll We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 68 Section 10 Specifications and Parts Parts Listings Bambi MAX Valve 28 Actuator and Controller MODEL PART NUMBER DESCRIPTION 000211 ACTUATOR ASSEMBLY 4453 19800 1 000206 IVC ASSEMBLY 1518MX HL9800MX r3 001606 SCREW 10 24 x 3 4 HXSL SS 9800 001848 WASHER LOCK SPLIT 810 SS 6 a We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 69 sl Section 10 Specifications and Parts Parts Listings Bambi MAX Valve 28 Actuator MODEL PART NUMBER DESCRIPTION 010735 SCREW SET CUP NYLON 10 32 X 1 4 SS li co iy 2 We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 70 5 z Section 10 Specifications and Parts Parts Listings Bambi MAX Valve 28 Actuator 2 000213 TUBE MOTOR 4453MX HL9800MX_ 1 007776 MOTOR GEAR 24 3 8 588 1 005843 O RING BUNA N 037 65 005994 O RING BUNAN 4039 65A 1 1 004016 KEY MACHINE C1045 SQ 4MM X 16MM 000760 BOLT HX 14 20X9 SS 4 000379 SCREW SC 1024X1 288 3 0000055 SCREW SC M5X08X16 988 4 002928 SEAL LIP 1 X 1 1 4 X 1 8 2 1
9. The company s products are not guaranteed for any specific length of time or measure of service but are warranted only to be free from defects in workmanship and material for a period of one year to the original purchaser c To the extent allowable under applicable law the company s liability for consequential and incidental damages is expressly disclaimed The company s liability in all events is limited to and shall not exceed the purchase price paid d This warranty is granted to the original purchaser of Bambi MAX systems and does not extend to a subsequent purchaser or assignee e The company must receive notification in writing of any claims of warranty from the original purchaser which must give details of the claimed defect in the product f Where the original purchaser is claiming under warranty the product must be returned to the company for inspection with all transportation and duty charges prepaid 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 warranty on such accessories must be requested from the manufacturer or dealer of the accessories 1 In the event the original purchaser does not give notice of a warranty claim within one year of the original pu
10. straps while short webbing are used for the vertical straps Long webbing diagonal straps Short webbing vertical straps When replacing straps do one set at a time to avoid confusion Cut off the old straps from the shackle and un tie them from the top of the bucket shell Attach replacement straps as per the originals We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 45 Section 9 General Repairs Repair Instructions 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 RY S We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version 46 Section 9 General Repairs Repair Instructions 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 We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 47 Section 9 General Repairs Repair Instructions 4 Rotate the eye to the opposite side 5 Pull strap end through the eye 6 Pull strap tight S We Engineer S
11. Controls using remote power supply 91 91 662Z225N Sy GIU OMIM 02 91 84 8 5 OMY 023 SHIM Sd 4 1 4 184 123 2 1 OAWOL MOS 3N I TONO Sdl HGL G YAON 9dl YlOvld323H HOLO3NNOO 951 5 2d HOLO3NNO2 NOILVOIJ3IOdaS NOLLdl 2S SINJNOdWO2 Q3UN3 WOO3H TER 2014 Bambi Service Manual Models HL4000 9800 Version A 86 We Engineer Solutions EE
12. Factory replacement lines come pre swaged with connection links to make replacing quick and easy Tools required Pin locked in place 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 Center holding sleeve SE We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version 44 INDUSTRI Section 9 General Repairs Repair Instructions 8 Place the connecting link with the pin located over the hole and using a 3 16 punch drive pin through the center holding sleeve 9 After the pin is free remove the old suspension line Place the new line in the connecting link by inserting the pin into one side of the connecting link Using a hammer drive the pin in until it is flush with both sides of the connecting link M Strap Replacement Replace 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 diagonal
13. 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 the IDS deployment cable using tie wraps or tape spaced about 36 apart At the head the final attachment will be at the IDS cable shackle We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 32 Section 7 Valve Maintenance Drive Cable Replacement Tools required Cable cutter or sharp side cutter Allen key 7 64 wrench 5 16 heat shrink tubing 1 8 heat gun If the helicopter is not available as a power and activator source a 24 28 DC power source can be used Connect the negative line to the narrow blade on the plug and the positive to the round pin The valve will be in the closed position To open the valve touch the positive wire to the wide blade on the plug If the valve doesn t operate check that the wiring in the plug hasn t been changed Open the plug and check the green 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 cable by pulling the unswaged end through the sheave and lift b
14. ONY 81 65 AHVHOSIAQOV vv HLIM JONVOYOIDY NI LIVYOUlY NOLLO3NNO2 Z I SNOLLWINDSAY Tv201 318v2l ddV HLIM o 7HMNOSH3d 4 TvnO INOA 38 OL SNOLLIV TT 11 A TINO 5 5 NOLLYTIYLSN Q3ON3OINIIOO3 SSSHL SILON 5 c 4 STEEL 2 4 H a gt o SSL SATWA Ne 1 SAWOL OAWSIL d ld zr lt LS MOS 6 91 EN 3NI19NO1 5 SS3 NON 5 82 e 91 91 6S 2Z50 Il uM C 0z 91 6SLZcSW 028 a Sd dGl SG YAAN S8d HOLIGNNOD 2 Sdl HGI G TIOVLd3233 HOLO3NNOO 451 5 WIN NOIO3NNOO E 5 WGN 3709143295 MOLIANNGS c Q gZ EZSrZSN AMVIN3AON 1545 HOLIMS p z 22 J amp bLFZSM S ELOZZSW S e O O NOLLVOIJIOddS NOlILdld2830 2 52 SIN3NOdAOO Q30N3lWO233 P 0 Q gt c Q re lt x lt ls Parts Listings ings Draw Appendix Pilot Controls US Interagency SNIH 201 NHO OMWV8L SAWS lOM1NOO 3ATVA MOS 6 91 JNI19NOT1 91 65 5 02 91 6 12258 028 19 1 461 VW3N 9d HOIO3NNO2 94
15. Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A z z m Section 1 Introduction Bambi MAX HL4000 9800 Section 1 Introduction Bambi MAX HL4000 9800 This manual provides helicopter operators with information on the service and maintenance of the Bambi MAX This service manual also includes all parts lists and installation drawings A separate Bambi MAX operations manual is also supplied which should be carried on board the helicopter For your own protection and for longer bucket life always read the instructions and warnings Ignoring these warnings could result in personal injury bucket damage or aircraft damage SEI Industries 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 model series 1518 3542 and series 4453 7590 In addition a number of accessories and enhancements are also available including the Power Pack with hand grip for valve only Sacksafoam and Marine Recovery Device For more copies of this manual please contact SEI or visit our website at www bambibucket com for more information on these products Valve serial number lo
16. head RY S We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 6 Section 2 Deploying the Bambi Deployment Instructions Connecting Power The power requirement to control the Bambi MAX valve is 5 amps 24 28 VDC The Bambi MAX comes with a three conductor 16 gauge control cable that comes from the valve to 3 above the head Attached to the end of the cable is a male waterproof Nema 5 15 electrical plug the female receptacle for the helicopter is attached If desired the operator may replace these plugs to match the receptacles installed on their aircraft If a longline is to be used the replacement plug at the head should be waterproof The purpose of this type of plug is to offer a clean breakaway if the Bambi MAX has to be jettisoned from the aircraft in an Bambi Max Model Current Draw Amps at 24 5 VDC emergency It is suggested that the plug be BBXHL4000PF lightly taped together with vinyl tape while in use to ensure that wind action BBXHLSOOOPF does not separate the plug during flight BBXHL 600PF BBXHL9800PF There are three types of suggested wiring installations see Appendix for diagrams 1 Pilot control In this configuration the control is wired into the pilot s control column through a relay 2 Pilot control US interagency In this configuration the control is wired into the pilot s control column through a 50 amp relay as per US interagency regulati
17. lift bar Place a heavy weight on the lift bar to hold it down 3 8 spacer 7 Turn on the power The valve will close Pull the cable tight and secure with cable anchor screws We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version 35 Section 7 Valve Maintenance 8 Install a piece of 1 8 1 heat shrink over the cable next to the anchor Cut off the excess cable as close to cable anchor as possible 9 Remove the weight and spacer 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 I heat shrink over the cable next to the anchor Cut off the excess cable as close to cable anchor as possible sl u We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 version A 36 Section 7 Valve Maintenance 11 Cycle the valve several times at both the fully open and fully closed actuator cam to see if there is any movement like a second hand on a clock If there is this means that the cam needs adjustment When the valve is open all the way the green light should be on and not flashing Whe
18. 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 top clamping ring These bolts are extra long to give us maximum holding strength in plastic Removing the head bolts S We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 version A 30 Section 7 Valve Maintenance 3 Remove the top 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 SEI We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 31 Section 7 Valve Maintenance 6 Now start all bolts into the tube turning them in about 1 8 This allows you to locate the holes in the tube easier by lifting the ring and seal to see the holes 7 Tighten all bolts equally as 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
19. to the bucket shell fabric isolated to one side of the material that do not cut through e 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 e Wear and abrasions to webbing protective strips e Up to 4 102 mm of peeled weld on panel strip e Up to four broken battens Category 4 Okay Does not need repair We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version 39 E an Section 8 Repair Quick Guide Cables Repair Criteria Cables Repair Criteria Category 1 Safety Cease operations and repair immediately e One or more broken suspension cables or end fittings e Broken deployment cable Category 2 Operational Repair before next days operation or eight hours flight time If three or more individual suspension cables or the deployment cable have the following defects e 10 more randomly distributed broken strands or four adjacent broken strands e Visible kink s e Separation of the strands due to twisting known as bird caging e Evidence of heat damage e Abrasion wear comprising of more than 1 3 of the original diameter of the outside indi vidual strands e visible reduction in outside diameter due to overload e Cracked or broken end fittings some elongation of cable eyes is acceptable Category 3 Monitor Monitor and or repair if c
20. 0 004346 BBX5566 BBXHL9800 004350 Sacksafoam II amp III 7 1 IB We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 12 cn Section 3 Using Accessories Bambi Mobility Sled Bambi Mobility Sled The Bambi Mobility Sled is a cart with wheels that moves larger buckets in hangars on runways or around remote sites PART NUMBER DESCRIPTION 009417 SKID 5566 7590 009387 SKID HL4000 HL9800 We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version 13 Section 4 Making Adjustments Adjusting Components section 4 Making Adjustments Adjusting Components Valve Adjustment The valve tube has seals located on the top and bottom of the tube The vertical position of the tube when in the closed position determines the amount of valve sealing The valve is adjusted at the factory to its correct position and should not require field adjustment under normal conditions Following major valve maintenance such as seal replacement or drive cable replacement the valve adjustment should be checked If the valve is adjusted too high it will leak If the valve is adjusted too low the motor protection circuit may be activated Determine the current state of valve adjustment as follows e Power up the bucket circuit to allow the valve to move to the closed position e If the indicator lamp flashes green or the cable drum sensor cam osc
21. 1 We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 71 5 z Section 10 Specifications and Parts Parts Listings Bambi MAX Valve 28 Sheave Bar and Guide Rods BBXHL4000 BBXHL9800 RING RETAINER EXT 1 4 PLT 005214 RING RETAINER EXT 5 8 55 2 BOLT 3 8 16 x 1 SS d2241 SCREW ESO O O O O 006276 WASHER FLAT 0 64 x 1 19 x 0 060 SS 6 si n ll We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 72 Section 10 Specifications and Parts Parts Listings Bambi MAX Valve 28 Lift Bar and Linkage DXN j E VON oc SNA 000235 BAR LIFT 28 HLAO00MX HL9800MX 1 008661 ARM LINKAGE LONG 4453MX HL9800MX 8 HL4000 HL9800 001685 NUT 10 32 8S 6 We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 73 10 n Section 10 Specifications and Parts Parts Listings Bambi MAX Valve 28 Lift Bar HL4000MX 001848 WASHER LOCK SPLIT 10 SS 001843 WASHER FLAT 0 20 x 0 50 x 0 6 SS 001685 NUT HX NYLOCK 10 32 SS s 000012 BOLT HX 10 32 x 1 17 32 CAD HL9800MX 001606 SCREW 10 24 X 3 4 HXSL SS n Ur xi Il ll We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 version A 74 Sectio
22. 5 al 20 m HL4000 9800 MODELS SERVICE MANUAL 2014 VERSION A Photo courtesy of Dan Sweet BAMBI SERVICE MANUAL Models HL4000 9800 Version A Issue Date August 2014 PLEASE READ BEFORE USING SEI INDUSTRIES LTD 7400 Wilson Avenue Delta B C Canada V4G 1 5 Phone 604 946 3131 Fax 604 940 9566 E Mail seisales sei ind com Website www sei ind com COPYRIGHT 2014 SEI INDUSTRIES LTD ALL RIGHTS RESERVED i We Engineer Solutions z m 2014 Bambi MAX Service Manual Models HL4000 9800 Version A Table of Contents Section 1 Introduction 1 Bambi HL4000 9800 cc cecccccccesssssceeeeceeeseeeeceeeeaaseeeeeesseauseeeeecsseasseeeeeessaasaes 1 NNN el SUC RN E 2 Sy SUI OVC 2 3 81 1 19 4 ONO 2 Section 2 Deploying the Bambi 6 Deployment INSIUCONS A a NES 6 Attaching to the Cargo Hook 6 0060 01007 2 5 05 E 6 COTA CUI TOW EE 2 OVO ACS ere Instant Deployment System IDS sees 10 Section 3 Using Accessories 11 81116 11 Sacksafoam Foam Injection System sisse seien 11 Compatible Bambi MAX Sacksafoam Models
23. 77 M STRAP STRAIGHT 47 1 4 HL7600 005478 M STRAP STRAIGHT 66 1 8 HL9800 005482 M STRAP STRAIGHT 74 1 4 HL5000 ABLE SUSPENSION LINE PAIR HL7600 009860 CABLE SUSPENSIO HL9800 009861 HL4000 309863 HL5000 HL7600 CABLE SUSPENSION LINE SINGLE HL9800 009865 HL4000 HAIN TOP 17 1 2 HL5000 7600 005532 CHAIN 26 HL9800 005540 CHAIN TOP 30 HL4000 1 HAIN TOP 20 HL5000 7600 005534 CHAIN TOP 28 3 4 HL9800 005536 CHAIN TOP 30 1 4 005483 M STRAP PROTECTOR HL9800 005538 CHAIN TOP 34 3 4 001789 SHACKLE ANCHOR 5 16 SCREW GLV ALL 000371 BOLT HEX HEAD 1 4 20 X 1 1 4 SS 001857 WASHER FLAT 1 4 X 1 1 2 FND SS 004057 LINK CONNECTING 9 32 PLT BOTTOM 001662 NUT HX NYLOCK 1 4 20 SS 8 006710 LINK CONNECTING 3 8 PLT NOTE 8 is the link used to connect the suspension line to the head shackle We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 78 i Section 10 Specifications and Parts Parts Listings IDS System Model HL4000 9800 SEI We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 79 Section 10 Specifications and Parts Parts Listings IDS System Model HL4000 9800 continued ITEM MODEL PART NUMBER DESCRIPTION 1 005387 BRACKET SHELL 10 ALL PATCH WEAR BRACKET BRACKET RESTRA
24. HL4000 9800 version A 53 Section 9 General Repairs Bambi MAX Shell Repairs Bambi MAX Shell Repairs Please read these instructions carefully and follow them exactly to obtain a good repair Failure to follow these instructions or poor repair workmanship can lead to failed repairs and or more damage to the bucket Before commencing repairs using glue the weather should be warm above 60 deg F or 15 deg C and dry Important Note Try a test repair before attempting to repair the bucket This will verify your technique without risking damage to the bucket It is much harder to fix a repair once a failed attempt has been made as the hardened glue is difficult to remove Repair Failures Repairs will likely fail if The area to be repaired is not perfectly 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 Dura Seal glue has been designed specifically for the SEI family of fabrics The shelf life of this adhesive 18 about one year Fresh adhesive can be obtained directly from SEI Industries Ltd a We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 54 z z m Section 9 General Repairs Bambi MAX Shel
25. INER 006194 PLATE BACKING RESTRAINER HL5000 CABLE IDS RESTRAINER HL4000 005322 CABLE IDS DEPLOYMENT We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 version A 80 du T Section 10 Specifications and Parts Parts Listings Ballast Systems Models HL4000 9800 007111 SPACER BALLASTBAR 6 000380 1 20 2 14 88 6 001834 WASHER FLAT 1 4 X 3 4 X 1 8 SS 6 001662 NUT HX NYLOCK 1 420 85 6 7 1 IB We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 version A 81 sb 3n Dm Section 10 Specifications and Parts Parts Listings Carry Bags PART NUMBER DESCRIPTION 005606 CARRY BAG BBXHL4000 BBXHL5000 005608 CARRY BAG BBX7600 005610 CARRY BAG BBXHL9800 Troubleshooter Kit PART NUMBER DESCRIPTION 001615 CABLE DRIVE ASSEMBLY 000236 BUSHING GUIDE i We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 82 z m Section 11 Warranty Parts Listings section 11 Warranty SEI Industries Ltd the Company agrees to grant a warranty for a period of one year from the date of purchase of Bambi MAX systems on the following conditions a The company s sole obligation under this warranty is limited to repairing or replacing at the company s sole discretion any product shown to be defective b
26. SED PARTIALLY OPEN a OPEN When the controller receives the open signal from the aircraft 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 tube remains in the closed position The sensor cam can rotated on the drum to adjust the valve position Rotating the cam clockwise will lower the valve counter clockwise will raise the valve See Section 4 Making Adjustments There is a status indicator lamp on the side of the control enclosure which indicates where the controller thinks the valve 18 1 sb zn ca i Flashing Green Valve Partially Open We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 4 E an Section 1 Introduction Valve System The controller has an internal motor protection system to prevent the motor from being overloaded When excessive current flows to the motor due to a stalled condition the motor 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 w
27. an immediate repair to prevent the loss of liquid through large rips or holes For example if a vehicle accidentally backed into a bucket and caused a 3 76 mm long rip in the bucket a repair clamp could be inserted to stop the loss of liquid Repair clamps are only used for temporary repairs The damage should be permanently repaired with a patch when the bucket can be set aside for 24 hours Important Note Leaving the clamp s string on makes it easier to remove the repair clamp when placing a permanent patch on the bucket 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 e For a cut or hole up to 2 5 cm use 3 7 6 cm clamp supplied e For a cut or hole up to 4 10 cm use 5 12 7 cm clamp supplied e For a cut or hole up to 6 15 cm use a 7 5 19 cm clamp special order Caution Use caution if deciding to enlarge the slit to insert a clamp Itis very easy to make the slit too large 2 Keeping hold of the string slip one half of the repair clamp through the hole as indicated 7 1 Il T We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 56 Section 9 General Repairs Bambi MAX Shell Repairs 3 Pull the bolt up through the hole Turn it until the clamp lines up with the hole 4 Placethe top of the clamp over the bolt
28. ar 4 To remove the cable ends from the cable anchors the motor will have to be started and stopped when a cable anchor is close to the top Now loosen the two cable anchor screws and pull the cable through Then activate the motor again to get the second cable anchor to the top loosen the two cable anchor screws and pull the cable out Important Note Use cyanoacrylate glue crazy glue on the ends of the cable if available to prevent fraying We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 33 ab n Section 7 Valve Maintenance Installing the new cable 1 Examine the new drive cable to determine the shorter 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 We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version 34 Section 7 Valve Maintenance 5 Connect the power control cable to a 24 28 volt DC power source open the valve 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
29. ar and spread with fingers We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version 58 Section 9 General Repairs Temporary Repairs Using Glue Gluing with Patches If there is dampness around the area to patched then dry the area with a hot air fan or heat gun Any loose coating should be cut back with scissors 1 Support the damaged area on a flat solid platform This platform should be strong enough to support the fabric flat and allow the patch to be rolled once it is in place The damaged area should be supported on a flat solid platform 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 Caution Solvent will damage the fabric if too much 18 used or if the fabric is left exposed to solvent residue 3 Wipe with arag dampened with solvent to remove any residue from cleaning Check to see if the area is totally clean and all coated surfaces and edges are dull If not repeat the cleaning This is critical for a good glue bond HT Il ip i We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 version A 59 Section 9 General Repairs Temporary Repairs Using Glue Cutting the Patch 1 Cuta patch The patch should be at least 2 50 mm larger in every direction
30. atch 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 SEG We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 61 INDUSTRIES E 5 an Section 9 General Repairs Hot Air Gun Patching Hot Air Gun Patching On most items hot air gun patching is the preferred method because it provides the most durable permanent repair possible Tools and materials required e Patches One plastic hand held roller One hot air gun Steinel HL 1800 E or equivalent 120 V 1500 800 to 1100 deg F 450 litres per min e One wide surface nozzle Isopropyl alcohol e 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 air gun Most welding will occur at temperatures of 800 1000 degrees F Wear gloves to protect skin from overheating burning and blistering We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version 62 Section 9 Ge
31. cation Bambi MAX shell serial number location RY S We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 1 af Section 1 Introduction Valve System Valve System System Overview The Bambi MAX uses a tubular type valve with seals located on the top and bottom of the tube When in the default closed position the seals make contact with top plate and bottom ring of the valve assembly When in the open position the tube is raised allowing water to flow between the bottom of the tube and the base ring and then through the opening in the base ring CLOSED OPEN 11 10 System Description Movement of the valve tube is controlled by an actuator and drive cable system The actuator 15 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 The cable is routed down around the deflector sheaves at the base of the valve and back up to the cable drum where the other end is terminated forming a closed loop The drive cable 18 also attached to a horizontal lift bar which itself is attached across the lower end of the tube 1 IB We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 version A 2 5 z m Section 1 Introduction Valve System OPENING CLOSING When
32. ch 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 position preferably by suspending the main shackle from an overhead hook An alternative is to suspend the bucket upside down from its bottom chain 5 Before storing the bucket for an extended period perform our recommended seasonal maintenance procedures We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 20 E an Section 6 Troubleshooting and Maintenance Troubleshooting section 6 Troubleshooting and Maintenance Troubleshooting Valve Troubleshooting Circuit breaker tripped Reset circuit breaker Off White No Power Check aircraft longline wiring Aircraft longline wiring Check aircraft longline wiring al Off White Mechanical jamb Clear jamb check linkage Valve adjusted too high Adjust valve down Valve adjusted too low Adjust valve up Flashing Motor protector Power cycle to reset Green activated Adjust valve up Aircraft longline wiring Check aircraft longline No open signal wiring Y ellow Valve Closed Won t Open Controller failure Contact service center Damaged drive cable drive cable Controller sensor Contact service center failure Flashing M
33. en into account when attaching to ensure that the terminations are not released from the belly bucket or hook etc It is also imperative to take extreme care when removing the conduit from the longline especially if a knife is used to remove the tape as one could inadvertently cut through the cover and the damage the synthetic rope It is important to remember that when conduit is duct taped 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 Length Feet Meters Wire Recommended Plugs 16 3 SOW NEMA 5 15P NEMA 5 15R 76 100 23 30 16 3 SOW NEMA 5 15P NEMA 5 15R 101 150 30 45 14 3 SOW NEMA 5 15P NEMA 5 15R 151 200 46 61 12 3 SOW NEMA 5 15P NEMA 5 15R Checking Suspension Cable Length Warning Using a Bambi MAX with a greater overall length than the distance from the cargo hook to the front tip of the tail rotor on your helicopter could result in a tail rotor strike and possible loss of control of the helicopter which could result in injury or death Measuring the bucket We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 8 Section 2 Deploying the Bambi Deployment Instructions Overall lengths of Bambi MAXs with standard rigging are provided in this manua
34. er of the IDS hub Once all the cable is outside the bucket with no slack inside the bucket and the IDS 18 fully extended push six inches of the control cable back into the bucket Now using one or two tie wraps attach the cable to the deployment cable eye on the hub We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 27 Section 7 Valve Maintenance 5 Reattach the control cable to the IDS deployment cable and head using tie wraps or tape spaced about 36 apart At the head the final attachment will be at the IDS cable shackle Bambi MAX Seal Replacement If either seal has to be changed we recommend that the valve be pulled from the shell although it may not be necessary to detach the control cable from the IDS deployment line Depending on circumstances the valve seals can be replaced while the valve is next to the shell but the valve should be placed on a clean level surface such as a piece of cardboard or 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 power to keep it in this location If you have several Bambi MAX buck
35. erator must also ensure that the bucket selected does not pose a tail rotor strike hazard x m a We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 65 Section 10 Specifications and Parts Parts Listings Parts Listings Bambi MAX Valve 28 Shell Assembly Models HL4000 9800 007333 RING BASE 28 HLAQOMX HLBS0ONK 11 BBXHL4000 BBXHL9800 We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version 66 iv Section 10 Specifications and Parts Parts Listings Bambi MAX Valve 28 Installation sl E 2 n 1 NER 1 F gt ne JI iw ITEM MODEL PART NUMBER DESCRIPTION QTY 002300 VALVE 28 ASSEMBLY HL4000MX L9800MX 007340 PLATE BLANK PUMP 4453MX HL9800MX BBXHL4000 005755 GASKET PUMP 4 BBXHL9800 000391 BOLT HX 3 8 16 X 1 SS 4 005773 SCREW SC 1 4 20 X 1 1 2 SS 001853 WASHER LOCK SPLIT 3 8 SS NUT HX 1 4 20 SS 2 We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 67 Section 10 Specifications and Parts Parts Listings Bambi MAX Valve 28 Seals MEE T 007132 TUBE VALVE 28 MACHINED 006450 SEAL VALVE BTM 28 HL4000MX HL9800MX 1 4 002328 CLAMP HOSE 1 2 55 002332 TENSIONER CLAMP HOSE 1 2 SS 010738 RINGS SEAL SPACER 28 005771 RING
36. ering information please see Section 10 of this manual The IDS can be purchased either as a complete kit or as individual pieces as required Follow the procedure below to replace the entire assembly 1 A Start by removing the old IDS including the shell brackets and the old restrainer cable brackets You will have to disconnect the tripline from the valve or control head since the tripline passes through the hub For re assembly first install the new shell brackets This can be accomplished by installing the bolts through the bucket shell fitting the fabric wear strips onto the bolts and then fitting the brackets to the bolts Install and tighten the Nylock nuts Install the two restrainer cable brackets One is found below the ballast and the other is directly opposite 6 o clock position No wear strips are required for the restrainer cable brackets 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 Attach the two spokes at either side of the 12 o clock position using the stainless steel clevis pins Complete by fitting the fender washer and cotter pin Working around the bucket perimeter attach the rest of the spokes Once the IDS is fully installed test for fit You should be able to pull the hub past the midpoint position with a slight effort If the IDS is either too loose or too tight it will require adjustment
37. ets a Power Pack 18 available from SEI This Power Pack can also be used as the main power source for operation of the bucket which eliminates wiring the helicopter for the Bambi MAX Valve in partially open position and shown with the Bambi Power Pack We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 28 Section 7 Valve Maintenance 2 Turn valve over as shown in this picture 3 Loosen the four hose tensioners and lower the clamp into the position shown in this 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 engaged enough to hold the clamp We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 29 Section 7 Valve Maintenance Top Seal Replacement Replacement of the top seal doesn t necessarily require removal of the valve unless you are planning other maintenance functions 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 replace the top seal with the valve still in
38. from the damaged area A round patch is recommended but if a rectangular patch covers the damage better then round all corners Clean the patch by scrubbing with a pad dampened with solvent Rub vigorously to remove the gloss from the fabric Clean both sides of the patch as it is easy to get the patch turned over during installation Another reason the patch should cleaned on both sides is that it will be painted with glue on the outside later The color of patch will vary depending on the product repair kit Applying the Patch 1 Apply the Dura Seal glue to the patch and damaged area Wait 30 minutes at 75 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 to avoid entrapping air bubbles in the bonded joint 2 Place the patch and roll it down with the roller Place the centre of the patch down first then roll it out towards the edges with the roller This expels trapped air Once the patch is rolled down do not let it lift up This will prevent air from getting under the patch which causes a weak bond We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 60 iv Section 9 General Repairs Temporary Repairs Using Glue 3 Weigh down the patch Place a plastic cover sheet over the p
39. ge If you are unsure of your bucket s status check with any Bambi Bucket Service Center in your area for more information and assistance Important Note If more information is required refer to the Bambi Bucket Operations manual the Bambi Bucket Service manual for the model being used or the Bambi Bucket Repair Assessment manual We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 38 Section 8 Repair Quick Guide Bucket Shell Repair Criteria Bucket Shell Repair Criteria Category 1 Safety Cease operations and repair immediately e One or more broken top loop knots M strap attachment point to the shell e Gross punctures through shell that cut or severely damage one or more panel strips Separation of fabric welds longer than 3 76 mm e Punctures or cuts through shell longer than 3 76 e Two or more broken bottom webbing loops Category 2 Operational Repair before next days operation or eight hours flight time e Top loop knots that are worn or have damage to more than 25 of the fabric e punctures or weld separations less than 3 and or cut through more than 25 of a panel strip e Bottom webbing loops with more than 25 damage to fabric strands e Broken or missing bottom webbing protective wear strips e Hive or more broken battens Category 3 Monitor Monitor and or repair if condition deteriorates Wear abrasions and cuts
40. hatever 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 10 seconds and turn the power back on again The valve should return to its normally closed state We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 5 Section 2 Deploying the Bambi Deployment Instructions section 2 Deploying the Bambi MAX Deployment Instructions Attaching to the Cargo Hook 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 15 correctly fitted to the helicopter Head Orientation The Bambi MAX is rigged for a longitudinal cargo hook Correct attachment is indicated when the ballast on the Bambi faces forward in flight Caution It is important that the ballast faces forward in flight This will avoid twisting of the suspension lines For this style of head if using a swivel hook always operate in the locked position to assure that the ballast is always facing forward in flight Warning When a ring is used to turn the bucket 90 degrees choose a ring that is the same size as the shackle on the
41. ill prolong the bucket life Sacksafoam Foam Injection System The Sacksafoam is SEI Industries advanced foam dispensing system for use with the Bambi MAX This system exclusive to the Bambi allows foam to be dispensed into the bucket in route from the filling source to the fire site There are three models of Sacksafoam to fit this range of Bambi MAXs The operation of the Sacksafoam is controlled by the pilot through a control unit which is mounted in the cockpit Sacksafoam I contains the foam reservoir directly installed inside the bucket The Sacksafoam 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 identical to the Sacksafoam II except that the controller is mounted in the foam resistant case in the Sacksafoam III Sacksafoam ll Model 5598 si n ll We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 11 Section 3 Using Accessories Using Foam If additional foam storage is required the Sacksafoam Plus can be purchased to add an additional 40 gallons of foam on board Sacksafoam Plus Compatible Bambi MAX Sacksafoam Models Model For Bambi Bucket Reservoir USG Capacity Liters 004240 BBX5566 BBXHL5000 60 228 004345 BBX5566 BBXhI980
42. illates when the valve is closed then the valve is adjusted too low Actuate the bucket dump switch and hold to keep the valve in the open position e If the indicator lamp flashes green or the cable drum sensor cam oscillates when the valve is open then the valve is adjusted too high The adjustment procedure is as follows e up the bucket circuit to allow the valve to close e Remove power from the bucket circuit e With the valve in the closed position locate the set screw on the top of the sensor cam which locks the cam to the cable drum It should be at approximately the 12 o clock position RY S We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 14 Section 4 Making Adjustments Adjusting Components e Notice particularly the location of the 9 o clock hole with respect to the cable anchor block It is helpful to draw a reference line on the sensor cam to a reference point on the anchor block e Loosen the set screw on the sensor cam using 3 32 hex key e If the valve is too low adjust the valve upwards by rotating the sensor cam counter clockwise so that your reference line moves approximately 1 16 Tighten the set Screw e If the valve is too high adjust the valve downwards by rotating the sensor cam clockwise so that your reference line moves approximately 1 16 1 mm Tighten one set screw e After adjustment power up the bucket circuit The valve sho
43. ion 9 General Repairs Repair Kits Repair Kits Bambi Repair Kit 003613 no glue Used for Bambi MAX s or other product lines where no glue is required or allowed Important Note It is the responsibility of the dealer and end user to ensure that the importation of glue is allowed in the country of use Repair Kit Parts Table BAG ZIPLOCK 9 X 12 2M CLAMP REPAIR SMALL 2 HOLE CLAMP REPAIR MEDIUM 4 HOLE Optional Supplies PART NUMBER DESCRIPTION 003090 ADHESIVE DURA SEAL 34 OZ 003091 ADHESIVE DURA SEAL 8 OZ 004504 CLAMP REPAIR LARGE 6 HOLE 10 n ll We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 64 Section 10 Specifications and Parts Capacity and Weight Specifications section 10 Specifications and Parts Capacity and Weight Specifications Bambi Max Model Gross Weight Empty eight imp Gat US Gal Liters b kg b BBXHL4000 BBXHL5000 5000 BBXHL7600 BBXHL9800 9800 10030 Note Capacities and weights are accurate to within 5 Specifications subject to change Check data plate found on shell shown below Caution The selection of a Bambi MAX model for a specific aircraft 18 dependent on many factors including aircraft weight fuel weight operation elevation and atmospheric conditions The helicopter operator must select a bucket model which is appropriate for their specific situation The op
44. kly 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 Check top and bottom valve seals We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 version A 23 Section 7 Valve Maintenance MAX Valve Repair and Replacement Section 7 Valve Maintenance MAX Valve Repair and Replacement Linkage Adjustment If excessive side movement develops in the linkage the bolts with arrows must be tightened Do not overtighten these bolts as they must be turned with only a small amount 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 ballast is on the bottom of the shell before removing the valve Detach the power cable from the head and IDS deployment cable coil the cable into an 18 coil and place it inside the top of the shell RY S We Engineer Solutions 2014 Bambi MAX Service Ma
45. l Before using the Bambi MAX check for the maximum total length To determine this length Bambi Max Model measure the distance from the cargo hook to the front tip of the tail rotor on the helicopter you will be using and subtract 6 10210101 Lengths are accurate to within 1 Overall lengths with standard rigging Specifications subject to change To determine overall bucket length 1 Stretch out the bucket on the ground secure the con trol head 2 Measure the distance from the shackle on the control head to the bottom of the bucket This measurement should be less than the maximum total length of the dimension taken from the helicopter Important Note To avoid potential rotor strikes when using the Bambi MAX the operator must measure the extended length of the Bambi MAX and the distance from the belly hook to the closest possible point of the tail rotor A Always measure the overall extended length of your Bambi MAX and B Measure the distance from the belly hook to the closest possible point on the tail rotor B must always exceed by at least six 6 inches We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 version A 9 E an Section 2 Deploying the Bambi Instant Deployment System IDS Instant Deployment System IDS The instant deployment system uses a hub and spoke mechanism to automatically expand the mouth of the bucket as soon as the weigh
46. l Repairs Repairing in High Humidity In conditions of high humidity a proper technique is essential for securing the bond strength desired The presence of surface moisture can destroy the effectiveness of the cemented bond The evaporation of solvent from the adhesive may reduce surface temperature below the dew point resulting in condensation of water vapour on the surface of the adhesive This is often visible as fogging or a milky 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 lighters or cigarettes Solvent and glue are both extremely hazardous Use solvent and glue under well ventilated conditions only Use an approved respirator mask to avoid breathing fumes When using a warm air fan either use one which is rated EXPLOSION PROOF or make sure that there is a steady flow of air past the work area to remove fumes as they are generated k a We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 55 z z m Section 9 General Repairs Bambi MAX Shell Repairs Making Temporary Repairs with Sealing Clamps Repair clamps are used for
47. n 10 Specifications and Parts Parts Listings Bambi MAX Head Model HL4000 5000 ITEM PART NUMBER DESCRIPTION 007273 HEAD MEDIUM 5566MX HL5000MX 001796 SHACKLE ANCHOR SCREW 5 8 GLV 006310 SHACKLE ANCHOR SCREW 3 4 ALLOY Bambi MAX Head Models HL7600 9800 k We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 75 Section 10 Specifications and Parts Parts Listings Bucket Shell Models HL4000 9800 MODEL PART NUMBER DESCRIPTION BATTEN ASSY 64 1 2 BATTEN ASSY 69 BATTEN ASSY 83 BATTEN ASSY 95 BBXH ae BBXHL5000 005687 STRIP WEAR 16 X 2 3 4 BBXHL7600 BBXHL9800 203 SCREW 10 24 X 3 4 PNPH SS ALL a 601 BBXHL4000 BBXHL5000 4 HAIN 5 1 H LV 603 senum 003846 C 9 16 GR30 G BBXHL9800 1 1 We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 76 5 z Section 10 Specifications and Parts Parts Listings Rigging Models HL4000 9800 umm S We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 77 Section 10 Specifications and Parts Parts Listings Rigging Models HL4000 9800 continued ITEM MODEL PART NUMBER DESCRIPTION QTY PEST 005477 M STRAP LOOP 20 5 8 7600 005479 M STRAP LOOP 30 3 8 HL9800 005481 M STRAP LOOP 34 3 8 HLB5000 0054
48. n it is closed the amber light should be on and not flashing Please refer to the cam adjustment information in this section to resolve any movement flashing light issues Actuator cam Changing the Guide Bushings To change the guide bushings follow the steps listed below 1 2 Open the valve about half way Remove the two bolts holding the old bushings in place and remove the old bushings Place the new bushing into position Insert the bolts attach the nuts and tighten Run the valve up and down If any slowing of the valve movement or jamming is noticed loosen the bolts on one bushing and pull the valve body away from the center of the valve and re tighten the bolts If slowing or jamming still occurs loosen the guide bushing bolts on the opposite side and repeat the operations of step 5 The valve should be opened and closed several times If it operates as it should the bushings are changed correctly I ll si n Ur xi We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 37 Section 8 Repair Quick Guide Overview of Repair Categories section 8 Repair Quick Guide Overview of Repair Categories This section 18 intended to provide the user with information that will allow for the quick repair assessment evaluation of the Bambi Bucket The repair assessment process is almost identical for all sizes of the Bambi Buckets with some exce
49. neral Repairs Hot Air Gun Patching Hot Air Gun Procedure 1 In a well ventilated location clean the area to be repaired as well as one side of the patch with an abrasive pad Wipe down the repair area and patch with isopropyl alcohol 2 Mount a wide surface air nozzle on the hot air gun so as to direct the heat flow in a large pattern Turn the power on adjust the temperature in the low range first and let the hot air gun warm Increase the temperature as required during the operation DO NOT OVERHEAT OR BLACKEN THE FABRIC Caution Overheating can occur quickly and can damage the product It s recommended that you test using the supplied fabric samples to determine the correct temperature to be used and the duration of heat to be applied 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 the patch down to fuse it to the fabric moving roller and gun simultaneously Repeat on the unfused portion of the patch Let the repaired area cool down Attempt to peel off at the edges with your fingers If there is even a slight peel repeat the operation locally Otherwise the repair is finished 1 We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 63 27 Sect
50. nual Models HL4000 9800 Version A 24 Section 7 Valve Maintenance 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 SEI We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 version A 25 Section 7 Valve Maintenance 5 Roll valve out of shell and move to repair area 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 AY S We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 26 Section 7 Valve Maintenance 3 Now go around to the base of the bucket and insert the four 3 8 bolts Some rotation 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 Note location of arrows for bolts 4 Next string the control line Before unrolling the coil of cable pass it through the cent
51. olutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version 4 48 Section 9 General Repairs Repair Instructions 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 umm We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 49 Section 9 General Repairs Repair Instructions 4 Rotate the eye to the opposite side 5 Pull strap end through the eye 6 Pull the strap tight S We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 50 Section 9 General Repairs Repair Instructions 7 strap set should now look like this 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 S We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version 4 51 Section 9 General Repairs Repair Instructions IDS Hub Spokes Replacement Protectors M Strap Hub Shell Brackets Spoke For part ord
52. ondition deteriorates Wear broken strands kinks and twisting in cable that do not exceed the limits defined in Category 2 defects Category 4 Okay Does not need repair i We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 40 z m i Section 8 Repair Quick Guide IDS Hub Repair Criteria IDS Hub Repair Criteria Category 1 Safety Cease operations and repair immediately e Cracks or breaks across the major section of the IDS hub e Two or more broken or cracked spoke brackets e Two or more broken or missing spokes clevis pins shell brackets e Three or more bent spokes bends in excess of 20 degrees broken Category 2 Operational Repair before next days operation or eight hours flight time e broken or cracked spoke bracket on IDS hub e broken or missing spoke e broken or missing clevis pin or shell bracket e two bent spokes Category 3 Monitor Monitor and or repair if condition deteriorates e Wear on IDS hub e Dents abrasions and wear on spokes e Clevis pin and shell bracket wear Category 4 Okay Does not need repair We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 41 z m i Section 8 Repair Quick Guide M Straps and Top Chains Repair Criteria M Straps and Top Chains Repair Criteria Category 1 Safety Cease operations and re
53. ons 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 Longlines Important Note It is recommended that operators who choose to use the Bambi MAX with a longline ensure that the longline is at least 50 long Longlines should be at least 50 ft long to keep the Bambi MAX well clear of the helicopter s tail rotor When using a longline care must be taken in selecting the correct gauge of control cable See the chart below for recommendations When purchasing a synthetic rope longline we recommend that the customer also purchase a protective cover and have the conduit inserted at the time of manufacture However if this is not feasible due to different conduits for different applications we recommend taping the conduit using duct tape grey at 3 4 ft intervals along the longline and cover We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version 7 5 an Section 2 Deploying the Bambi MAX Deployment Instructions We do not recommend using zip ties to attach wiring conduit as this tends to damage the cover and longline When attaching conduit allowances must be made for any stretch in the load bearing line and this must be tak
54. otor protector Power cycle to reset Green activated Adjust valve down Valve Open Won t Close Green Controller failure Contact service center Yellow Damaged drive cable Replace drive cable Controller sensor failure Damaged seals Replace seals Valve Leaks Yellow Valve adjusted too high Adjust valve down Contact service center We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version 21 ay i Section 6 Troubleshooting and Maintenance Troubleshooting Checking Aircraft Longline Wiring e Set the multimeter to measure DC voltage e nstall the black lead into the narrow socket of the helicopter wiring harness Install the red lead into the round socket of the helicopter wiring harness e The multimeter should read approx 28V e 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 OV e Actuate the bucket dump switch The multimeter should now read 28V If a longline is being used re connect the longline into the aircraft wiring harness and repeat the above procedure for the receptacle on the bottom of the longline We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version 22 T T Section 6 Troubleshooting and Maintenance Maintenance Procedures Maintenance Procedures Wee
55. pair immediately e Broken top chains e Broken or missing shackles e Two or more broken M straps Category 2 Operational Repair before next days operation or eight hours flight time e Mestraps with more than 25 of the fabric strands broken e Visibly worn top chains e Bent gouged worn or cracked shackles and shackle pins Category 3 Monitor Monitor and or repair if condition deteriorates e Damage to an M strap that does not exceed 25 of the fabric e Minor wear impact marks or corrosion on chains e Minor wear impact marks or corrosion on shackles Category 4 Okay Does not need repair We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 42 z m Section 8 Repair Quick Guide Control Head Repair Criteria Control Head Repair Criteria Category 1 Safety Cease operations and repair immediately e visible crack or break on the head e Visibly bent shackles e Broken or missing safety wire on shackle pins e Broken or exposed electrical conductors e Broken or missing break away plug i We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 43 z m Section 9 General Repairs Repair Instructions section 9 General Repairs Repair Instructions Suspension Line Replacement A suspension line should be replaced whenever it displays noticeable kinking or fraying
56. pension 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 We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 17 Section 5 Packing and Storage Packing and Storing 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 SEI We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 18 Section 5 Packing and Storage Packing and Storing 9 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 We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version 19 Section 5 Packing and Storage Packing and Storing The Bambi MAX carrying bag makes a suitable shipping container when shipping via airfreight Because of the compactness of the Bambi many operators carry it aboard the helicopter at all times during the fire season This allows for rapid deployment when required Storing the Bambi MAX The following guidelines will help to 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 whi
57. ptions for minor bucket design variations between the models This section also offers specific guidelines that sort the component defects into one of four categories Safety Operational Monitor and OKAY Use the guideline definitions to determine how urgently a repair should be carried out Category 1 Safety All defects in this category must be repaired immediately before further operation of the Bambi Bucket oc curs Ignoring defects in this category could result 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 to Category 1 defects if not addressed within a short time frame Category 3 Monitor Many defects such as wear abrasion and minor impact damage do not need urgent attention Defects of this nature should be monitored daily and repaired before they progress to a Category 2 defect Category 4 OKAY The Bambi Bucket does not need repairs Important Note Unfortunately it is impossible to provide a recommended service time frame as some buckets are used often while others are used only rarely In addition buckets are shifted between operators making it difficult to track usa
58. rchase of the product it 1s understood that the purchaser has waived the claim for warranty and the purchaser and or any subsequent purchaser must accept the condition of the product without warranty 1 Any technical information supplied by the company regarding the product 1s not a condition of warranty but rather is information provided by the company to the best of its knowledge k There are no implied warranties nor 18 there any warranty that can be assumed from any representation of any person except the company itself Exclusions 1 This warranty is void if the product is not installed used and or maintained in accordance with the operations manual supplied by SEI m All Bambi MAX s are designed and manufactured with substantial safety margins It is the responsibility of the user to ensure that the bucket 1s maintained to a safe standard We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 version A 83 E an o co 2 E 3 4 V SNOILONHLSNI SHIHNLIVANNYVIN 14 SONVOHOOSOV NI INOJ STWNIWHEL Gado ONY STYNIWHAL Q3H30108 5 TIV E m WALSAS JHL 31vH3dO OL 31vrIO30v SI ALIOVdV2 HOLVHSNJO AHNSNSA OL SISATYNY OVO1 2 14 JHL 5 0119 3553 HO AON3ON3IW3 SI SNA 14 ANY OL WALSAS AWYA JHL LOSNNOD LON Wz ZL EFOV
59. t of the Bambi 15 taken up by the suspension cables When the bucket 15 full the IDS deployment cable 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 lower bucket shell are tight The IDS restraining cables are set at the factory and normally should not require any adjustment yi 2 2 225 f 4 2 D EM 2 179 m 24 1 i 2 i gt LE 1 gt I v B HH 4 gt e c 1 CESS 1 1 t Natu Y 74 4 b Grasp the hub of the IDS and pull utward fully to tighten cables Correct IDS position S We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version 4 10 Section 3 Using Accessories Using Foam section 3 Using Accessories Using Foam The Bambi MAX is designed to be effective with foam All materials used in the manufacture of the Bambi MAX are resistant to the chemical action of foam Caution After using foam or retardants cycle through several dumps with water only or hose down with fresh water This w
60. the motor and cable drum is rotated clockwise the drive cable pulls up on the lift bar opening the valve When the motor and cable drum 15 rotated counter clockwise the other end of the drive cable pulls down on the lift bar via the deflector sheaves closing the valve It is normal for there to be slackness 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 via a momentary push button and relay 28 VDC c NON ESS BUS Caution The control enclosure 15 hermetically sealed Unauthorized opening will void the warranty af We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version A 3 z z m Section 1 Introduction Valve System Valve position feedback to the controller is provided by a sensor cam and two sensors The sensor cam 18 located on the front of the cable drum and rotates with the motor and cable drum The sensors are located in the controller enclosure As the sensor cam rotates a cut out in its face actuates the sensors signalling to the valve controller if the valve is closed open or somewhere in between The sensors are a proximity type and are not affected by any non metallic contamination of the water 111 11 CLO
61. uld move to the closed position The indicator light should have a steady yellow color e The cable drum sensor cam should not oscillate Actuate the bucket dump switch and hold The valve should move to the open position The indicator light should have a steady green colour The cable drum sensor cam should not oscillate e Release the dump switch to allow the valve to close e Re adyjust the valve as necessary until the correct open and close conditions are met e Check to see if set screw 18 tight e Note the position of the reference line or draw a new line at the correctly adjusted position We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 version A 15 53 an Section 5 Packing and Storage Packing and Storing section 5 Packing and Storage Packing and Storing Packing the Bucket 1 Open the valve 1 2 inches Important Note Always leave the valve open to 2 inches as this prevents the bottom seal from collapsing during long periods of storage leading to longer seal life 2 Collapse the IDS by pushing the hub into the bucket S We Engineer Solutions 2014 Bambi MAX Service Manual Models HL4000 9800 Version 16 Section 5 Packing and Storage Packing and Storing 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 sus

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