SEI Industries BAMBI MAX BBXHL4000PF User manual

2016 VERSION D
BAMBI MAX
(4453–7590 MODELS)
SERVICE
MANUAL
Photo courtesy of Dan Sweet

2016 Bambi MAX Service Manual – Models 4453-7590 (Version D)
We Engineer Solutions
BAMBI MAX SERVICE MANUAL - Models 4453-7590
Version D
Issue Date: January 2017
PLEASE READ BEFORE USING.
SEI INDUSTRIES LTD.
7400 Wilson Avenue
Delta, B.C. Canada
V4G 1H3
Phone: [phone]
Fax: [phone]
E-Mail: [email protected]
Website: www.sei-ind.com
USA Patent # 9,265,977
Australia Patent AU2012201273
Canada Patent Pending
COPYRIGHT © 2016 SEI INDUSTRIES LTD. ALL RIGHTS RESERVED

2016 Bambi MAX Service Manual – Models 4453-7590 (Version D)
We Engineer Solutions
Table of Contents
Section 1: Introduction 1
Bambi MAX (Models 4453–7590) .................................................................................1
Valve System ................................................................................................................2
System Overview ............................................................................................2
System Description .........................................................................................2
Section 2: Deploying the Bambi MAX 6
Deployment Instructions ...............................................................................................6
Attaching to the Cargo Hook ..........................................................................6
Head Orientation ............................................................................................6
Connecting Power ..........................................................................................7
Using Longlines ..............................................................................................7
Instant Deployment System (IDS) ..............................................................................10
Section 3: Using Accessories 11
Using PowerFill ...........................................................................................................11
Overview .......................................................................................................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
Packing the Bucket .......................................................................................18
Storing the Bambi MAX ................................................................................22
Section 6: Troubleshooting and Maintenance 23
Troubleshooting ..........................................................................................................23
Valve Troubleshooting ..................................................................................23
Checking Aircraft / Longline Wiring ..............................................................24
Maintenance Procedures ............................................................................................25
Weekly Inspections .......................................................................................25
Weekly Inspection Checklist .........................................................................25

2016 Bambi MAX Service Manual – Models 4453-7590 (Version D)
We Engineer Solutions
Section 7: Valve Maintenance 26
MAX Valve Repair and Replacement .........................................................................26
Linkage Adjustment ......................................................................................26
Valve Removal .............................................................................................26
Valve Installation ..........................................................................................28
Bambi MAX Seal Replacement ....................................................................30
Drive Cable Replacement .............................................................................35
Changing the Guide Bushings ......................................................................39
Section 8: Repair Quick Guide 40
Overview of Repair Categories ...................................................................................40
Category 1: Safety ........................................................................................40
Category 2: Operational ...............................................................................40
Category 3: Monitor ......................................................................................40
Category 4: OKAY ........................................................................................40
Bucket Shell Repair Criteria .......................................................................................41
Cables Repair Criteria ................................................................................................42
IDS Hub Repair Criteria ..............................................................................................43
M-Straps 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 Shell Repairs ..........................................................................................56
Repair Failures .............................................................................................56
Repairing in High Humidity ...........................................................................57
Making Temporary Repairs with Sealing Clamps .........................................58
Temporary Repairs Using Glue ..................................................................................60
Applying the Glue .........................................................................................60
Gluing with Patches ......................................................................................61
Cutting the Patch ..........................................................................................62
Applying the Patch ........................................................................................62
Hot Air Gun Patching ..................................................................................................64
Hot Air Gun Procedure .................................................................................65
Repair Kits ..................................................................................................................66
Repair Kit Parts Table ..................................................................................66
Optional Supplies .........................................................................................66

2016 Bambi MAX Service Manual – Models 4453-7590 (Version D)
We Engineer Solutions
Section 10: Specifications and Parts 67
Capacity and Weight Specifications ...........................................................................67
Bambi MAX Capacity and Weight Specifications .........................................67
Bambi MAX with PowerFill Capacity and Weight Specifications ..................67
Parts Listings ..............................................................................................................68
Bambi MAX Valve 25” Shell Assembly, Models 4453-5566 .........................68
Bambi MAX Valve 25" Shell Assembly, Models 6578-7590 .........................69
Bambi MAX Valve 25" Installation ................................................................70
Bambi MAX Valve 25" Seals ........................................................................71
Bambi MAX Valve 25" Actuator and Controller ............................................72
Bambi MAX Valve 25" Actuator ....................................................................73
Bambi MAX Valve 25" Sheave Bar and Guide Rods ....................................74
Bambi MAX Valve 25" Lift Bar and Linkage .................................................75
Bambi MAX Valve 25" Lift Bar ......................................................................76
Bambi 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 Systems, Models 4453 - 7590 ..........................................................89
PowerFill MAX Pump Assembly, Models 4453-7590 ...................................90
PowerFill MAX Flapper Valve and Impeller, Models 4453-7590 ..................91
PowerFill MAX Screens, Models 4453-7590 ................................................92
PowerFill MAX Standoff, Models 4453-5566 ................................................93
PowerFill MAX Standoff, Models 6578-7590 ................................................94
Carry Bags ....................................................................................................95
Troubleshooter Kit ........................................................................................95
Section 11: Warranty 96
Appendix: Drawings 97
Pilot Controls ...............................................................................................97
Pilot Controls, US Interagency ..................................................................98
Crew Controls (using remote power supply) ...............................................99
PowerFill MAX Wiring .................................................................................100

Section 1: Introduction Bambi MAX (Models 4453–7590)
2016 Bambi MAX Service Manual – Models 4453-7590 (Version D) 1
We Engineer Solutions
Section 1: Introduction
Bambi MAX (Models 4453–7590)
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 HL4000-HL9800. In addition, a number of accessories and enhancements are
also available including the PowerFill system, 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.
Bambi MAX inside bucket.
Bambi MAX valve serial number location. Bambi MAX shell serial number location.

Section 1: Introduction Valve System
2016 Bambi MAX Service Manual – Models 4453-7590 (Version D) 2
We Engineer Solutions
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.
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. 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 is also attached to a horizontal lift bar which itself is attached across the lower
end of the tube.

Section 1: Introduction Valve System
2016 Bambi MAX Service Manual – Models 4453-7590 (Version D) 3
We Engineer Solutions
When 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 is 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 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 via a momentary push button and relay.
Caution
The control enclosure is hermetically sealed. Unauthorized opening will void the warranty.

Section 1: Introduction Valve System
2016 Bambi MAX Service Manual – Models 4453-7590 (Version D) 4
We Engineer Solutions
Valve position feedback to the controller is provided by a sensor cam and two sensors. The sensor cam is
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.
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 is.
Indicator Status
White (Off) No Power
Yellow Valve Closed
Flashing Green Valve Partially Open
Green Valve Open
Red Sensor Fault

Section 1: Introduction Valve System
2016 Bambi MAX Service Manual – Models 4453-7590 (Version D) 5
We Engineer Solutions
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 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 10 seconds and turn the power back on again. The valve should return to its normally closed
state.