Bambi MAX BBXHL4000 User manual

BAMBI MAX BUCKET
Models HL4000 –HL9800
SERVICE MANUAL
2023A

BAMBI MAX BUCKET SERVICE MANUAL
Models HL4000-HL9800
Version: 2023A
Part Number: 017008
Maintenance Level: Organizational (O)
PLEASE READ BEFORE USING.
This manual is applicable to the following models:
BBXHL4000 (# 007912)
BBXHL5000 (# 007914)
BBXHL7600 (# 007916)
BBXHL9800 (# 007918)
PATENTS
AU2012201273
CA2770005
US9265977
Physical copies of this manual (#011750) are available from SEI.
This manual is available on the SEI website.
Register for manual update notifications at [e-mail].
This manual is based on information that was available at the time it was printed and may not
be applicable to products received before the issue date and customized items.
SEI INDUSTRIES LTD.
7400 Wilson Avenue
Delta, B.C. Canada
V4G 1H3
Phone: [phone]
Fax: [phone]
E-Mail: [e-mail]
Website: www.bambibucket.com
COPYRIGHT © 2020 SEI INDUSTRIES LTD. ALL RIGHTS RESERVED

Revision Summary
Version
Release Date
Revision Description
Pages
App.
2020A
21-Jan-2020
•General Revision
-
AW
2020B
25-Nov-2020
•General Revision
•IVC 2
•PowerFill MAX Wiring diagram revised.
-
AW
2021A
06-Apr-2021
•General Revision
•Weight and Capacity Revision
•PowerPack now upgraded to 28.8 VDC
•Updated Section 6: Troubleshooting
•PowerFill MAX Drive Assembly & Pump
Assembly parts revised
•IVC Indicator revised
-
AW
2021B
18-Jun-2021
•Guide Rod, Support Rod, & Attachment
fasteners changed.
70, 75
AW
2022A
03-Jan-2022
•General Revision
•PowerFill Part Number Change
•Added shell bracket assembly to Parts Section
83
70
GN
2023A
28-Dec-2022
•Removed PowerFill Option
-
GN
VALIDATION OF OPERATIONS DESCRIBED IN THIS MANUAL
The maintenance operations described in this manual have been checked in manufacturer's
workshops by an exact carrying out of dismantling, reassembly, test and repair instructions
which are detailed in this document.
These operations are those in use at the latest revision date of the document.

Table of Contents
Section 1: Introduction............................................................................................................ 1
Valve System............................................................................................................................................2
Section 2: Deploying the Bucket............................................................................................. 5
Attaching to the Cargo Hook....................................................................................................................5
Connecting Power.....................................................................................................................................6
Longlines ..................................................................................................................................................7
Checking Tail Rotor Clearance.................................................................................................................8
Instant Deployment System (IDS)............................................................................................................9
Section 3: Accessories...........................................................................................................11
Foam Injection Systems..........................................................................................................................11
Power Pack..............................................................................................................................................13
Section 4: Making Adjustments.............................................................................................15
Adjusting Components............................................................................................................................15
Section 5: Packing and Storage.............................................................................................17
Packing....................................................................................................................................................17
Storage....................................................................................................................................................20
Section 6: Troubleshooting and Maintenance......................................................................21
Troubleshooting......................................................................................................................................21
Maintenance Procedures.........................................................................................................................25
Section 7: Repair Assessment Guide....................................................................................27
Overview of Repair Categories...............................................................................................................27
Head Repair Criteria...............................................................................................................................28
Cables Repair Criteria.............................................................................................................................29
M-Straps/Top Chains Repair Criteria.....................................................................................................30
IDS Hub Repair Criteria .........................................................................................................................31
Bucket Shell Repair Criteria...................................................................................................................32
Section 8: Repairs...................................................................................................................33
Rigging Repairs ......................................................................................................................................33
Valve Repair and Replacement...............................................................................................................39
Shell Repairs...........................................................................................................................................51

Section 9: Specifications and Parts.......................................................................................58
Capacity and Weight Specifications.......................................................................................................58
Parts ........................................................................................................................................................59
Section 10: Drawings..............................................................................................................82
Section 11: Warranty ..............................................................................................................86

Section 1: Introduction
Bambi MAX Service Manual –Models HL4000-HL9800 1
Section 1: Introduction
The Bambi MAX Bucket (Bambi MAX) is a collapsible firefighting bucket with a multiple drop valve.
The multiple drop capability allows an operator to split the bucketload over several locations. It also allows
the operator to adjust the amount of water carried in the bucket to match the lifting capability of the aircraft
throughout its fuel cycle.
This manual provides information on the service and maintenance of Bambi MAX models HL4000 to
HL9800. 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 you are ordering parts, please provide the model and serial number of your Bambi MAX as shown
on the data tags located inside the bucket shell.

Section 1: Introduction
Bambi MAX Service Manual –Models HL4000-HL9800 2
Valve System
Description
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.
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.
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.

Section 1: Introduction
Bambi MAX Service Manual –Models HL4000-HL9800 3
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.
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 counter-
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.

Section 1: Introduction
Bambi MAX Service Manual –Models HL4000-HL9800 4
The sensor cam can be 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 AdjustmentsError!
Reference source not found..
There is a status indicator lamp on the side of the control enclosure which indicates the location of the
valve tube.
*Valve adjusted too low by a minor distance. Motor protection is activated, but no immediate action is necessary.
The controller has a motor protection system to prevent the motor from being overloaded.
The motor protection will activate if the valve does not reach its fully open or fully closed position within
a given time period, the valve is in its partially open position for too long, or if the valve is severely out of
adjustment.
When activated, the motor protection system 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 its current state when
the motor protection was activated.
The valve will remain operational when the motor protection is activated. For example, if the valve is unable
to reach its fully closed position, the motor protection will activate, and the valve can still be opened by
triggering the dump switch. Alternatively, if the valve cannot reach its fully open position, the motor
protection will activate, and the valve can still be closed by releasing the dump switch.
NOTICE
The information in this manual may only be applicable to products received after the most recent release
date of this manual.
Indicator
Status
○
Off
No Power
●
Yellow
Valve Closed
☀
Flashing Yellow
Valve Closed / Motor
Protection Activated*
☀
Flashing Green
Valve Partially Open
●
Green
Valve Open
●
Red
Motor Protection
Activated
☀
Flashing Red
Sensor Fault
CAUTION
The control enclosure is hermetically sealed. Unauthorized opening will void the warranty.

Section 2: Deploying the Bucket
Bambi MAX Service Manual –Models HL4000-HL9800 5
Section 2: Deploying the Bucket
Attaching to the Cargo Hook
Correct attachment of the head is indicated when the ballast on the bucket faces forward in flight which
will avoid twisting of the suspension lines. If using a swivel hook, it is recommended to operate in
the locked position to assure that the ballast is always facing forward in flight.
The Bambi MAX Bucket is rigged for a longitudinal cargo
hook. The top shackle on the head acts as the secondary ring
for the cargo hook. The operator must supply a primary ring
in accordance with the cargo hook manufacturer’s
recommendations.
If the helicopter has a lateral cargo hook, an additional ring
or shackle will be required between the top shackle and the
primary ring to rotate the bucket 90°.
WARNING
Ensure that all rings and shackles are rated with a minimum safety factor of five for the gross weight of
the bucket as shown on the data plate.
CAUTION
The Bambi MAX Bucket may not be suitable for a direct hook-up to the cargo hook. The actual hook-
up will be different for various aircraft and operators must comply with all instructions and bulletins
supplied by the aircraft manufacturer. It is the operator’s responsibility to ensure that the Bambi MAX
is correctly fitted to the helicopter.