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.

Section 2: Deploying the Bucket
Bambi MAX Service Manual –Models HL4000-HL9800 6
Connecting Power
The minimum power requirement to control the Bambi MAX valve is 24-28 VDC, supplying 8 amps,
measured at the head of the bucket. 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
NEMA5-15P electrical plug (the female receptacle for the helicopter is attached). If an additional new plug
is required, an IP67 or better must be used.
The purpose of this type of plug is to offer a clean breakaway if the Bambi MAX must be jettisoned from
the aircraft in an emergency. It is suggested that the plug be lightly taped together with vinyl tape, while
in use, to ensure that wind action does not separate the plug during flight.
There are three types of suggested wiring installations (see Section 10: Drawings).
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 ampere relay as per US interagency regulations. This system can
also be used to control a heli-torch, etc.
3. Crew control (remote power supply): This configuration allows a crew member or a pilot
to control the dumping of the bucket using a battery pack to supply the power to the remote
switch. This also eliminates the cost of pre-wiring the aircraft.
Confirm the aircraft has been wired correctly by using the supplied test plug and following the procedure
detailed in Section 6 for checking aircraft wiring.
Below is a table which shows the power requirements for the Bambi MAX valve by bucket model.
Model
Current @24.5 VDC
Valve
BBXHL4000
8 A
BBXHL5000
8 A
BBXHL7600
8 A
BBXHL9800
8 A
CAUTION
Changing the supplied plug and/or receptacle to a non-waterproof (non-IP67) alternative will
compromise the hermetic seal of the IVC and actuator enclosures. This may lead to water ingress and
failure. Changing the connector(s) may void the warranty.

Section 2: Deploying the Bucket
Bambi MAX Service Manual –Models HL4000-HL9800 7
Longlines
NOTICE
If using a longline, the minimum recommended length is 50 ft (15 m).
When using a longline, care must be taken in selecting the correct gauge of control cable. See the chart
below for recommendations.
Wire Length
Wire Type
Connectors
Feet
Meters
Top
Bottom
0–100
0–30
14/3 SOW
NEMA 5-15P
NEMA 5-15R
100–200
30–61
12/3 SOW
NEMA 5-15P
NEMA 5-15R
When purchasing a synthetic rope longline, it is recommended 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, it is recommended to tape the conduit using duct tape (grey) at
3-4 ft intervals along the longline and cover.
It is not recommended to use 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
taken 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.

Section 2: Deploying the Bucket
Bambi MAX Service Manual –Models HL4000-HL9800 8
Checking Tail Rotor Clearance
WARNING
Using a Bambi bucket with insufficient tail rotor clearance could result in a tail rotor strike which could
result in serious injury or death.
When a Bambi MAX Bucket is attached directly to the helicopter cargo hook or attached using a longline
less than 50 ft (15 m) in length, it is important to confirm that there is adequate tail rotor clearance. Before
using the Bambi MAX Bucket, check the tail rotor clearance.
1. Determine the tail rotor length by measuring the distance from the cargo hook to the closest
point on the helicopter tail rotor.
2. Determine the bucket overall length from the following chart:
Model
Overall Length
BBXHL4000
27’- 9”
8.46 m
BBXHL5000
29’- 9”
9.07 m
BBXHL7600
30’- 8”
9.35 m
BBXHL9800
31’- 5”
9.58 m
Lengths are accurate to within 1%.
Specifications subject to change.
To confirm the bucket overall length, stretch out the bucket on the ground, pulling the suspension
cables taut. Measure the distance from the shackle on the head to the bottom of the shell.
3. The tail rotor clearance is equal to the tail rotor length minus the bucket overall length.
4. The tail rotor clearance must be a minimum of 6” (0.15 m).
If the tail rotor clearance is insufficient, shorter suspension lines and deployment lines must be used and
can be ordered from SEI. Please specify the model and serial number when ordering

Section 2: Deploying the Bucket
Bambi MAX Service Manual –Models HL4000-HL9800 9
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 weight of the Bambi MAX is taken up by the suspension cables.
When the bucket is 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.
To deploy the IDS on the ground, reach in-to 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.
Correct IDS position.

Section 2: Deploying the Bucket
Bambi MAX Service Manual –Models HL4000-HL9800 10
THIS PAGE INTENTIONALLY LEFT BLANK

Section 3: Accessories
Bambi MAX Service Manual –Models HL4000-HL9800 11
Section 3: Accessories
Accessories are optional. Not included with the bucket.
Foam Injection Systems
Sacksafoam is a foam injection system that uses a pump to dispense a controlled amount of foam
concentrate from a reservoir into the water in the bucket. The operation of the Sacksafoam is controlled
by the pilot through a control unit, which is mounted in the cockpit. There are two models of Sacksafoam
available depending on the location of the foam concentrate reservoir.
Sacksafoam Bladder
The Sacksafoam Bladder uses a collapsible reservoir located
in the bucket. An internal check valve stops water from
flowing into the bladder and ensures that foam is dispensed
only while the injection pump is operating. Because the
foam in the bladder displaces the water in the bucket, the
total gross weight is always constant.
The Sacksafoam Bladder interfaces with the Sacksafoam
controller. Dispensing can be controlled directly from the
controller screen or a remote switch.
Bucket
Model
Part #
Reservoir Capacity
Gross Weight
Power
Imp Gal
USG
Liters
lb
kg
BBXHL4000
004340
60
72
272
327
146
5 A @
28 VDC
BBXHL5000
See the following chart for recommended longline wire sizes for the Sacksafoam Bladder.
Wire Length
Wire Type
Connectors
Feet
Meters
Top
Bottom
0–100
0–30
14/2 SOW
NEMA 1-15P
NEMA 1-15R
100–200
30–61
12/2 SOW
NEMA 1-15P
NEMA 1-15R

Section 3: Accessories
Bambi MAX Service Manual –Models HL4000-HL9800 12
Sacksafoam Heli-Case
The Sacksafoam Heli-Case is a self-contained unit that can be
stowed onboard the helicopter. The foam concentrate is stored
in a 20 USG tank inside a large plastic case with provision for
an extra 5 USG container. The case is designed to prevent foam
from contacting the helicopter.
The Sacksafoam Heli-Case interfaces with the Sacksafoam
controller which can be mounted directly in the control panel or
externally by using the supplied blanking plate and harnesses.
Dispensing can be controlled directly from the Sacksafoam
controller screen or using the remote control grip.
The Sacksafoam Heli-Case can also interface with the Bambi MAX Bucket, allowing the bucket to be
actuated using the trigger on the remote control grip.
Bucket
Model
Part #
Reservoir Capacity
Gross Weight
Power
Imp Gal
USG
Liters
lb
kg
BBXHL4000
012743
19
23
87
267
122
15 A @
28 VDC
BBXHL5000
Foam Compatibility
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.
NOTICE
After using foam or retardants, cycle through several dumps with water only or hose down with fresh
water to prolong the bucket life.

Section 3: Accessories
Bambi MAX Service Manual –Models HL4000-HL9800 13
Power Pack
The Bambi Power Pack is a 28.8VDC, rechargeable power supply
that allows the Bambi Bucket or Bambi MAX to be operated
independently of the aircraft power.
The plastic case contains a NiMH battery pack and battery charger.
The charger operates on either a 120V/60Hz or 240V/50Hz mains
power supply. Two power cords are included. One has a NEMA 1-
5P plug and the other has a CEE7/16 Europlug.
The Power Pack also includes a dump switch harness to operate the
bucket valve, a bucket wiring harness to connect to the bucket, and
a grounding harness to ground the system to the airframe to
eliminate static charge buildup. All of the wiring harnesses and
power cords are stowed inside of the case.
A manually operated circuit breaker located on the front of the case
can be used to disconnect the battery power from the bucket
harness.
Bucket
Model
Power Pack
Part #
Specifications
Gross Weight
Type
Output
Capacity
lb
kg
BBXHL4000
015989
NiMH
28.8
VDC
3 AH
16
7
BBXHL5000
BBXHL7600
BBXHL9800

Section 3: Accessories
Bambi MAX Service Manual –Models HL4000-HL9800 14
THIS PAGE INTENTIONALLY LEFT BLANK

Section 4: Making Adjustments
Bambi MAX Service Manual –Models HL4000-HL9800 15
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:
1. Power up the bucket circuit to allow the valve to move to the closed position.
•If the indicator lamp flashes green or the cable drum / sensor cam oscillates when the valve
is closed, then the valve is adjusted too low.
2. Actuate the bucket dump switch and hold to keep the valve in the open position.
•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:
1. Power up the bucket circuit to allow the valve to
close.
2. Remove power from the bucket circuit.
3. 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.
4. 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.
5. Loosen the set screw on the sensor cam using a 3/32" hex key.
6. 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" (1.6 mm). Tighten the set screw.
7. 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" (1.6 mm). Tighten the set screw.