REPORT DTM-4-II

INSTALLATION INSTRUCTIONS

APOLLO P/N DTM-4 SPRAY SYSTEM

FOR THE
ROBINSON R44 HELICOPTER

FAA Project Number

ST2875CH-R

October 30, 1999

FOR:
APOLLO SPRAY SYSTEMS
15369 Madison Rd.
Middlefield, Ohio 44062-8404

BY:

JEFFREY FOX
DERT 605173-NM

REV DATE BY COMMENTS

N/C 10/30/99 JCF ORIGINAL REPORT
A 2/1/2000 JCF Revised Complete report, all pages
B 5/26/08 JCF Added R44II to section 1.0 General
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JCF INSTALLATION INSTRUCTIONS DTM-4-II 1

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DTM-4 SPRAY SYSTEM A

TABLE OF CONTENTS

SUBJECT Page

Table of Contents i

1.0 Introduction 1.1

2.0 Electrical installation 2.1
3.0 Spray System Installation 3.1

Appendix A Electrical System Wiring and Drawing A-1

REFERENCES

1 AC43.13-1B/2A Acceptable Methods, Techniques, And Practices

Aircraft Inspection Repair & Alteration

2. Robinson R44 Helicopter Maintenance Manual, RTR 460

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JCF INSTALLATION INSTRUCTIONS DTM-4-II 1.1

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DTM-4 SPRAY SYSTEM B

1.0 GENERAL

This report presents the installation instructions for the Apollo Spray Systems Model
DTM-4 Agricultural Spray System for the Robinson R44 and R44II helicopter.

The DTM-4 Spray System consists of a 90 gallon Polyethylene tank and support
structure installed beneath the belly of the R44 Helicopter. The tank supporting structure
consists of welded aluminum tubing. The structure is attached to the landing gear of the
R44 and R44II helicopters.

The spray boom is fabricated from aluminum tubing attached to the forward portion of
the assembly and is removable using quick release fittings.

The spray pump is powered by a gas-powered motor attached to the left side of the
system with sprayer controls routing into the cockpit to pilots’ cyclic stick. The fluid flow
is controlled by an electric valve that is activated by the toggle switch installed on the
pilot’s cyclic stick.

The following Figures show the major components to be installed.

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JCF INSTALLATION INSTRUCTIONS DTM-4-II 1.2

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DTM-4 SPRAY SYSTEM A

MAJOR COMPONENTS

Figure 1: FRAME AND TANK ASSEMBLY

Figure 2 SPRAY BOOMS

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JCF INSTALLATION INSTRUCTIONS DTM-4-II 1.3

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DTM-4 SPRAY SYSTEM A

MAJOR COMPONENTS

Figure 3: FORWARD BRACKET ASSEMBLY

Forward Bracket Assembly

2 required consisting of

Upper Bracket
Lower Bracket
2 each AN4H-7A Bolts
2 each AN960-416 Washers

1 each AN4-22A Bolt

2 each AN960-416 Washers
1 each AN364-416 Nut
1 each MS27151-13 Palnut

Figure 4: AFT SUPPORT PLATES

Aft Support Plates

2 sets consisting of:

2 each Hanger plates

1 each AN4- 20A
2 each AN960-416 Washers
1 each AN364-416 Nut
1 each MS27151-13 Palnut
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JCF INSTALLATION INSTRUCTIONS DTM-4-II 1.4

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DTM-4 SPRAY SYSTEM A

MAJOR COMPONENTS

Figure 5:

AK550-6 CONVERTER

Figure 6:

TOGGLE SWITCH
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JCF INSTALLATION INSTRUCTIONS DTM-4-II 1.5

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DTM-4 SPRAY SYSTEM A

Figure 7:

PLUG
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JCF INSTALLATION INSTRUCTIONS DTM-4-II 2.1

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DTM-4 SPRAY SYSTEM A

2.0 ELECTRICAL INSTALLATION

WIRING INSTALLATION INSTRUCTIONS (Reference Appendix A)

COMPONENTS:

1 each Male/Female plug (female side mounted on belly panel, male side to KZCO valve)
1 each AK-550-6 Converter
1 each Male Cannon Plug included with AK-550-6 Converter.
1 each Double-pole, double-throw switch to mount on cyclic stick.
1 each 5 amp circuit breaker
1 each 15 amp circuit breaker
Wire Cover “snake skin”.

Using the wiring diagram on page A.3, Mil-W-22759/16 wire of designated gage, fabricate the
following wiring assemblies and using the Guidelines of AC43.13

Wire Harness Number 1: KZCO Valve to Male Plug

2 wires, 5 feet of 18 gage from KZCO Valve to Male Plug .

Encase in “snake skin”.

Wire Harness Number 2: Toggle switch to Converter and Female Plug

3 wires, 5 feet of 18 gage from supplied toggle switch to supplied female Plug mounted on belly
panel and cannon plug terminal C per wiring diagram in Appendix A.
Encase in “snake skin”.

Wire switch as shown on wiring diagram in Appendix A

Install 5 amp circuit breaker per wiring diagram in Appendix A

Install 15 amp circuit breaker in circuit breaker panel

Install 2 wires 2 feet long, 16 gage from circuit breaker to terminals A and E of the supplied
Canon plug
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JCF INSTALLATION INSTRUCTIONS DTM-4-II 2.2

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DTM-4 SPRAY SYSTEM A

2.0 ELECTRICAL INSTALLATION

Wiring Harness Number 1

From Belly Plug to Valve

2 wires, 3 feet of 18 gage from

KZCO Valve to Male Plug .
Encase in “snake skin”.

Wiring Harness Number 2

From toggle switch to Circuit Breaker Panel and Plug

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JCF INSTALLATION INSTRUCTIONS DTM-4-II 2.3

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DTM-4 SPRAY SYSTEM A

2.0 ELECTRICAL INSTALLATION

Install Valve On-Off Toggle switch

on Pilot’s cyclic stick
Using existing hardware and
aluminum angle bracket supplied
with kit

Install 5 amp and 15 amp in existing circuit

breaker panel in vacant locations.

Attach wires from Harness Number 2 per

wiring diagram in Appendix A and run 2
wires to belly plug through existing opening
in keel panel. Attach wires to matching
terminal for Harness number 2
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JCF INSTALLATION INSTRUCTIONS DTM-4-II 2.4

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DTM-4 SPRAY SYSTEM A

2.0 ELECTRICAL INSTALLATION

ON-OFF SWITCH
WIRING CONFIGURATION

Install 5 amp and 15 amp circuit

breakers in vacant locations in the
circuit breaker pane in front of left
front seat

Install wiring Assembly Number 2,

per appendix A page A.2, through
circuit breaker panel

ON-OFF SWITCH
WIRING CONFIGURATION

Attach wiring harness to cyclic stick using tie wraps

as shown.

CAUTION

ENSURE FREE MOVEMENT OF STICK FROM

STOP TO STOP IN ALL DIRECTIONS
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JCF INSTALLATION INSTRUCTIONS DTM-4-II 2.5

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DTM-4 SPRAY SYSTEM A

2.0 ELECTRICAL INSTALLATION

AK550-6 CONVERTER

Install Converter beneath left seat

using

5 AN525 R6 Screws
5 AN364 or AN365-832 Nuts or
5 MS21042L08 Nuts
5 AN960-8 or –8L Washers

Locate the converter approximately

1 inch forward of the forward seat
edge and approximately centered
beneath the seat laterally.

Drill quantity 5 - 0.171 dia. holes in

the fiberglass floor using the flange
of the converter as a drill guide.

Install converter beneath using

above hardware

FEMALE PLUG INSTALLATION

VIEW OF FORWARD “BELLY

PANEL:
AN525 SCREW
AN365-832 NUT
Remove forward belly panel. AN960-8 WASHERS
2 PLACES
Install supplied FEMALE PLUG in
Belly Panel as Shown 3.5 - 4 in.

Drill 1 inch dia. hole located aft of

the front edge and on the
longitudinal centerline of the panel
as shown.

Using Plug as drill guide, drill 2 DRILL 1 INCH DIA.

0.171 diameter holes HOLE IN PANEL
FOR PLUG
Install Female Plug using: FEMALE
2 AN525 R6 Screws PLUG
2 AN365-832 Nuts or
2 MS21042L08 Nuts
2 AN960-8 Washers
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JCF INSTALLATION INSTRUCTIONS DTM-4-II 3.1

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DTM-4 SPRAY SYSTEM A

3.0 SYSTEM INSTALLATION

Remove Landing Gear

Belly Panel by
removing existing
screws

Remove 2 screws and

VOR Antenna
If Installed

Some R44’s do not

have installed
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JCF INSTALLATION INSTRUCTIONS DTM-4-II 3.2

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DTM-4 SPRAY SYSTEM A

3.0 SYSTEM INSTALLATION

REMOVING ANTENNA

Disconnect plug and tuck

plug inside bracket

Install Upper Forward Bracket on right side

by slipping around landing gear cross tube and
slide laterally over the landing gear Elbow until it
touches the elbow bolt boss.

Repeat for left side

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JCF INSTALLATION INSTRUCTIONS DTM-4-II 3.3

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DTM-4 SPRAY SYSTEM A

3.0 SYSTEM INSTALLATION

Locate Upper Forward Bracket on Landing Gear Elbow

as shown

Install Lower Forward Bracket

Using Fasteners
2 each AN4H-7A Bolts
2 each AN960-416 Washers

Torque per R44 Maintenance Manual, Page 1.22

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JCF INSTALLATION INSTRUCTIONS DTM-4-II 3.4

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DTM-4 SPRAY SYSTEM A

3.0 SYSTEM INSTALLATION

Install Safety Wire on AN4H-7A

Bolts as shown.
Left and right sides

Install Aft Hanger Plates in 2 Places:

Remove existing NAS Landing Gear Bolt

Install Aft Support Plates
Install NAS6604-4 Bolt
Replace AN960-416L Washer
MS21042L4 Nut

Torque per R44 Maintenance Manual, page 1.22

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JCF INSTALLATION INSTRUCTIONS DTM-4-II 3.5

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DTM-4 SPRAY SYSTEM A

3.0 SYSTEM INSTALLATION

Install Landing Gear Wheels

Push tail down and slide
Tank/Frame Assembly under
aircraft

Lift system and

Install Aft Hanger Support
Fasteners in two places

1 each AN4- 20A

2 each AN960-416 Washers
1 each AN364-416 Nut
1 each MS27151-13 Palnut

Torque per R44 Maintenance

Manual, page 1.22
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JCF INSTALLATION INSTRUCTIONS DTM-4-II 3.6

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DTM-4 SPRAY SYSTEM A

3.0 SYSTEM INSTALLATION

Install
1 each AN4-22A Bolt
2 each AN960-416 Washers
1 each AN364-416 Nut
1 each MS27151-13 Palnut

Torque per R44 Maintenance Manual, page 1.22

View showing forward side with

AN364-416 Nut
MS27151-13 Palnut
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JCF INSTALLATION INSTRUCTIONS DTM-4-II 3.7

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DTM-4 SPRAY SYSTEM A

3.0 SYSTEM INSTALLATION

Install Engine and pump

Assembly on platform on left
side of system

Install supplied
Engine Fasteners
Nuts

Torque per R44 Maintenance

Manual, page 1.22,
Relieve torque to line up nearest
cotter pin hole and install Cotter
Pins
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JCF INSTALLATION INSTRUCTIONS DTM-4-II 3.8

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DTM-4 SPRAY SYSTEM A

3.0 SYSTEM INSTALLATION

View Showing Cotter Pins

installed
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JCF INSTALLATION INSTRUCTIONS DTM-4-II 3.9

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DTM-4 SPRAY SYSTEM A

3.0 SYSTEM INSTALLATION

KZCO VALVE “KZCO”

Install Tube and WIRING VALVE
Valve assembly. HARNESS
AND PLUG

Lock “Quick
Disconnects” latches and
install cotter pins

QUICK
DISCONNECT
LATCHES, TYP
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JCF INSTALLATION INSTRUCTIONS DTM-4-II 3.10

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DTM-4 SPRAY SYSTEM A

3.0 SYSTEM INSTALLATION

Install male plug from KZCO

valve into female electrical plug
connection mounted on belly
panel

Drill 2 .191 dia holes through

front of left seat box using
holes on supplied tube as drill
guides

Install Throttle Control Lever

On front of left front seat
Using supplied AN525 screws
and AN Nuts as shown.
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JCF INSTALLATION INSTRUCTIONS DTM-4-II 3.11

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DTM-4 SPRAY SYSTEM A

3.0 SYSTEM INSTALLATION

Loosen Nut until

arm is free to
move

Install Throttle cable on engine as

shown using the fittings on engine Run
cable through cable eyelet and tighten

Loosen nut shown until throttle

operates freely

Tie Wrap throttle Cable

to the Pump/valve Tubing
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JCF INSTALLATION INSTRUCTIONS DTM-4-II 3.12

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DTM-4 SPRAY SYSTEM A

3.0 SYSTEM INSTALLATION

Install center Spray

Boom Section

Close Quick
Disconnect Levers
Install Cotter Pin
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JCF INSTALLATION INSTRUCTIONS DTM-4-II 3.13

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DTM-4 SPRAY SYSTEM A

3.0 SYSTEM
INSTALLATION

Install cotter pins on outer

guide tubes

View of
Center Boom Installed
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JCF INSTALLATION INSTRUCTIONS DTM-4-II 3.14

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DTM-4 SPRAY SYSTEM A

3.0 SYSTEM INSTALLATION

QUICK
DISCONNECT
LEVERS
Install Outer Boom
Sections

Lock Quick
Disconnects and
Install cotter pins

INSTALLATION COMPLETE

REMOVE IN REVERSE OF PROCEDURES

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JCF INSTALLATION INSTRUCTIONS DTM-4-II A.1

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DTM-4 SPRAY SYSTEM A

APPENDIX A

WIRING DIAGRAM
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JCF INSTALLATION INSTRUCTIONS DTM-4-II A.2

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DTM-4 SPRAY SYSTEM A

WIRING INSTALLATION INSTRUCTIONS

COMPONENTS:

1 each Male/female plug (female side mounted on belly panel, male side to KZCO valve)
1 each Male Canon Plug to fit AK-550-6 converter.
1 each AK-550-6 Converter
1 each Double pole, double throw switch to mount on cyclic stick.
1 each 5 amp circuit breaker
1 each 15 amp circuit breaker

Using the wiring diagram on page A.3, Mil-W-22759/16 wire of designated gage, fabricate the
following wiring assemblies and using the Guidelines of AC43.13

Wire assembly number 1: KZCO Valve to Male Plug

2 wires, 3 feet of 18 gage from KZCO Valve to Male Plug .

Encase in skin
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JCF INSTALLATION INSTRUCTIONS DTM-4-II A.2

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DTM-4 SPRAY SYSTEM A

Wire Assembly Number 2 Toggle switch to Converter and Female Plug

3 wires, 3 feet of 18 gage from supplied toggle switch to supplied female Plug mounted on belly
panel and canon plug terminal C per per wiring diagram in Appendix A.
Encase in skin

Wire switch as shown on wiring diagram in Appendix A

Install 5 amp circuit breaker in vacant

hole in circuit breaker panel in front of
left front seat.

Install 15 amp circuit breaker in circuit

breaker panel

Install 2 wires 2 feet long, 16 gage

from circuit breaker to terminals A and
E of the supplied Canon plug

Connect Wire Assy. 2 per wiring

diagram in Appendix A

Wire Assembly Number 3: Circuit breaker Panel to Canon plug at Converter

3 - 16 ga.. wires, 56 inches long

1 – 16 ga. wire 45 inches long

Connect Wire Assy. 3 per wiring

diagram in Appendix A.
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JCF INSTALLATION INSTRUCTIONS DTM-4-II A.3

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DTM-4 SPRAY SYSTEM A

DTM-4 WIRING DIAGRAM

AK-550-6
CONVERTER
HARNESS
C/B 15 AMP ASSY NO 3

DTM01A16 A +14 VDC Input

AIRCRAFT
BUS DTM02A16
E +14 VDC Input

B DC Ground
DTM03A18
DTM02A18 C +28 VDC Output

D Spare
SUPPLIED
CANON PLUG

SUPPLIED FEMALE
PLUG MOUNTED ON
BELLY

KZCO VALVE
99H-50K-Y
SWITCH DPDT
DTM05A18 DTM06A18
DTM04A18

HARNESS
C/B 5 AMP ASSY NO. 1

DTM08A18 DTM07A18

HARNESS
ASSY NO.2
PLUG SUPPLIED MALE
PLUG TO VALVE
ON ENGINE SIDE