and installation instructions for the h150e 6001 coupling … · 23. position coupling and 1 inch...

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Page 1 of 19 Rev A, 10/27/2015 2001 Airway Ave., Ft. Collins, CO 80524 970-224-3898 FAX 970-224-3899 Paravion Heliporter models H150E and H200E Installation Instructions for the H150E6001 Coupling Conversion Kit **Reference drawings are in Figures 29 thru 32 ** CAUTION: Read and understand the entire instructions before proceeding. 1. Block nondrive rear wheels to prevent movement while driveaxle wheels are raised off the ground. Figure 1: Block wheels 2. Raise the upper frame of the Heliporter. Place a wood block under the upper frame. Lower the upper frame onto the wood to raise the wheels off the ground between 1 and 2 inches. Figure 2: Wood block under upper frame

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Page 1: and Installation Instructions for the H150E 6001 Coupling … · 23. Position coupling and 1 inch key on shaft, tighten set screw. NOTE: Test fit coupling to the drive‐axle shaft

 

Page 1 of 19 Rev A, 10/27/2015 

2001 Airway Ave., Ft. Collins, CO 80524 970-224-3898 FAX 970-224-3899

Paravion Heliporter models H150E and H200E Installation Instructions 

for the H150E‐6001 Coupling Conversion Kit **Reference drawings are in Figures 29 thru 32 ** 

CAUTION: Read and understand the entire instructions before proceeding. 

1. Block non‐drive rear wheels to prevent movement while drive‐axle wheels are raised off the ground. 

 Figure 1: Block wheels 

2. Raise the upper frame of the Heliporter. Place a wood block under the upper frame. Lower 

the upper frame onto the wood to raise the wheels off the ground between 1 and 2 inches. 

 Figure 2: Wood block under upper frame 

Page 2: and Installation Instructions for the H150E 6001 Coupling … · 23. Position coupling and 1 inch key on shaft, tighten set screw. NOTE: Test fit coupling to the drive‐axle shaft

 

Page 2 of 19 Rev A, 10/27/2015 

2001 Airway Ave., Ft. Collins, CO 80524 970-224-3898 FAX 970-224-3899

 Another view of the wood under the upper frame. 

3. Stack pieces of wood, such as 2x4’s, under the lower frame to support the Heliporter while 

the drive wheels are raised off of the ground. Raise the upper frame until the weight of the 

Heliporter is completely supported by the pieces of wood under the lower frame. The 

wheels should be off the ground, 1 inch of ground clearance is sufficient. If the Heliporter is 

raised too high, the coupling conversion will be more difficult. 

 Figure 3: Wood blocks under lower frame 

Page 3: and Installation Instructions for the H150E 6001 Coupling … · 23. Position coupling and 1 inch key on shaft, tighten set screw. NOTE: Test fit coupling to the drive‐axle shaft

 

Page 3 of 19 Rev A, 10/27/2015 

2001 Airway Ave., Ft. Collins, CO 80524 970-224-3898 FAX 970-224-3899

4. Loosen the set screw in the coupling attached to the motor. 

 Figure 4: Motor coupling set screw 

5. Support the motor before removing bolts. Loosen and remove the two bolts holding the 

motor. Slide motor to left to disengage the coupling. Keep bolts and nuts for re‐assembly. 

CAUTION: The motor is heavy, it may require a second person or wood blocks for support. 

Failure to support the motor could result in injury or bending of the shaft. 

 Figure 5: Removing motor 

Page 4: and Installation Instructions for the H150E 6001 Coupling … · 23. Position coupling and 1 inch key on shaft, tighten set screw. NOTE: Test fit coupling to the drive‐axle shaft

 

Page 4 of 19 Rev A, 10/27/2015 

2001 Airway Ave., Ft. Collins, CO 80524 970-224-3898 FAX 970-224-3899

6. Loosen and remove the bolts attaching the drive‐axle assembly to the Heliporter. Keep 

bolts, nuts and washers for re‐assembly. CAUTION: Drive‐axle assembly is heavy. If the 

heliporter is raised too high, it may require a second person or wood blocks for support. 

Failure to support the assembly could result in injury. 

 Figure 6: Removing drive‐axle assembly 

 Components removed from heliporter. 

Page 5: and Installation Instructions for the H150E 6001 Coupling … · 23. Position coupling and 1 inch key on shaft, tighten set screw. NOTE: Test fit coupling to the drive‐axle shaft

 

Page 5 of 19 Rev A, 10/27/2015 

2001 Airway Ave., Ft. Collins, CO 80524 970-224-3898 FAX 970-224-3899

7. Loosen set screws for collars and coupling as disassembly allows. 

 Figure 7: Drive‐axle assembly 

8. Remove and discard the coupling and key, use a bearing puller if needed. 

 Figure 8: Remove coupling 

Page 6: and Installation Instructions for the H150E 6001 Coupling … · 23. Position coupling and 1 inch key on shaft, tighten set screw. NOTE: Test fit coupling to the drive‐axle shaft

 

Page 6 of 19 Rev A, 10/27/2015 

2001 Airway Ave., Ft. Collins, CO 80524 970-224-3898 FAX 970-224-3899

9. Coupling and collar removed. Clean and lubricate shaft, as needed, to aid in disassembly. 

 Figure 9: Coupling and collar removed 

10. Inspect the shaft for burrs where the set screw was tightened. The burr may prohibit the 

shaft from sliding through the bearing and/or wheel. File the shaft to remove the burr if 

needed. 

 Figure 10: File burrs as needed 

Page 7: and Installation Instructions for the H150E 6001 Coupling … · 23. Position coupling and 1 inch key on shaft, tighten set screw. NOTE: Test fit coupling to the drive‐axle shaft

 

Page 7 of 19 Rev A, 10/27/2015 

2001 Airway Ave., Ft. Collins, CO 80524 970-224-3898 FAX 970-224-3899

11. To remove the HE38500 Bearings: 

i.   Loosen the set screw. 

ii.  Twist the locking collar to free the shaft from the bearing. 

iii. Inspect the shaft of burrs where the set screw was tightened. The burr may prohibit 

the shaft from sliding through the bearing. File the shaft to remove the burr if needed. 

 Figure 11: Remove bearing 

12. Remove the remaining components from the shaft. Inspect the shaft for burrs where the set 

screw was tightened. The burr may prohibit the shaft from sliding through the bearing. File 

the shaft to remove the burr if needed. Clean and lubricate shaft as needed. Discard keys. 

 Figure 12: Disassembly of drive‐axle 

NOTE: Observe where the 

washers are used for 

spacing, the location of the 

washers will need to be the 

same during re‐assembly. 

REF. Figure 31 

Page 8: and Installation Instructions for the H150E 6001 Coupling … · 23. Position coupling and 1 inch key on shaft, tighten set screw. NOTE: Test fit coupling to the drive‐axle shaft

 

Page 8 of 19 Rev A, 10/27/2015 

2001 Airway Ave., Ft. Collins, CO 80524 970-224-3898 FAX 970-224-3899

13. Use a press to remove the components from the shaft if needed. Clean and lubricate shaft, 

as needed, to aid in disassembly. 

 Figure 13: Pressing out shaft 

14. Remove and discard the coupling and washers from the motor, use a bearing puller if 

needed. 

 Figure 14: Remove coupling from motor 

Page 9: and Installation Instructions for the H150E 6001 Coupling … · 23. Position coupling and 1 inch key on shaft, tighten set screw. NOTE: Test fit coupling to the drive‐axle shaft

 

Page 9 of 19 Rev A, 10/27/2015 

2001 Airway Ave., Ft. Collins, CO 80524 970-224-3898 FAX 970-224-3899

15. Re‐assemble the Drive‐Axle Assembly using the new shaft. NOTE, if shaft fits tightly due to 

tolerance variations, it may be necessary to lightly polish outer diameter of shaft for proper 

fitment of wheels and bearings. 

 Figure 15: Assemble with new shaft 

16. Slide shaft and 2 inch key through wheel far enough so that the collar can be installed. Place 

collar on the shaft so that the shaft extends approximately 0.050” beyond the collar. 

Tighten the set screw. 

 Figure 16: Install wheel and collar 

Note short keyway location 

Page 10: and Installation Instructions for the H150E 6001 Coupling … · 23. Position coupling and 1 inch key on shaft, tighten set screw. NOTE: Test fit coupling to the drive‐axle shaft

 

Page 10 of 19 Rev A, 10/27/2015 

2001 Airway Ave., Ft. Collins, CO 80524 970-224-3898 FAX 970-224-3899

17. Position collar against wheel and tighten set screw. 

 Figure 17: Install collar 

18. Position bearing on the shaft. Twist locking collar to lock the bearing on the shaft. Tighten 

set screw. 

 Figure 18: Install bearing 

Page 11: and Installation Instructions for the H150E 6001 Coupling … · 23. Position coupling and 1 inch key on shaft, tighten set screw. NOTE: Test fit coupling to the drive‐axle shaft

 

Page 11 of 19 Rev A, 10/27/2015 

2001 Airway Ave., Ft. Collins, CO 80524 970-224-3898 FAX 970-224-3899

19. Position collar and tighten set screw. Position washers and 2 inch key. 

 Figure 19: Install collar, washers and key 

20. Position wheel and collar on the shaft, tighten set screw. 

 Figure 20: Install wheel and collar 

Page 12: and Installation Instructions for the H150E 6001 Coupling … · 23. Position coupling and 1 inch key on shaft, tighten set screw. NOTE: Test fit coupling to the drive‐axle shaft

 

Page 12 of 19 Rev A, 10/27/2015 

2001 Airway Ave., Ft. Collins, CO 80524 970-224-3898 FAX 970-224-3899

21. Position bearing on the shaft. Twist locking collar to lock the bearing on the shaft. Tighten 

set screw. 

 Figure 21: Install bearing 

22. Position collar, 2 washers and collar as shown, tighten set screws. 

 Figure 22: Install collars and washers 

Page 13: and Installation Instructions for the H150E 6001 Coupling … · 23. Position coupling and 1 inch key on shaft, tighten set screw. NOTE: Test fit coupling to the drive‐axle shaft

 

Page 13 of 19 Rev A, 10/27/2015 

2001 Airway Ave., Ft. Collins, CO 80524 970-224-3898 FAX 970-224-3899

23. Position coupling and 1 inch key on shaft, tighten set screw. NOTE: Test fit coupling to the 

drive‐axle shaft and motor shaft before installing on Heliporter. Lightly polish keys for both 

shafts if needed. 

 Figure 23: Install coupling 

24. Reinstall the drive‐axle assembly onto the Heliporter using the existing bolts, washers and 

nuts. Note: Only hand tighten nuts. 

 Figure 24: Install drive‐axle assy 

Page 14: and Installation Instructions for the H150E 6001 Coupling … · 23. Position coupling and 1 inch key on shaft, tighten set screw. NOTE: Test fit coupling to the drive‐axle shaft

 

Page 14 of 19 Rev A, 10/27/2015 

2001 Airway Ave., Ft. Collins, CO 80524 970-224-3898 FAX 970-224-3899

25. Install 3/4 inch key onto the motor shaft and then slide the motor shaft into the coupling. 

Reinstall bolts and nuts and tighten. 

 Figure 25: Install motor 

26. Tighten the set screw on the motor coupling only. 

 Figure 26: Tighten set screw 

Page 15: and Installation Instructions for the H150E 6001 Coupling … · 23. Position coupling and 1 inch key on shaft, tighten set screw. NOTE: Test fit coupling to the drive‐axle shaft

 

Page 15 of 19 Rev A, 10/27/2015 

2001 Airway Ave., Ft. Collins, CO 80524 970-224-3898 FAX 970-224-3899

27. Place wood block under the upper frame and then lower the upper frame to raise the lower 

frame off of the wood blocks. Remove the wood pieces from under the lower frame. 

 Figure 27: Remove wood blocks 

28. Raise the upper frame to lower the Heliporter. Tighten the nuts for the Drive‐Axle Assy (4 

each). Remove the wood blocks from the left side of the Heliporter. The conversion is now 

complete. 

 Figure 28: Tighten nuts and set screws 

Page 16: and Installation Instructions for the H150E 6001 Coupling … · 23. Position coupling and 1 inch key on shaft, tighten set screw. NOTE: Test fit coupling to the drive‐axle shaft

 

Page 16 of 19 Rev A, 10/27/2015 

2001 Airway Ave., Ft. Collins, CO 80524 970-224-3898 FAX 970-224-3899

 

Figure 29: Heliporter Disassembly Detail 

 

 

DISCARD

DISCARD

DISCARD

Page 17: and Installation Instructions for the H150E 6001 Coupling … · 23. Position coupling and 1 inch key on shaft, tighten set screw. NOTE: Test fit coupling to the drive‐axle shaft

 

Page 17 of 19 Rev A, 10/27/2015 

2001 Airway Ave., Ft. Collins, CO 80524 970-224-3898 FAX 970-224-3899

 Figure 30: Disassembly of the Drive‐Axle Assembly 

 

 

 

DISCARD

DISCARD

DISCARD

DISCARD 

Page 18: and Installation Instructions for the H150E 6001 Coupling … · 23. Position coupling and 1 inch key on shaft, tighten set screw. NOTE: Test fit coupling to the drive‐axle shaft

 

Page 18 of 19 Rev A, 10/27/2015 

2001 Airway Ave., Ft. Collins, CO 80524 970-224-3898 FAX 970-224-3899

 

 Figure 31: Re‐assemble Drive‐Axle Assembly 

 

NEW 

NEW 

NEW 

NEW 

Page 19: and Installation Instructions for the H150E 6001 Coupling … · 23. Position coupling and 1 inch key on shaft, tighten set screw. NOTE: Test fit coupling to the drive‐axle shaft

 

Page 19 of 19 Rev A, 10/27/2015 

2001 Airway Ave., Ft. Collins, CO 80524 970-224-3898 FAX 970-224-3899

 

Figure 32: Re‐assembly of Heliporter