TurboMill Kit Assembly Guide

Table of Contents
READ ALL INSTRUCTIONS BEFORE ASSEMBLING PRODUCT Part 1: TurboMill Kit Part 2: Back Upright to Base Rail Assembly Part 3: Top Rail Assembly Part 4: End Uprights to Base Rail Assembly Part 5: Turbine Assembly Part 6: Front Upright Assembly Part 7: Top Rail Cover Assembly

Part 1: TurboMill Kit

1.1 Generator Box: A. Base Rail B. Top Rail C. Top Rail Cover D. (4) Uprights (left, right, front and back) Hardware Kit: E. (6) Plastic Screw Covers F. (6) #6 Screws G. (2) M5 Screws H. (18) M6 Screws I. (2) M6 Washers E F

G Base Rail Top Rail

Top Rail Cover

Right and Left End Uprights

Front and Back Uprights

1.2. Turbine Box Includes: J. (3) Blades

1.3. Tools Required: (2) Allen Wrenches M4 M5 Phillips Head Screwdriver

1.4. Recommended Tools: Mallot Drift Punch

Part 2: Back Upright to Base Rail Assembly

2.1. Find base rail. TIP: WindStream logo located on the front. 2.2. Remove the (2) 6 mm screws and washers from the center back of the base rail assembly.

2.3. Set aside to reinstall later. TIP: The screws and washers are NOT the same screws and washers included in Hardware Kit. 2.4. Find the back upright. TIP: Back upright top has single rectangular bracket. 2.5. Install back upright to the base rail by sliding feet into extrusion slots in the center.

2.6. Attach with (2) 6mm screws and washers previously removed in Step 2.2.

Part 3: Top Rail Assembly

3.1. Find Top Rail. 3.2. Remove the bearing caps (3).

3.3. Set aside to reinstall later. TIP: Requires M5 Allen wrench. 3.4. Top rail attaches to the back upright from the view shown. TIP: Have (2) M5 screws in hand. 3.5. Tilt top rail to locate the bracket in the extrusion.

3.6. Place the flats into the extrusion slots.

3.7. Press down on the front to lock into place.

3.8. Attach with (2) M5 screws. TIP: Make sure screw inserts into tinnermans. TIP: Drift punch is helpful to align holes.

Part 4: End Upright to Base Rail Assembly

4.1. Find both end uprights (Right and Left). TIP: End uprights resemble the letter A. 4.2. Remove all (4) 6mm screws and washers from the base rail on both ends of the front and back.

4.3. Set aside to reinstall later. TIP: The screws and washers are NOT the same screws and washers in Hardware Kit. 4.4. From top view, end uprights have 2 flat surfaces with holes in each: a rectangular bracket and a square bracket. NOTE: Rectangular bracket towards front. NOTE: Square bracket towards back. Back 4.5. Tilt upright to locate the rectangular bracket in the top rail extrusion. The square bracket fits under the top rail extrusion. TIP: Will need to maneuver into place. TIP: Drift punch is helpful align to the holes.

Front 4.6. Start (2) M6 screws one for the rectangular bracket and one for the square bracket. 4.7. Slide bottom feet into the front and back end extrusion slots on base rail. TIP: Mallot is helpful to maneuver feet into slots. TIP: Drift punch is helpful to align holes with tinnermans in extrusions.

Part 4: (Continued)
4.8. Insert (2) 6mm screws and washers removed in Step 4.2. 4.10. Repeat for opposite end upright.

4.9. Hand tighten. 4.12. Replace the (2) end bearing caps removed in Step 3.2 of Top Rail Assembly.

4.11. Secure all screws. 4.13. Latch into groove of extrusion. CAUTION: Once tightened you should NOT be able to pull bearing cap away from extrusion.

4.14. Secure screws.

4.15. Ensure bearing caps are square with tubing. TIP: End bearing cap holes are on the back of top rail.

Part 5: Turbine Assembly

5.1. Find the (3) turbine blades. 5.3. Starting with the center turbine, align the bottom receiver plate.

5.2. In a vertical position: the rounded edge of the turbine should be on your left. The scoop edge should be on your right. This defines top and bottom of the turbine. 5.5. Outside edges of turbine will sit within the ridges on the bottom receiver plate.

5.4. Center of turbine will be over the center of the bottom receiver plate. 5.7. Tighten screw for a loose fitting.

5.6. Align over the holes and attach using (2) M6 screws (one for each side of blade). TIP: Drift punch is helpful to align holes. 5.9. Repeat the process for the remaining (2) turbines.

5.8. Repeat the process to attach top of turbine to top receiver plate. 5.10. Secure all (12) turbine screws.

Part 6: Front Upright Assembly

6.1. Find front upright. 6.3. Slide feet into the extrusion slots of base rail.

6.2. Remove the (2) 6mm screws and washers from the base extrusion in the center on the front of base rail. 6.5. From the top rail, press the bracket under the extrusion.

6.4. Attach with (2) 6mm washers and screws that were removed in Step 6.2. TIP: Drift punch is helpful to align holes. 6.7. Replace center bearing cap removed in Step 3.2 of Top Rail Assembly.

6.6. Attach with (2) M6 washers and (2) M6 screws. 6.8. Latch into groove of extrusion. CAUTION: Once tightened you should NOT be able to pull bearing cap away from extrusion. 6.10. Ensure bearing cap is square with tubing. TIP: Center bearing cap hole is on the front of top rail.

6.9. Secure screw.

Part 7: Top Rail Cover Assembly

7.1. Find top rail cover. 7.2. Place top rail cover over the top rail.

7.3. Install (6) #6 screws into (6) plastic screw covers.

7.4. Starting with the center 2 holes, align top cover holes on cover with the bearing cap holes.

7.5. Start all (6) #6 screws for each hole on the top cover.

7.7. Close caps.

7.6. Secure screws.

You just assembled the TurboMill!