Koenders Superior Windmill User manual

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CONGRATULATIONS...
Congratulations on the purchase of your Superior Windmill. You are now the owner of North
America’s most superior wind powered aeration systems. Proper maintenance and assembly will
lead to a long life of service from our products.
THEORY OF OPERATION
Under the water’s surface there are aerobic bacteria feeding on organic matter, which consumes
large quantities of oxygen. When this oxygen becomes depleted, hydrogen sulfide gas is
produced as a byproduct. This causes the water to turn black and a foul odor similar to rotting
eggs is given off. When you use a Superior Windmill the water stays aerated preventing this
problem from happening. Using our double diaphragm (TURBO JET STREAM) pump keeps the
oxygen level even higher and your water cleaner.
CAUTION
1) DO NOT attempt to repair or service the windmill on a very windy day. It is too unpredictable
and dangerous, and you could be easily injured.
2) Even in low winds, be very careful when servicing. Be certain that the blade is securely tied
before beginning any work.
3) DO NOT climb the tower while the blades are in motion. The head can turn without warning
and is very dangerous. Use a ladder to climb the tower that is properly and safely secured.
DO NOT use the tower members as steps as they cannot safely support your weight. The
recommended method is to lay the tower on its side for any servicing.
4) ALWAYS teach children about the dangers of the windmill and keep them away from it.
5) Keep your distance from the windmill in thunder, strong winds and lightning storms.
6) STAY OFF the pond ice in winter, as it is thin from the air movement under the surface.
AVOIDING THESE SAFETY WARNINGS CAN RESULT IN
SERIOUS INJURY OR DEATH
WARRANTY
The Superior Windmill comes with 18 full months of warranty from the day of purchase. This
guards against defects in material and workmanship. You can either return the faulty component
for repair or you can take it apart yourself and phone the factory for replacement parts. You will
need to have proof of purchase date and if within the 18-month time frame the parts will be sent
to you at no additional cost.
PLEASE NOTE: This windmill has been designed for maximum strength however it is possible
that a severe storm may damage or destroy it. Due to this the windmill should be covered by your
own applicable insurance policy.

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Item Quantity
In 12’ set
Quantity
In 20’ set
Description Diagram
(Not to scale)
S1 3 TOP PORTION TOWER LEGS
S2 6 6 48" TOWER LEGS
S21 3 TOP PORTION SHORT STRUT
S22 3 TOP PORTION LONG STRUT
S31 3 3 22 3/4" STRUT
S32 6 32" STRUT
S33 3 12 41 1/4" STRUT
S41 6 15 3/4" CROSS BAR SUPPORTS
S42 6 19" CROSS BAR SUPPORTS
S43 6 27 1/4" CROSS BAR SUPPORTS
S44 3 29 1/2" CROSS BAR SUPPORTS
S45 6 3 33 3/4" CROSS BAR SUPPORTS
S46 6 35 1/4" CROSS BAR SUPPORTS
S47 3 3 38 1/2" CROSS BAR SUPPORTS
S48 3 41" CROSS BAR SUPPORTS
S49 6 43 1/4" CROSS BAR SUPPORTS
S50 3 45 1/4" CROSS BAR SUPPORTS

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Item # Quantity
in 12’ set
Quantity
in 20’ set
Description Diagram (not to scale)
1 1 PLASTIC TOWER TOP
2 6 6 CROSS BAR TENSIONER
3 24 5/16" SELF TAPPING SCREWS
4 6 GROUND STAKE CLAMPS
5 3 GROUND STAKE
6 1
SINGLE DIAPHRAM
COMPRESSOR UNIT OR
DOUBLE DIAPHRAM
COMPRESSOR UNIT
7 1 PIVOT POST
8 1 RIM WASHER AND BEARING
9 2 TAIL ARMS
10 2 TAIL FIN
11 12 FAN BLADES
12 12 BLADE BRACES
13 1 DOME
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1 HUB ASSEMBLY

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FRAME SETUP INSTRUCTIONS
IMPORTANT NOTE: Do not tighten any bolts until tower is fully assembled.
The setup of this tower will go much quicker and more organized if you do some pre-assembly.
The entire cross bar supports can be bolted together as per Figure 1. Also, the multi-strut
systems can be bolted together. The section you opt to end at finishes with the ground stake
clamps (item 4). These will be bolted to the last two holes of the bottom legs used. See Figure 3
next page for more details.
NOW TO BEGIN ASSEMBLY...
A) Begin the tower at the very top. Take all three top portion tower legs (ITEM S1) and fasten
them to the plastic tower top (ITEM 1) with twenty-four 5/16” self-tapping screws (ITEM 3).
Tighten all of these screws. DO NOT OVER TIGHTEN AS THESE SCREWS CAN STRIP IN
PLASTIC.
Note: These screws are all you should tighten until the tower is complete.
B) After these legs are fastened, install the top portion struts (ITEMS S21, and S22). These are
to be mounted with the flat side of step against the inside of the tower leg.
C) Hold the next set of 48” tower legs (ITEM S2) to the back of the first set of legs. You also
have to hold up a 23” brace (ITEM S31) to the back of the legs and run a 1/4” x 3/4” bolt
through the top hole of all three items. (Don’t put the bolt through the bottom hole yet as the
cross bar supports will have to be added.)
D) After all three 23” struts are in place put a bolt through the top hole of the 19” support bars
(ITEM S42) and bolt it to the bottom hole of the top tower leg (ITEM S1).
E) The next step involves assembling several parts at the same time. You have to run a bolt
through a 33 3/4” cross bar support (ITEM S45), the top hole of the second and third level of
48” legs, and finally the 41” strut (ITEM S33). On the other side of the leg instead of the 33
3/4" cross bar supports you need to bolt in the cross bar tensioner (ITEM 2) and the 29 1/2"
cross bar (ITEM S44).
Note: Make sure that only one cross bar tensioner ends up in each corner.
Note: Make sure that 5/16” x 1/2” inch nuts and bolts are used to secure center of all cross
bar supports.
F) The next cross bar assembly consists of two 27 1/4" cross bars (ITEM S43), one 38 1/2”
cross bar (ITEM S47), one 33 3/4" cross bar (ITEM S45), and a cross bar tensioner (ITEM 2).
Bolt the two 27 1/4" pieces to the bottom holes of the second level legs. Bolt the 38 1/2" piece
and the 33 3/4" with the tensioner to the top hole at the bottom of the third level legs. You
stop at the 12’ section bolt on the two 32” struts (ITEM S32) between each leg. Bolt on the
ground stake clamps and you’re done. If you’re building the 20’ assembly please read on.
G) Before you bolt on the 32” struts, add another 48” leg in between them and the third level leg.
A 35 1/4" cross bar support (ITEM S46) will also have to be added to the outside of these
holes.
H) Repeat steps A-F to complete the 20’ assembly using Figure 1 to find correct part placement.
I) Tighten all nuts and bolts.

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Bolt clamps to bottom of leg that your windmill frame ends with. Also note that the clamps come
in pairs to allow the stakes to be driven vertically into the ground. Check that you have them
paired up correctly. Bolt the ground stake in with six 1/4" x 1/2” hex nuts and bolts and twelve 1/4”
flat washers (install washers on the outside of both pieces). Pound the stakes into the ground
leaving only enough sticking out to level the windmill. Level the bottom struts and tighten the
remaining bolts on the clamp assembly to firmly grip the ground stake.
Please Note: It is up to the customer to make sure the windmill has been anchored securely. The
ground stakes (ITEM 5) supplied are usually adequate in very heavy clay based soils, but
additional anchoring may be needed in other soil conditions.
WE STRONGLY RECOMMEND THE TOWER BE MOUNTED ON CONCRETE
PILES AS SEVERE WINDS AND VARIED SOIL CONDITIONS CAN CAUSE
THE WINDMILL TO FALL
HEAD UNIT ASSEMBLY AND SETUP INSTRUCTIONS
J) Lay down the hub assembly (ITEM 14) in an area large enough for entire fan assembly.
K) Attach fan blades (ITEM 11) by lining up the three bolt holes in the bottom of the fan blade
with the three diagonal bolt holes in the center unit sidewalls.
L) Bolt together with 1/4" x 3/4” bolts, nuts and lock washers on inside of hub. Do not tighten any
of these bolts until all blades are attached.
M) Next, fasten the blade braces (ITEM 12) in between each blade with 1/4" x 1/2” bolts, nuts
and lock washers.
N) When all blades and braces are in place, start tightening bolts.
O) Next move to the tail assembly. Line up the four sets of holes punched in the tail fins (ITEM
10). Bolt together the back three sets of holes leaving the first set to bolt the tail arms to
(ITEM 9).
P) Bolt together one tail arm to each side of tail fins with 1/4" x 3/4" bolts. The crimp in the arms
is attached to the tail fin and the straight ends to the compressor. Bolt the opposite end of the
arms to the threaded holes in the compressor unit (ITEM 6) with 5/16 bolts and lock washers.

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Q) Slide the compressor unit over the pivot post (ITEM 7) and tighten u-clamp bolt from
compressor around pivot post. Next hook up a short hose between the air fittings on top of
compressor and the pivot post air fitting, secure with hose clamp.
R) Next, slide crankshaft through center of hub assembly (ITEM 14) and tighten setscrews then
jam nuts to secure. After the fan is securely fastened to the compressor unit, bolt on the
dome (ITEM 13) to the front of the fan assembly using ¼” x ¾” bolts and lock washers
S) The head unit is now ready to mount onto the plastic tower top (ITEM 1). Slide the rim washer
then the bearing (ITEM 8) onto the pivot post. Grease the bearing then slide into the plastic
tower top.
Note: The pivot post should be greased before installation and once a year after that.
T) Connect the 1/2" hose to the air coupling supplied then connect to the bottom of the pivot
post fitting and run it down the side of the windmill frame.
U) Clamp hose to the tower frame halfway down using supplied metal hose clips.
NOTE: If you have purchased the air diffuser skip to Step W.
NOTE: If you have purchased the freeze control unit skip to Step X.
V) Run the other end of the tube to the body of water you wish to aerate. Use a rope and a
weight (not supplied) to hold the end of the hose about one foot off the bottom of the dugout.

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W) If you have also opted for the air diffuser, follow the same instructions as in Step V but
instead of using the rope and weight to hold the end of the hose underwater, attach that end
of the hose to the air diffuser. To prevent stirring up mud we recommend that you place the
stone inside a plastic pail or bucket. Gravel or stones should be placed in the pail to ensure it
stays at the bottom. Run a nylon rope through the sides of the pail (not the handle, as it will
rust off) so that you can retrieve it at any time. See Figure 4 for details.

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X) If you have also opted for the freeze control unit you have to mount the ethanol tank to the
windmill leg about 5 feet off the ground. Instead of running the hose directly to the dugout,
attach it to the check valve on the bottom of the ethanol tank. Run another hose out of the
check valve into the T-Joint assembly. The third section of hose fits between the fitting in the
top of the ethanol tank and connects to another port in the T-Joint assembly. After this is
done you can run a hose from the last opening in the T-Joint assembly to the body of water.
Refer to Steps V or W for further instructions. The pressure gauge normally will read from 5
to 10 lbs psi depending on the depth of the air diffuser in the pond. The deeper it is
submerged the higher the reading on the gauge. In shallow water applications the gauge may
read lower or zero. If the line or diffuser is plugged the pressure will rise dramatically. This
situation must be resolved immediately as prolonged backpressure can cause the
compressor to fail.

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APPENDIX A
BOX CONTENTS
COMPRESSOR
ITEMS QTY
1 Single / Double Compressor Unit 1
2 Plastic Tower Top 1
3 28” Pivot Post 1
4 8100 Bearing (set) 1
5 Bearing Washer 1
6 Swivel 1
7 U-Bolt Clamp 1
BLADE & TAIL
ITEMS QTY
1 Tail Fan - Pair 1
2 Fan Blades 12
3 Nuts & Bolts Package #5 1
WHEEL & DOME
ITEMS QTY
1 Wheel or Hub Assembly 1
2 Dome 1
3 Blade Braces 12
4 Nuts & Bolts Packages #1 & #2 2
TOWER 12'-A PKG
ITEMS QTY
1 Top Portion Short Strut (S21) 3
2 Top Portion Long Strut (S22) 3
3 Strut – 22 ¾” (S31) 3
4 Strut – 32” (S32) 3
5 Strut – 41 ¼” (S33) 3
6 Tail Arms 2
7 Cross Bar Supports – 33 ¾” 3
8 Ground Stake Clamps 6
9 90ºTensioner 3
10 Hose Clips 3
TOWER 12'-B PKG
ITEMS QTY
1 Top Portion Tower Legs (S1) 3
2 Tower Legs – 48” (S2) 6
3 Cross Bar Supports – 19” (S42) 6
4 Cross Bar Supports – 27 ¼” (S43) 6
5 Cross Bar Supports – 29 ½” (S44) 3
6 Cross Bar Supports – 33 ¾” (S45) 3
7 Cross Bar Supports – 38 ½” (S47) 3
8 Ground Stakes – 47 ½” 3

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APPENDIX A (cont.)
12-16 EXTEN. – Optional
ITEMS QTY
1 Tower Legs – 48” (S2) 3
2 Strut – 41 ¼” (S33) 6
3 Cross Bar Supports – 35 ¼” (S46) 6
4 Cross Bar Supports – 41” (S48) 3
5 Cross Bar Supports – 45 ¼” (S50) 3
6 90º tensioner 3
7 Hose Clip 1
8 Nuts & Bolts Package #3 1
16-20 EXTEN. – Optional
ITEMS QTY
1 Tower Legs – 48” (S2) 3
2 Strut – 22 ¾” (S31) 3
3 Strut – 41 ¼” (S33) 6
4 Cross Bar Supports – 15 3/4” (S41) 6
5 Cross Bar Supports - 33 3/4” (S45) 3
6 Cross Bar Supports - 38 1/2” (S47) 3
7 Cross Bar Supports - 43 1/4” (S49) 6
8 90º Tightener 3
9 Hose Clip 1
10 Nuts & Bolts Package #4 1
FREEZE CONTROL PKG – Optional
ITEMS QTY
1 Tank 1
2 Pressure Release Valve 1
3 Pressure Gauge 1
4 Brass T Connector 1
5 950 mm metal band 1
PRESSURE GAUGE UNIT – Optional
1 Pressure Gauge 1
2 Tee Assembly 1
3 Hose Clamps 2

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APPENDIX B
NUTS & BOLTS
Package #1
SIZE NOTE QTY
1 1/4×1/2 BOLTS BLADE BRACES 24
2 1/4×3/4 BOLTS DOME COVER ON HUB 3
3 1/4 NUTS BRACES BETWEEN BLADES 24
4 ¼ LOCK WASHER FOR DOME & BLADE BRACES 27
5 1/4×3/4 BOLTS FOR TOWER LEGS 36
6 1/4 NUTS FOR TOWER LEGS 36
Package #2
SIZE NOTE QTY
1 5/16×3/4 SELF TAPPING SCREWS PLASTIC TOWER TOP 24
2 1/4×2¾ EYE BOLT TENSIONERS FOR STRAPS 6
3 1/4×1/2 BOLTS S01.S02 JOINING S21 S22 24
4 ¼ NUTS 36
5 ¼ WASHER FOR EYE BOLT 12
6 5/16×1/2 BOLTS FOR CROSS BAR SUPPORTS
CENTERS 18
7 5/16 NUTS FOR CROSS BAR SUPPORTS
CENTERS 18
8 1/4×1/2 BOLTS TOWER GROUND STAKE CLAMPS 18
9 1/4 NUTS TOWER GROUND STAKE CLAMPS 18
Package #3 - Included with 20 Foot Tower Only
SIZE NOTE QTY
1 1/4×2 3/4 EYE BOLT FOR CROSS BAR TENSIONERS 3
2 1/4 NUTS FOR EYE BOLT 6
3 1/4 WASHER FOR EYE BOLT 6
4 5/16×1/2
BOLTS FOR CROSS BAR SUPPORTS CENTERS, UPPER
SECTION 3
5 5/16 NUTS FOR CROSS BAR SUPPORTS CENTERS, UPPER
SECTION 3
6 5/16×1/2
BOLTS FOR CROSS BAR SUPPORTS CENTERS, LOWER
SECTION 3
7 5/16 NUTS FOR CROSS BAR SUPPORTS CENTERS, LOWER
SECTION 3
8 1/4×1/2 BOLTS FOR S33 12
9 1/4 NUTS FOR S33 12
10 1/4×1/2 BOLT FOR HOSE CLIP 1
11 1/4 NUT FOR HOSE CLAMP 1
12 1/4×3/4 BOLTS FOR TOWER LEGS 12
13 1/4 NUTS FOR TOWER LEGS 12

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APPENDIX B (cont.)
Package #4 - Included with 20 Foot Tower Only
SIZE NOTE QTY
1 1/4×2 3/4 EYE BOLT FOR CROSS BAR TENSIONER 3
2 1/4 NUTS FOR EYE BOLT 6
3 1/4 WASHER FOR EYE BOLT 6
4 5/16×1/2
BOLT FOR CROSS BAR SUPPORTS CENTERS, UPPER
SECTION 3
5 5/16 NUTS FOR CROSS BAR SUPPORTS CENTERS, UPPER
SECTION 3
6 5/16×1/2
BOLT FOR CROSS BAR SUPPORTS CENTERS, LOWER
SECTION 3
7 5/16 NUTS FOR CROSS BAR SUPPORTS CENTERS, LOWER
SECTION 3
8 5/16×1/2 BOLT FOR S41S45S47 6
9 5/16 NUTS FOR S41S45S47 6
10 1/4×1/2 BOLT FOR S31S33 24
11 1/4 NUTS FOR S31S33 24
12 1/4×1/2 BOLT FOR HOSE CLIP 1
13 1/4 NUT FOR HOSE CLIP 1
14 1/4×3/4 BOLTS FOR TOWER LEGS 12
15 1/4 NUTS FOR TOWER LEGS 12
Package #5
SIZE NOTE QTY
1 5/16×1/2 BOLTS TAIL ARMS TO COMPRESSOR 4
2 5/16 LOCK WASHER FOR TAIL ARM BOLTS 4
3 1/4×3/4 BOLTS TAIL ARMS TO TAIL FIN 2
4 1/4×1/2 BOLTS TAIL FIN BOLTS 6
5 1/4 NUTS 8
6 1/4×3/4 BOLTS FOR BLADE TO HUB ASSEMBLY 36
7 1/4 NUTS FOR BLADE TO HUB ASSEMBLY 36
8 1/4 LOCK WASHER FOR BLADE TO HUB ASSEMBLY 36