Cushcraft XM240 Instructions

ASSEMBLY &

INSTALLATION

XM240

40 Meter 2 Element Yagi

COMMUNICATIONS ANTENNAS

951477 (8/98)

XM240

Thank you for your purchase of the Cushcraft XM240 . This kit is designed and manufactured to give the best performance and trouble free
service. The antenna will perform as specified if the instructions are followed during assembly and installation. If you have technical questions

and have access to the World Wide Web you can visit Cushcraft’s
enables the user to place parts orders, ask technical questions, locate part numbers, initiate warranty inquires and review

Questions

at [phone] or can be e-mailed at

WARNING

THIS ANTENNA IS AN ELECTRICAL CONDUCTOR. CONTACT WITH POWER LINES CAN RESULT IN DEATH OR SERIOUS INJURY.
DO NOT INSTALL THIS ANTENNA WHERE THERE IS ANY POSSIBILITY OF CONTACT WITH OR HIGH VOLTAGE ARC-OVER FROM
POWER CABLES OR SERVICE DROPS TO BUILDINGS. THE ANTENNA, SUPPORTING MAST AND/OR TOWER MUST NOT BE CLOSE
TO ANY POWER LINES DURING INSTALLATION, REMOVAL OR IN THE EVENT PART OF THE SYSTEM SHOULD ACCIDENTALLY FALL.
FOLLOW THE GUIDELINES FOR ANTENNA INSTALLA TION RECOMMENDED BY THE U.S. CONSUMER PRODUCT SAFETY COMMISSION
AND LISTED IN THE ENCLOSED PAMPHLETS.

Antenna System Planning

Before assembly, take time to review your installation plans for the antenna. Location of the antenna is very important. Surrounding objects such
as trees, power lines, buildings, and other antennas will interact with an HF Yagi. To minimize the effects of surrounding objects, mount the
antenna as high and in the clear as possible. Metallic guy wire within 30 feet of this antenna, if broken with strain insulators, will improve
performance.

OPERATION. DEADLY VOLTAGES AND CURRENTS MAY EXIST. ALSO, SINCE THE EFFECTS OF EXPOSURE TO RF ARE NOT FULLY
UNDERSTOOD, LONG TERM EXPOSURE TO INTENSE RF FIELDS IS NOT RECOMMENDED. THERE IS A WARNING STICKER WHICH
MUST BE ATTACHED TO THE BOOM AS SHOWN IN FIGURE A

they are qualified to assist you. Make certain that everyone involved understands that you are in charge and that they must follow your instructions.
If you have any doubts at all, employ a professional antenna installation company to install your antenna.

System Grounding

Direct grounding of the antenna, mast and tower is very important. This serves as protection from lightning strikes and static buildup. A good
electrical connection should be made to one or more ground rods directly at the base of the tower or mast using at least #10 AWG ground wire
and non-corrosive hardware. For details and safety standards, consult the National Electrical Code. A coaxial lightning arrester should be used.
Cushcraft offers several different models such as the LAC series.

. Our technical support staff can be reached by phone at [phone] (8 AM to 5 PM Eastern time or voice mail after hours), faxed

[e-mail].

YOU MUST INSURE THAT NEITHER PEOPLE OR PETS CAN COME IN CONTACT WITH YOUR ANTENNA WHILE IT IS IN

TECHEXPRESS

. Plan your installation carefully. If you use volunteer helpers be sure that

support service (http://www.cushcraft.com). The site

Frequently Asked

Assembly
The assembly procedure for the XM240 consists of assembling the following subassemblies. 1) Verification of Parts. 2) Boom Assembly.

3) Element Assembly. 4 )X-Hat Assembly. 5) Feed System Assembly. 6) Boom-to-Mast Clamp Assembly. 7)Boom Truss Assembly.

Assembly of the XM240 will be easiest if the preceding steps are performed in the given order.

procedure before beginning.

Please read through the entire assembly

1-Verification of Parts

Verify all parts are present by using the XM240 Master Parts List. Check off each part when it is counted. There are extra parts intentionally
shipped with this antenna. Place common hardware in temporary containers for ease of assembly. Note all hardware is Stainless Steel.

Part No. Description Metric Equivalent Quantity Qty Check

LCA 40 Meter Loading Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ____

MNXM Matching Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ____

XM240BA 2-1/2” x 59-15/16” Aluminum Tube, 6 holes . . . . . . . . . . . . . . . . . . . . . . . . .6.3 x 152.2 cm 1 ____

XM240BB 2-1/2” x 71-15/16” Aluminum Tube, 6 holes . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 x 182.7 cm 2 ____

XM240BC 2-1/2” x 59-15/16” Aluminum Tube, 10 holes . . . . . . . . . . . . . . . . . . . . . . . . 6.3 x 152.2 cm 1 ____

XM240BD 2-3/8” x 12” Aluminum Tube, 8 holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.0 x 30.5 cm 2 ____

XM240BE 2-3/8” x 12” Aluminum Tube, 4 holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.0 x 30.5 cm 1 ____

XM240EA 1-3/8” X 84” Aluminum Tube slotted both ends . . . . . . . . . . . . . . . . . . . . 3.5 x 213.4 cm 1 ____

XM240EB 1-1/4” x 48” Aluminum Tube slotted one end . . . . . . . . . . . . . . . . . . . . . . . 3.2 x 121.9 cm 4 ____

XM240EC 1-1/8” x 48” Aluminum Tube slotted one end . . . . . . . . . . . . . . . . . . . . . . . 2.9 x 121.9 cm 4 ____

XM240ED 1” x 32” Aluminum Tube slotted one end . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 x 81.3 cm 4 ____

XM240EF 1/2” x 48” Aluminum Tube slotted one end . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 x 121.9 cm 4 ____

XM240EG 3/8” x 36” Aluminum Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 x 91.4 cm 2 ____

1

XM240

Part No. Description Metric Equivalent Quantity Qty Check

XM240EH 1-38” x 42” Aluminum Tube slotted one end, drilled one end . . . . . . . . . . 3.5 x 106.7 cm 2 ____

XM240EJ 3/8” x 42” Aluminum Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 x 106.7 cm 2 ____

X79FS 6” Feed Strap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.2 cm 2 ____

XHR 34-1/2” x 3/16” Aluminum Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 x 87.6 cm 8 ____

010011 #8-32 Stainless Steel Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ____

010082 1/4-20 x 1" Hex Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.6 cm - 20 x 2.5 cm 32 ____

010084 1/4" Stainless Steel Flat Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.6 cm 60 ____

010085 1/4-20 Stainless Steel Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.6 cm 4 ____

010207 3/8" Stainless Steel Flat Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.9 cm 6 ____

010208 3/8" Stainless Steel Lock Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.9 cm 6 ____

010209 3/8" Stainless Steel Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.9 cm 6 ____

010719 1/4”-20 x 3” Stailless Steel Hex Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.6 cm 8 ____

010120 8-32 x 2” Stainless Steel Machine Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 cm 2 ____

010231 8-32 x 1-3/4” Stainless Steel Machine Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 cm 8 ____

011941 #8 Stainless Steel Lock Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4____

013209 2-7/8" Center-to-center U-Bolt 4" Long . . . . . . . . . . . . . . . . . . . . . . 7.3 cm -10.2 cm Long 3 ____

014387 #8-32 Stainless Steel Lock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 ____

014399 1/4” Stainless Steel Lock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.6 cm60____

014498 1-3/8” Cush-a-Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 cm 8 ____

014588 1/4" x 3-1/2" Stainless Steel Hex Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.6 x 8.9 cm 4 ____

014592 1/4" Stainless Steel Flat Washer 1/8" Thick . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.6 x 0.3 cm 2 ____

014597 8-32 x 2-3/4” Stainless Steel Mahcine Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0 cm 2 ____

024259 1/8” Thimble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3 cm 4 ____

024624 1/8” Cable clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3 cm 12 ____

024623 5/16” x 4” Turnbuckle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.8 x 10 cm2____

030407 5/8" Worm Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 cm 8 ____

030409 11/16" Worm Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 cm 4 ____

030411 1-1/8" Worm Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 cm 8 ____

030412 1-1/2" Worm Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8 cm 8 ____

050077 3/8" Black Plastic Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.9 cm 4 ____

054526 2-1/2" Black Plastic Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4 cm 2 ____

094622 30’ Phillystran cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.14m 1 ____

124567 1" x 8" Drilled Fiberglass Insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 x 20.3 cm 1 ____

170035 2-1/2" Formed Aluminum Vee Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4 cm 3 ____

190026 Element Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 ____

190028 Half Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 ____

194542 8" x 8" x 1/4" Aluminum Mounting Plate . . . . . . . . . . . . . . . . . . . . . . . . 20.3 x 20.3 x 0.6 cm 1 ____

194791 2” x 4” x 1/8” Drilled aluminum truss bracket . . . . . . . . . . . . . . . . . . . . . 5.1 x 10.2 x 0.3 cm 1 ____

194707 4” x 24” x 3/16”. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.2 x 61.0 x .5 2 ____

290326 Danger Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ____

324506 8" x 5-1/4" x 3/16" Drilled Extruded Aluminum Bracket . . . . . . . . . . . . . 20.3 x 13.3 x 0.5 cm 2 ____

324509 4" x 5-1/4" x 3/16" Drilled Extruded Aluminum Bracket . . . . . . . . . . . . . 10.2 x 13.3 x 0.5 cm 4 ____

2

XM240

Figure 1A

BA

59-15/16”

(152.2 cm)

84

19

BD

12”

(30.5 cm)

84

19

BB

71-15/16 ”
(182.7 cm)

See Figure 1C

19

84

99

Figure 1B

84

19

99

BE

12”

(30.5 cm)

99

BB

71-15/16 ”
(182.7 cm)

BD

12”

(30.5 cm)

BC

59-15/16”

(152.2 cm)

1-Boom Assembly

Lay out boom sections as shown in Figure 1A. Secure the two outer
connections as shown in Figure1B. The middle connection is made using
the mast mounting hardware as shown in Figure 1C.

ID Part # Description Dimensions Qty

BA XM240BA Aluminum 2-1/2” x 59-15/16” 1

BB XM240BB Aluminum 2-1/2” x 71-15/16” 2

BC XM240BC Aluminum 2-1/2” x 59-15/16” 1

BD XM240BD Aluminum 2-3/8” x 12” 2

BE XM240BE Aluminum 2-3/8” x 12” 1

19 010719 SS Hex 1/4-20 x 3” 8

84 010084 SS Lock 1/4” 8

99 014399 SS Lock 1/4-20 8

3

Tube (6.3 x 152.2 cm)

Tube (6.3 x 182.7 cm)

Tube (6.3 x 152.2 cm)

Tube (6.0 x 30.5 cm)

Tube (6.0 x 30.5)

Bolt (7.6)

Washer

Nut