JK-404 GRANDE - DX EngineeringJK Antennas Limited Warranty and Liability JK Antennas (“Manufacturer”) warrants to the original purchaser that this product will be free from defects

JK-404 GRANDE

Four Element Full Size 40M Yagi

PO Box 266, Croton Falls, NY 10519-0266

845.228.8700 (TEL) ▪ 845.279.5526 (FAX) ▪ [email protected]

JK Antennas Limited Warranty and Liability

JK Antennas (“Manufacturer”) warrants to the original purchaser that this product will be free from defects in material, and workmanship for a period of one (1) year from the date of purchase. The determination of whether any part or parts will be covered by this limited warranty and whether any part or parts will be repaired, replaced or refunded will be solely determined by JK Antennas. Such determination will be made following evaluation of claim of alleged defect and subject to evaluation of possible misuse, abuse, unauthorized modifications, extreme weather conditions or improper installation. This warranty does not cover delivery, transportation, installation or any other costs that may be incurred from any defect.

The purchaser, final customer, installer and user of these products individually and collectively acknowledge that these products can cause injury or death and individually and collectively accept full responsibility and liability for any and all personal and property damage (direct, indirect and punitive) caused during installation and subsequent use.

Copyright Notice

This publication is Copyright ©2014 by JK Antennas. All rights reserved.

No part of this publication or addendum or attachments may be reproduced, stored in a retrieval system or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without prior permission of JK Antennas.

WARNINGS

Installation of this antenna near power lines is dangerous. Contact with any high voltage power lines could result in electric shock or loss of life. Do not install this antenna where there is any possibility that the antenna or any part of the supporting structure could come in contact with power lines.

Also ensure that no persons or pets can come in any contact with the antenna after it is installed. Dangerous voltages can exist on the antenna when it is in operation and no part of the system is insulated to prevent shock.

Consult with FCC OET Bulletin 65 to properly evaluate whether the chosen installation site for this antenna will comply with the FCC guidelines for human exposure limits to radio frequency electro-magnetic fields.

This antenna structure is not designed to be used as a support structure. No persons or objects should be supported by or suspended from the antenna structure at any time.

Because most antenna systems are installed at high heights, the installed location must take into account that falling debris may pose a hazard to humans, animals and property on the ground below.

Be aware of and follow all local codes and ordinances when installing this antenna.

JK404 Grande 4 Full Size Elements on 40M / 46 Foot Boom

INITIAL GUIDELINES

1. Open the boxes and layout the elements, hardware kits and parts 2. Using the parts list at the end this document, check to make sure all tubing, hardware kits and parts

are included (extra numbers of bolts, screws, nuts and washers are included) 3. A bottle of Penetrox or Noalox (Anti-seize/Anti-Oxidant) has been included with your antenna. Use a

drop or 2 of this anti-seize paste on all screws before fastening. This will prevent the stainless-steel hardware from accidently locking up.

The document has been separated into different assembly sections based on the packaged hardware kits. While it is recommended to assemble in the order presented, please adjust as needed based on your working conditions and assembly area.

Boom to Mast Plate and Clamps

To make ground assembly and installation of such a large antenna easier, the JK404 Grande comes with a 12" x 18" Boom to Mast Plate with positioning for a separate 2”OD truss mast – 48” tall (mast not included). The Boom to Plate Kit includes six (6) sets Boom to Plate Clamps sized 3” ID for the JK404 Grande Boom, along with appropriate assembly hardware. The Mast to Plate Kit includes six (6) sets Mast to Plate Clamps sized 3” ID as default size for your tower mast, along with appropriate assembly hardware. Also included is a set of 2” ID clamps for the truss mast.

Mast Plate with Truss Mast Mounted Narrower half of Mast clamps pre-mounted to the plate

IMPORTANT NOTE: Whenever any clamp set has uneven halves (i.e. one half is narrower than the other), the narrower half is always mounted on the plate side. The Mast to Plate clamps have a tapped hole on the narrower half to enable mounting it to the plate ahead of time. This provides easier assembly on top of the tower after tramming or lifting the antenna with a crane.

The Truss Mast is mounted towards the rear side of the boom from the Main Mast. In the sample picture above left, the Reflector or Rear side of the boom is to the Left and the Front side of the Boom is to the Right.

Boom

The JK404 Grande has a 3" OD boom - with one (1) 8 foot Boom Rear End Section (holes on one end only), one (1) 6 foot Boom Front End Section (holes on one end only), four (4) Boom Center Sections (holes on both ends), five (5) 24" Boom Sleeves and one (1) 6 foot Boom Center Sleeve.

Total Boom length of the J404 Grande is 46 feet.

Mast Position for the JK404 Grande is 251” from the rear end of the antenna boom. This position will fall on the 3rd boom section from the Rear.

Recommended: Mount a short (5 foot tall) temporary mast above the ground. Mount the Boom to Mast Plate onto the short mast with the clamps and hardware from the Mast to Plate Kit.

IMPORTANT NOTE: Whenever any clamp set has uneven halves (i.e. one half is narrower than the other), the narrower half is mounted on the plate side.

Lay out the boom sections sequentially in order of assembly. Identify and mark the Mast Position on the laid out Boom sections (3rd section from the rear), and mount that marked section at the identified Mast position onto the Mast Plate using the clamps and hardware from the Boom to Plate Kit. An alternative method would be to assemble the boom sections in the proper order on saw horses.

Insert the Boom Center Sleeve into the mounted boom section. This is the 6ft (2.5” OD, 1/8” wall) plain tubing without any holes on it. This sleeve is inserted into the Mast Center section (section 3 from the rear) of the boom to provide additional reinforcement for the maximum stresses present in and around the mast position of the boom.

Next, insert a regular boom sleeve into one end of the mounted boom section, line up the holes, and attach with the supplied nuts, bolts and lock washers (Boom Hardware Kit). Each boom section joint has 4 through holes (2-up/down & 2-across). Insert the next appropriate section of the boom onto the sleeve and attach with the provided boom hardware. Insert the remaining boom sections in the appropriate order on both sides of the mast center and attach with the hardware to complete the boom assembly.

Assembled Boom Joints

NOTE: We recommend the sleeves be attached to the boom with the bolt head on the top side (facing the sky) and nut on the bottom (facing the ground).

40M Full Size Element Assembly

The 40M Elements are comprised of telescoping sizes of aluminum tubing, starting from 2" OD center sections down to .375" tips for the reflector, Driven & D1, and 0.5” tips for D2. The center section of each of the four (4) 40M Elements of the JK404 Grande are attached to the Boom using three-sided channels.

Pull out one 32” Channel and one 32” Channel Plate. The order of clamps and plate are identical for Ref, D1, D2 whereas for the DRV element there an extra spacer involved. The detailed assembly is noted below for both.

For the Driven Element only, place six BCAL aluminum spacers in-between the black clamps and the channel.

Top each of the BCAL spacers with one-half of a Black Clamp set, insert the 2” OD Driven Element Center section (pre-assembled at factory), and position the other half of the black clamp. Top each black clamp with a BCSS stainless steel spacer. Attach the entire clamp section with the appropriate screws and nuts (Element to Channel Kit) with the bolt head against the BCSS spacer.

* Make sure to position the center of 2” OD element section exactly at the midpoint of the channel.

Driven Element to Channel Assembly Partially Assembled Reflector Center Assembled Driven Element Center (showing BCAL aluminum spacer)

The Reflector, D1 and D2 Element center sections are assembled the same way as the Driven Element, only without the aluminum spacers. The aluminum spacers are used exclusively on the Driven Element assembly.

Once each of the center sections are mounted on the channels, they can be attached to the boom using the Boom to Channel Kit and following the element positioning indicated in the diagram below.

REMEMBER: Whenever any clamp set has uneven halves (i.e. one half is narrower than the other), the narrower half is mounted on the plate/channel side.

Another view of Channel and Channel Plate

Examples of mounted 40M Channels with Channel Plate

Each channel is mounted using two (2) Boom to Element Clamps.

The elements for the JK404 Grande are positioned on the boom using the table below :

40M Ref 3” from Rear of Boom

40M DRV 181” from Rear of Boom

40M D1 260.5” from Rear of Boom

40M D2 549” from Rear of Boom or 3” from Front of Boom

Please Note: The channels are 4” wide, which for example means that the position of the rear of the channel on the reflector will be exactly 1” from the rear end of the boom. The 3” (Ref) or other element positions from the rear of boom specified in the above table will be the channel center position on the boom.

Minor adjustments to the driven element position may be necessary in cases where the vertical hole of the boom joints falls near the element channel-mounting clamp. This can be avoided by flipping the boom sections 90 degrees ahead of time which will help avoid the bolt/nut on the joint. The Clamps are made in such a way that the thickness of the clamps clearly avoids the bolt head underneath it on the boom.

Once the center sections have been mounted, the remaining tubes can be sleeved in to complete the tapered element sections. Each set of tubing has been marked for REF, DRV, D1 and D2. The REF, DRV, D1 elements each have 10 tapered aluminum sections on each side of the 2” center sections, ranging from 1.75” (largest) to .375” (smallest), whereas the D2 element has only 9 tapered aluminum sections on each side with 0.5” being the smallest. The double walling of some sections such as 1.75”, 1.5”, 1.25” has been completed at the factory.

Following that taper schedule below, assemble the element tubes in descending order on both sides of the element center sections. Align the holes and attach them to each other firmly using the appropriate screws and nuts in the Element Hardware Kit. Do not forget to use the anti-seize paste.

Transition Screw Size Nylon Nut Size

2” – 1.75” SH1024-5 (2-1/2") NN1024

1.75” – 1.5” SH1024-5 (2-1/2") NN1024

1.5” – 1.25” SH1024-3 (2") NN1024

1.25" - 1.125" SH1024-2 (1-3/4") NN1024

1.125" - 1" SH1024-1 (1-1/2") NN1024

1" - .875" SH832-4 (1-1/2") NN832

.875" - .75" SH832-3 (1-1/4") NN832

.75" - .625" SH832-2 (1-1/8") NN832

.75” - .625” Slit (D2 only) SH832-2 (1-1/8”) NN832

.625” Slit – 0.5” (D2 only) HC-2 None

.625" - .5” Slit" (Ref, DRV, D1) SH832-1 (1") NN832

.5" Slit - .375" (Ref, DRV, D1) HC-2 None

We recommend assembled elements to have the screw head on the top side of the element (facing the sky) and the nut on the bottom side of the element (facing the ground).

1) Slide the end of the 6ft 1.75” OD tube assembly with no holes approximately 31” into the center section 2” OD tube and align the holes. Attach using the appropriate hardware (Element Hardware Kit) as shown in the table above. (Use a drop of anti-seize paste on all screws).

2) Locate the pre-assembled rivet on the 6ft 1.5” OD tube assembly. Slide the end closest to the rivet into the 1.75” OD tube, align the holes and attach.

3) Slide the end of the 6ft 1.25” OD tube assembly with the end closest to pre-assembled rivet into the 1.5” tube, align the holes and attach.

4) Slide either end of the 3ft 1.125” OD tube into the 1.25” tube, align the holes and attach.

5) Insert the end of the 6ft 1” OD tube with no holes on the end approximately 31” into the 1.125” tube to act as a doubler to the 1.125” tube, align the holes and attach.

6) Insert the end of the 6ft .875” OD tube with no holes approximately 42” into the 1” OD tube to act as a doubler, align the holes and attach.

7) Continue to assemble and attach the progressively smaller tapers of aluminum tubing, using the appropriate hardware, as shown in the table above.

The smallest taper on each element is inserted into the slit end of the previous size, and attached using a hose-clamp (and not the screws). Adjust the exposed tip length of the smallest taper on each element to exactly follow the table below :

Tip Length

40REF 2” 1.75” 1.5” 1.25" 1.125" 1" .875" .75" .625" .5" slit .375”-Tip 39"

40DRV 2” 1.75” 1.5” 1.25" 1.125" 1" .875" .75" .625" .5” slit .375”-Tip 30"

40D1 2” 1.75” 1.5” 1.25" 1.125" 1" .875" .75" .625" .5” slit .375”-Tip 7”

40D2 2” 1.75” 1.5” 1.25" 1.125" 1" .875" .75" .625" slit .5”-Tip - 12”

Please note: The tip for D2 is 0.5” OD tubing unlike the other elements (Ref, DRV, D1)

Truss Assembly

The JK404 Grande has four (4) Truss Cables - one (1) 95" cable, one (1) 125"cable, one (1) 150" cable, and one 240" cable.

Using the hardware in the Boom to Truss Kit, mount the four (4) Boom to Truss Clamps, with the screws positioned horizontal to the ground, onto the Boom at the following locations:

Approximately 240” and 125” from the mast on the boom's front side

Approximately 150” and 95” from the mast on the boom's rear side (Please note that these position will move +or- a few inches on the boom depending on your install)

As the clamps are positioned, slide one end of the corresponding-length Truss Cable onto the screw on the top (sky) side of the boom.

Mount the separate recommended 2" OD Truss Mast (not included) on the Boom to Mast Plate using the clamps and hardware in the Truss Mast To Plate Kit. Using the hardware in the Mast to Truss Kit, mount the two (2) Mast to Truss clamps, with the screws of the clamps perpendicular to the boom, at approximately 36" and 40" above the boom.

Mount the eye-side of the two (2) larger Jaw-Eye Turnbuckles (packaged with the 240" and 150" Truss Cables) on the screws of either side of the top Mast Clamp. Mount the two (2) smaller turnbuckles (packaged with the 125" and 95" cables) on either side of the bottom Mast Clamp. Loosen the turnbuckles and apply anti-seize paste to the threads. Attach the loose ends of the appropriate truss cables to the jaw-side of the turnbuckles on the same side of the mast clamp (i.e. the two longer cables placed farthest from the mast on the boom are attached to the top clamp, the two shorter cables closer to the mast are attached to the bottom clamp.

Example of Mast to Truss Cable Assembly

Ensure that the cables are tight. Adjust the tensions of the turnbuckles as needed and level the boom after mounting the antenna on the tower.

Driven Element – Balun Leads Assembly

The Driven Element Center section (with the fiberglass rod center) has been pre-assembled at the factory. The balun leads are mounted on the Driven Element as follows, using the appropriate screws, nuts and washers in the Driven Element Hardware Kit:

Mount the Balun on the side of the boom towards the Mast. The Balun can be mounted as close as possible to the Driven element with the coax connector facing towards the mast and the studs facing towards the Driven element.

1. Insert the star or toothed lock washer into the Driven Element center screws.

2. Now insert the lead from the balun (keep lead as short as possible for the best swr)

3. Insert the supplied #10 plain hex nut and tighten - Make sure to tighten lightly - do not over tighten

4. Now insert and screw another plain hex nut, which will act as a lock

5. Check the entire setup for a snug fit and make sure there are no loose joints in balun leads

JK404 Grande Parts List

Description

BOOM TO MAST ASSEMBLY

BMP Version 2

18" x 12" Mast Plate 3/8" (9mm) thick 1

Mast to Plate Assembly

MPC (3/4" thick) 2" ID Mast to Plate clamp 6

HH3816-8 Hex Head Screw 3/8-16 (5-1/2") 12+2

HN3816

Plain Hex Nut 3/8-16 12+2

LW38

Lock Washer 3/8 12+2

Boom to Plate Assembly

BMC (3/4" thick) 3" ID Boom to Plate clamp 6

HH3816-5 Hex Head Screw 3/8-16 (4-1/2") 12+2

HN3816

Plain Hex Nut 3/8-16 12+2

LW38

Lock washer 3/8 12+2

BOOM & TRUSS ASSEMBLIES

AT3.0Boom 8ft-2S

Boom Section 8ft 3.0" OD 4

AT3.0Boom 8ft-1S

Boom End Section 3.0" OD 1

AT3.0Boom 6ft-1S

Boom End Section 3.0" OD 1

AT2.75Sleeve

Boom Sleeve 5

AT2.75SpecialSleeve Boom Center Sleeve 1

Boom Assembly Hardware

HH3816-4 Hex Head Screw 3/8-16 (3-3/4") 40+2

NN3816

Nylon Nut 3/8-16 40+2

LW38


Boom Truss Assembly

TC

3" ID Truss Clamp on Boom 4

HH3816-4 Hex Head Screw 3/8-16 (4-1/2") 8+2

NN3816

Nylon Nut 3/8-16 8+2

Mast Truss Assembly

TC

3" ID Truss Clamp on Mast 2

HH3816-4 Hex Head Screw 3/8-16 (4-1/2") 4+2

NN3816

Nylon Nut 3/8-16 4+2

Clamp

2" ID

Mast-Plate Clamps for BMP-2 Truss Mast 2

HH3816-5 Hex Head Screw 3/8"-16 (4-1/2") 4+2

PN3816

Plain Nut 3/8-16 4+2

LW38

Lock Washer 3/8 4+2

Truss Cable Assembly

TC240

240" truss cable 1

TC125

125" truss cable 1

TC95

95" truss cable 1

TC150

150" truss cable 1

TBJE1

Turnbuckle #1 (800#) for TC125/TC95 2

TBJE2

Turnbuckle #2 (1200#) for TC240/150 2

BOOM TO ELEMENT ASSEMBLIES

BC2.0

Black Polyamide clamps 2.0" ID 24 + 1

BEC Assembly Hardware

BEC40G

Boom to Element Plate Clamp 8

LW38


NN3816

Nylon Nut 3/8-16 16+2

HH3816-5 Hex Head Screw 3/8-16 (5-1/2") 16+2

40M Channel Assembly

40M Channel-2

40M Element Center Plate 4

HH1420-4 Hex Head Screw 1/4-20 (3-3/4") 48+2

NN1420

Nylon Nut 1/4-20 48+2

BCSS

Stainless Steel Clamp Plate 24

BCAL

Aluminum Clamp Plate 6

Channel Plates Channel top reinforcing plate 4

40M ELEMENT ASSEMBLIES

6AT2.0 40G

6 ft Alum Tube 2.0" OD 4

6AT1.75 40G Element Assembly 6 ft Alum Tube 1.75" OD 8



3AT1.125 40G


6AT1.0 40G


6AT.875 40G

6 ft Alum Tube .875" OD 8

3AT.75 40G


3AT.625 40G


3AT.625S 40G

3 ft Alum Tube .625" OD (slit end) 2

3AT.5S 40G

3 ft Alum Tube .5" OD (slit end) 6

3AT.5 40G


3AT.375 40G


3AT.375 40G

46" Alum Tube .375" OD 2

Element Assembly Hardware

SH1024-5

Socket Head Screw 10-24 (2-1/2") 16+2

SH1024-5


SH1024-3

Socket Head Screw 10-24 (2") 16+2

SH1024-2


SH1024-1


NN1024

Nylon Nut 10-24 80+10

SH832-5


SH832-3


SH832-2


SH832-1

Socket Head Screw 8-32 (1") 16+2

NN832

Nylon Nut 8-32 64+6

HC-2

Hose Clamp 9/16" Band Width 8+2

40M DRIVEN ELEMENT HARDWARE

FG1.5DE

Fiberglass Rod for Driven Element 1

SH1024-5

Socket Head Screw 1024 (2-1/2") 2+1

SH1024-7

Socket Head Screw 1024 (3") 2+1

HN1024

Plain Hex Nut 10-24 8+2

NN1024

Nylon Nut 10-24 4+2

FW10

Flat Washer #10 2+2

LW10ExT

Lock Washer #10 External Tooth 12+2

SUPPLIES

Penetrox

Anti-Oxidant 1

JK404 Grande Specifications

JK404 Grande

No. of Elements 4

Boom Length 46 feet

Peak Gain *

Freespace

At 90ft

8.3 dBi

13.2dBi

Peak F/B 30+ dB

Peak F/R 27 dB

2:1 SWR -

1.5:1 SWR 300 KHz

Max. Element 73.2 feet

Approx. Wt. 325 lbs.

Wind Area 18.7 sq.ft.

Max. Wind Speed 96 MPH

Turning Radius 43.2 feet

Documents

JK-404 GRANDE - DX EngineeringJK Antennas Limited Warranty and Liability JK Antennas (“Manufacturer”) warrants to the original purchaser that this product will be free from defects