Elecraft K3 Assembly Manual User Manual

ELECRAFT K3 HIGH-PERFORMANCE 160 – 6 METER TRANSCEIVER K3 KIT ASSEMBLY MANUAL Rev M, September 3, 2014 Copyright © 2014, Elecraft, Inc. A

9Unpacking and Inventory CAUTION Do not handle the circuit boards without anti-static protection! Doing so may damage sensitive components. See P

10Standoffs A number of threaded standoffs are used. As with the screws and washers, be sure you use the correct size as specified in the text. Sta

11Assembly IMPORTANT ASSEMBLY INFORMATION 1. Screws and other Fasteners: A variety of screws and fasteners are used to assemble your K3:  Stai

12RF Board and Chassis RF Board Description The RF PCB (Printed Circuit Board) is the heart of the K3 transceiver, both physically and electrically

13Install a 4-40 3/8” (9.5 mm) standoff on the RF board near connector Z1 as shown in below and Figure 11 on page 16. This standoff will support th

14Install hardware to attach Q3 to the RF board near the rear left corner as shown in Figure 9 and Figure 11 on page 16. Figure 9. Installing Q3 H

15Install the filters as shown in Figure 10. Refer to the list of filters you created in Table 1 to determine which filter to install at each locat

16 Figure 11. RF Board Partially Assembled.

17Install the Low Power Amplifier (LPA) board in the cutout on the RF board as shown in Figure 12. The LPA board is held in place by its connectors

18Mount a 2D fastener on each ear of the front panel shield, and then mount the shield on the RF board as shown in Figure 13. Be sure the 2D fasten

1Contents Introduction ... 2Customer Service and Support ...

19Locate the two side panels. They are approximately 4” (10 cm) by 9-7/8” (25 cm) in size. Both panels have six counter-sunk screw holes near the e

20Mount a 2D fastener at the top back corner of the left side panel (the one you just installed) with a 4-40 3/16” (4.8 mm) black flat head screw (

21If you have the KRX3 Subreceiver option kit on hand, you may wish to install the AUX RF antenna connector at this time. The AUX RF connector is o

22Thread the BNC/TMP cable through the AUX RF connector hole from the outside, lining up the flat on the threaded section of the connector with the

23Preparing Right Side Panel for Installation Install the four rubber side feet in the holes in the right side panel as shown in Figure 21. Two sug

24At the upper rear corner of the side panel you just identified in the previous step, mount a 2D fastener as shown in Figure 22, using a black 4-4

25Peel the backing from the self-adhesive serial number label and attach it to the back panel as shown in Figure 25. You may wait until the assembl

26Connect the wires from the SO239 connector(s) to the KANT3 or KAT3 board as shown in Figure 28. Use needle-nose pliers to grip the terminals on t

27If you installed the KANT3 board, the hole for the ANT2 jack is not used. Insert the larger of the hole plugs in the opening until it clicks in p

28Mount two 1-1/4” (31.8 mm) standoffs in the two holes on the KIO3 board as shown in Figure 33 using a zinc 4-40 1/4” (6.4 mm) screw and inside to

2Key to Symbols and Text Styles Identifies important information. -100 Characters displayed on the LCD screen DISP Tap switch function (labeled

29Install the KIO3 Main board with the Audio I/O daughter board attached into the K3 as shown in Figure 34. The KIO3A main board plugs into J76 on

30 Install the KIO3 rear panel as shown in Figure 36. Figure 36. Mounting the KIO3 Connector Panel.

31Front Panel and DSP Front Panel and DSP Description The Front Panel is a large plug-in module that provides the K3’s user interface (LCD, switche

32On the front side of the board, mount four standoffs as shown in Figure 38. IMPORTANT! 1. Place the split lock washers between the standoff an

33Install the two soft foam light blockers at the ends of the LCD display as shown in Figure 39. Remove the paper strip covering the adhesive on ea

34Ensure the flange on the MIC connector is not caught behind the panel. The flange should be slightly above the panel as shown all the way around

35Place the VFO A encoder in the opening near the center of the front panel board so the shaft protrudes through the opening under the LCD. Be care

36 CAUTION! In the following steps you will attach the plastic LCD cover and VFO A trim panels to the front cover using small screws. Use the scre

37Mount the cover on the front panel over the LCD as shown in Figure 47 oriented so the beveled edges are away from the panel. If the cover seems t

38 CAUTION! You may damage the encoders while installing the knobs in the next step unless you align the flats in the knobs with the flats on the

3Introduction This manual will guide you through assembly of your Elecraft K3 transceiver. We’re confident that you’ll find the K3 easy to build, e

39Mount the last knob on the VFO B encoder shaft to the right (under the pushbutton switches) as shown in Figure 51. Before tightening both set scr

40Mount the three 7/16” (11mm) male/female standoffs on the component side of the main DSP board as shown in Figure 53 using 4-40 nuts and #4 split

41 Locate resistor R3 on the front panel board (mounted on the front panel). If R3 is positioned above the board on its leads as shown in Figure 55

42Mounting the DSP Board Assembly on the Front Panel Locate the main DSP board and install the nylon standoff near J51 as shown below. Be sure you

43Squeeze the boards together while ensuring the pins are mating with the connectors until the DSP board is resting against the three standoffs on

44Screw the knurled nut onto the threaded shaft of the PHONES jack where it exits the front panel (see Figure 60). Screw it only finger tight. Do n

45 ESD SENSITIVE: Wear a grounded wrist strap or touch an unpainted metal ground before handling the RF Board in the following steps. Turn the cha

46 REMOVING THE FRONT PANEL: If you need to remove the front panel assembly, remove the five screws holding it to the chassis (three on the top lip

47Attach voltage regulators U13 and U12 to the right side panel as shown in Figure 65 using a 4-40 3/8” (9.5 mm) black flat head screw (SS), #4 ins

48Resistance Checks The following resistance checks confirm that the main power busses in the K3 aren’t shorted to ground. If any of the values mea

4 Elecraft's 1-Year Limited Warranty This warranty is effective as of the date of first consumer purchase (or if shipped from factory, date pr

49Initial Power On Check The following check confirms that the power supply and power control circuits are working properly. Be sure your K3 passes

50Mount the TCXO module on the KREF3 board as shown in Figure 69. Be certain the leads go into the corner holes in the socket and the black dot is

51 CAUTION In the following step it is easy to drop screws and lock washers into the K3. If this happens, you must find and retrieve the hardware.

52KSYN3 Synthesizer KSYN3 Description The KSYN3 module is a high-performance, wide-range synthesizer covering 8 to 46 MHz. It uses a crystal-filter

53 CAUTION In the following step it is easy to drop screws and lock washers into the K3. If this happens, you must find and retrieve the hardware.

54Locate the three TMP cables. They are about 1/8” (3 mm) diameter coaxial cables with connectors at each end as shown in Figure 75. Check each cab

55Loudspeaker Loudspeaker Description The built-in loudspeaker is mounted on the top cover. A grill cloth covering the sound holes keeps dust and

56Mount the speaker using the hardware shown in Figure 78. A suggested procedure for doing this is as follows: Find a book or other flat-smooth sur

57Install the shield over the speaker magnet as shown in Figure 79. Figure 79. Installing Speaker Magnet Shield. KPA3 Shield If you are not plann

58 Attach the shield to the RF board and to the rear panel as shown in Figure 81. The screws, washers and nut are in the KPA3 Option kit. The stand

5Preventing Electrostatic Discharge Damage There is no climate or work location where the components of your K3 are safe from Electrostatic Dischar

59Bottom Cover Bottom Cover Description The bottom cover is divided into two parts, the rear and forward sections. The rear section is slightly thi

60Identify the bottom cover forward section by test fitting it on the bottom of the K3. The forward section is the thinner panel with a notch along

61Locate the rear bottom cover section. This cover has eight rectangular slots cut in it. Like the front section, bare metal is exposed in some are

62 Plug the noise blanker board into J77 and attach it to the standoff using the hardware shown in Figure 87. Figure 87. Installing the Noise Blan

63KBPF3 General Coverage Receive Option If you have the KBPF3 General Coverage Receive option kit, install the board as follows. Otherwise skip th

64Power Amplifier Jumper Block The Power Amplifier (PA) jumper block is required to operate the K3 without the optional KPA3 100 watt power amplifi

65Bottom Covers Turn the K3 over so the bottom is exposed. Position the forward section of the bottom cover with the feet and bail toward the front

66Install the rear bottom cover section as follows (see Figure 93): Position the cover so the holes near the center line up with the transistors on

67Top Cover Even if you have the KPA3 100-watt module to install, install the top cover and speaker at this time for initial testing and calibratio

68If you have the KPA3 shield installed, place three 4-40 3/16” (4.8 mm) black flat head screws (SS) through the holes across the middle of the cov

6We strongly recommend you take the following anti-static precautions (listed in order of importance) to avoid trouble:  Leave ESD-sensitive part

69Test and Calibration It’s time to apply power! In the following tests and procedures you will check out and calibrate essential functions of your

70If you checked the “Yellow Dot” box on page 28 while inspecting the KIO3 Audio Board, do the following. Otherwise skip this step and proceed to

71Filter Setup Turn to the Crystal Filter Installation and Setup section of your Owner’s Manual and perform the following procedures. If you have i

72Option Modules Enable Modules Enable the KNB3 noise blanker and, if installed, the KBPF3, KAT3, KDVR3 and KXV3 option modules as described in the

A- 1Appendix A Illustrated Parts List Your kit contains a number of envelopes, boxes and packages of parts. Check the contents of each one carefully a

A- 2E850323 KREF3 TCXO Module Bag ILLUSTRATION DESCRIPTION QTY ELECRAFT PART NO. KREF3 TCXO Module, 49.380 MHz, ±5 ppm stability This module is not

A- 3Optional Filter ILLUSTRATION DESCRIPTION QTY ELECRAFT PART NO. KFL3A-2.8K Filter (optional) 1 KFL3A-2.8K Screw, 4-40, either 1/4” (6.4 mm) Zi

A- 4ILLUSTRATION DESCRIPTION QTY ELECRAFT PART NO. K3 DSP Printed Circuit Board Assembly ESD Sensitive 1 E850233 LPA (Low Power Amplifier) PCB Assemb

A- 5ILLUSTRATION DESCRIPTION QTY ELECRAFT PART NO. KNB3 Noise Blanker PCB Assembly ESD Sensitive. 1 E850280 KREF3 PCB Assembly ESD Sensitive.

A- 6ILLUSTRATION DESCRIPTION QTY ELECRAFT PART NO. KIO3 Main PCB Assembly ESD Sensitive. 1 E850237 KIO3 Audio I/O PCB Assembly ESD Sensitive. NOTE

7 Figure 1. Typical Assembled K3/10 (Less Top Cover and Chassis Stiffener Bar).

A- 7Miscellaneous Components Packed in separate bags and envelopes as follows: E850239 K3 FP Encoder Assembly Bag ILLUSTRATION DESCRIPTION QTY ELECRAF

A- 8E850306 K3 Knob and Band for VFO A (bag) ILLUSTRATION DESCRIPTION QTY ELECRAFT PART NO. Knob, VFO A Tuning 1 E980093 Finger Grip, Main VFO Tuni

A- 9E850263 K3 RF Misc. Bag You will find bags included inside this bag. Where a bag or envelope inside this bag contain several parts with individua

A- 10 Typical Standoffs (May be round or hexagonal) Standoff, 4-40, 1/4” (6.4 mm) long 6 E700026 Standoff, 4-40, 3/8” (9.5 mm) long 2 E700153

A- 11 E850067 Allen Wrench Envelope (in K3 RF Misc Bag) ILLUSTRATION DESCRIPTION QTY ELECRAFT PART NO. Allen Wrench, 5/64” (in envelope) 1 E980004

A- 12E850229 SO239 Ant Connector Assembly Bag (in K3 RF Misc Bag) ILLUSTRATION DESCRIPTION QTY ELECRAFT PART NO. SO239 (UHF) Female Panel Mount Conne

A- 13E850241 Front Panel Hardware Bag ILLUSTRATION DESCRIPTION QTY ELECRAFT PART NO. Felt Washer 3 E700033 Knurled Nut (Phones Jack) 1 E700138 T

A- 14 E850341 VFO A Bezel Screws Envelope (in Front Panel Hardware Bag) Do not mix these screws up with other parts in the Front Panel Hardware bag.

A- 15E850350 K3 RF BSF Assembly (in box) RF Board ESD Sensitive 1 E850557 PA Jumper Block Assembly (pre-installed on RF board) 1 E850325

A- 16E850262 K3 Chassis Set (in box) ILLUSTRATION DESCRIPTION QTY ELECRAFT PART NO. Front Panel 1 E100209SS Top Cover 1 E100212 Rear Panel 1

8Tools and Test Equipment Required 1. #0 and #1 size Phillips screwdrivers. To avoid damaging screws and nuts, do not use a power screwdriver. Us

A- 17E850312 Side Panels ILLUSTRATION DESCRIPTION QTY ELECRAFT PART NO. Left Side Panel 1 E100210 Right Side Panel 1 E100211 E850313 Bottom Cov