The following is a Trouble Shooting exchange between myself and Don [W3FPR Wilhelm]
===================================================

Robert 'RC' Conley wrote:
40m transmitter alignment... 
no power out no adjustment holds  at 0.01
using internal meter w/DL-1  or WM-1 and DL-1

RX pre-alignment everything peaks nicely using N-gen

per trouble shooting checked R67/R68 okay
R66/R69 okay D9  1n5711 okay

checked T1, 2 , 3 seems right

resistance check in assembly part were good

found break in RFC7 1.5uh on first color band
could be culpert

I only have 10uh choke in junque box could I sub this to check if RFC break problem?

RC kc5wa

===================================================

RC,

The lowest value that the K2 power display goes to is 0.01, so what you
are seeing is normal when there is no power output.

RFC7 along with C104 is a series tuned circuit to drain off any residual
IF signal (4915 kHz) at the output side of the bandpass filter, so it
must be a proper value.  You can just remove it for now (until you can
get a proper replacement). and go on with your troubleshooting.  The
value for RFC7 is 15 uH.

I believe the best way to proceed is to go to the Transmit Signal
Tracing steps on Page 12 of Appendix E (Troubleshooting) and measure the
RF voltages at each stage.  The only other way is to simply check
everything because there are many potential causes for no transmit - it
is much easier to try to isolate it to a particular stage.  You could
try the DC voltage checks first to be certain you have power to each of
the transmit stages.

73,
Don W3FPR

===================================================

After completing the Voltage measurements on the RF Board (page 17 REv G)
Here are those reading that jumped out at me.
REF_PIN_VDC_READING
Q18...G...-1.0...0.0
..........S....2-3...2.388
..........D....6.3...7.662

Q20...S....0.0....0.0
..........G...8.0....7.57
..........D...0.0.....064

Q24...G...0.0...0.0
..........S...1.2....1.86
..........D...1.3...3.88

Q23 behind Control board
I wonder if I wound or installed  T1 T2 T3 incorrectly
RC

===================================================
RC,

Those voltages look to be within the realm of normalcy.  
A 10% variation from the 'typical' numbers is to be expected.

The drain voltage in Q24 is normal for a K2 that is not producing 
adequate power output - the drain voltage is how the K2 controls 
the power output (it changes the BFO injection level), and your K2 
is trying to drive harder to produce power output.

So bottom line - you have something broken in the transmitter chain - 
dig out the RF probe and do the RF voltage measurements so it can be 
isolated to a particular stage.


73,
Don W3FPR


===================================================

DON HERE ARE THE CHECKS
FOR THE TRANSMITTER
-------------------
page 12  Prep for Signal tracing
step 3
12v check D10 13.37vdc
Q5 case 13.34vdc
Q6 collector 13.34vdc
----
Basic voltage checks
Display  E13.3 i0.22
actual xmit mode V13.2v Current 0.60A
step 4
key down voltages on anodes
D7 should be about 8v actual 7.55
D6 near 0V actual 0.224
step 5
actual power in TUNE 0.01

Side tone works

ALC
step 3
Power Control test (VPWR line)
expected .07-2.5VDC actual 4.92vdc
step 4
 if VPWR reads too hi >4.5v
check components in RF detector...OKay

Transmit Mixer, Buffer, BPF, T-R sw
XMIT MIXER OUTPUT expected 0.016vrms..actual  0.054vrms
BUFFER OUTPUT expected 0.200vrms actual .468
BPF OUTPUT expected 0.030vrms actual 0.177vrms
T-R SWITCH #1 OUTPUTexpected 0.029vrms actual 0.176

PRE-DRIVER, DRIVER AND PA

PRE-DRIVER OUTPUT(collector/case of Q5) expected 0.120 vrms actual .794vrms
DRIVER INPUT B of Q6 expected 0.026vrms actual 0.218vrms
DRIVER OUTPUT C of Q6expected 1.8vrms actual 2.16vrms
PA INPUT Q7 expected 0.38 vrms actual 2.16 vrms
PA INPUT Q8 EXPECTED 0.38VRMS ACTUAL .001VRMS
RF DETECTOR INPUT expected 2.0 vrms actual 0.013vrms

PA TRANSISTOR TEST
Q7
+ lead on base
B-E expected 0.600k actual 2.640k
B-C expected 0.600k actual 2.929k

- lead on base
B-E expected 1.3k actual 2.252k
B-Cexpected > 3k actually starts at open and counts down

Q8
+ lead on base
B-E expected 0.600k actual 2.650k
B-C expected 0.600k actual 2.959k

- lead on base
B-E expected 1.3k actual 2.254k
B-C expected > 3k actually starts at open and counts down

I REALLY DON'T KNOW WHAT TO THINK....RC
===================================================
RC,

Either Q7 and Q8 are bad
*OR* there is something wrong between the Q6 collector and the bases of Q7/Q8

First check the 3-4 winding of T2
Then check R53, R54, R55, R56, C127, C128, RFC8 and RFC9.

Somewhere in that group of components or Q7/Q8 themselves you will find the problem.
Since you have no RF voltage on Q8 base and your transistor power off resistance 
checks seem to be off, it certainly could be bad transistors, but the other components 
could also cause that condition.  Also, your particular DMM may not yield the resistance 
measurements normal for most DMMs when doing a check of the diode base-emitter measurements, 
so it is hard to tell for sure.

Look carefully for a solder bridge on any of the components above.  
If you have excess solder (more than just a bit more than required to fill 
the thru-plated hole), remove the excess with solder wick and retest.

Those RF voltages that are higher than expected are normal for a K2 that is 
not delivering power output.  The K2 tries to increase the drive until it 
maxes out.  I note in your readings that all RF voltages are higher than 
expected through the Q6 collector, but the RF voltage on the Q8 base goes 
to zero (or nearly zero).

Since Q8 appears to be the troublesome component, you could remove Q8 and 
see if you get any RF output - if you do, then replacement of the PA transistors 
is in order.  Since this is a new kit, Scott will send you a pair if you send 
an email to parts@elecraft.com


===================================================

GM Don
I worked last night saw your message when I got in at 7:30. 
GIANTS were losing so went to bed  early 9:00
2:30am CST I could not sleep.

I checked the values of R53,R54,R55,R56 they are colour coded
correctly. and since I measure each resistor before installing them.
they were correct...

I checked the values C126,C127,C129,C130, RFC8,RFC9...
again marked correctly

Pulled the Heat sink (bottom cover) checked the Q7 & Q8 area using my
magnified lens (3.5 diopter) everything looked good EXCEPT T2 pins 3 &
4 ( they looked like toothpicks sticking up through doughnuts). I
wicked out (removed) T2 from the PCB and re-flowed ALL the joints to
be sure they  were good then cleaned the T2 holes

Most likely T2 was/is the issue. Bad components don't happen that
often. In all the Elecraft kits I've built (15+) I can only remember
one 8v regulator. Bad solder joints are more likely.

Now I'm going back to bed I'm not on call until the 22nd and I'll
rewind and install T2 later today. Then the heat sink and start over
checking for power. Thank You
RC

===================================================
Well It worked Don
I have rewound and installed T2
I now have 10+ watts output on 40m band verified with my Elecraft WM1
I was curious so cranked it up full bore and the WM1 says I have 15watts
display reads 13.6watts. Now I can finish it up

Bad solder joints will KILL IT every time.
Thank you my friend
RC kc5wa
===================================================