Kenwood TS-590 Service Manual

The Kenwood TS-590 is a high-performance HF/6m all-mode transceiver featuring 100W output power, advanced DSP technology, dual receive capability, built-in antenna tuner, and comprehensive connectivity options. This service manual covers technical specifications, block diagrams, alignment procedures, circuit descriptions, troubleshooting, and maintenance guidelines for qualified service technicians.

1. Technical Specifications 2. Block Diagrams 3. Circuit Descriptions 4. Alignment Procedures 5. Disassembly Instructions 6. Troubleshooting Guide 7. Parts List 8. PCB Layouts 9. Wiring Diagrams 10. Maintenance Schedule 11. Safety Precautions

Technical Specifications

Complete technical specifications and performance characteristics of the Kenwood TS-590 transceiver.

Parameter	Specification
Frequency Range	1.8-50 MHz (Amateur bands)
Modes	SSB, CW, AM, FM, Digital
Output Power	5-100W (adjustable)
Receiver System	Double conversion superheterodyne
IF Frequencies	69.450 MHz (1st), 10.695 MHz (2nd)
Sensitivity	0.13 μV for 10 dB S/N (SSB)
Selectivity	2.4 kHz, 1.8 kHz, 500 Hz, 250 Hz
Power Supply	13.8V DC ±15%
Current Drain	Receive: 1.5A, Transmit: 22A max
Dimensions	240W × 98H × 260D mm

Block Diagrams

System block diagrams showing signal flow and major functional blocks.

RF Unit Block Diagram: Shows antenna input through RF amplifier and mixer stages.
IF Unit Block Diagram: Details DSP processing and filter stages.
Audio Unit Block Diagram: Audio processing and amplifier circuits.
Power Supply Block Diagram: Voltage regulation and distribution.
Control Unit Block Diagram: Microprocessor and interface circuits.

WARNING! These diagrams are for qualified technicians only. Improper use may cause equipment damage.

Circuit Descriptions

Detailed circuit descriptions for each major section of the transceiver.

RF Circuit: Front-end filtering, RF amplifier, and first mixer.
IF Circuit: Crystal filters, IF amplifiers, and DSP processing.
PLL Circuit: Frequency synthesis and VCO control.
Audio Circuit: Microphone preamp, audio filters, and power amplifier.
Power Supply Circuit: Voltage regulators and protection circuits.

CAUTION! High voltages present in power supply section. Disconnect power before servicing.

Alignment Procedures

Step-by-step alignment procedures using proper test equipment.

PLL Alignment: VCO adjustment for proper lock range.
RF Alignment: Front-end tracking and sensitivity optimization.
IF Alignment: Filter alignment and DSP level settings.
Audio Alignment: Microphone gain and audio response.
Power Amplifier: Bias current and output power calibration.
Antenna Tuner: SWR sensing and matching network calibration.
Supported formats: Requires oscilloscope, frequency counter, power meter, dummy load.
Power Requirements: 13.8V DC stabilized power supply.

Disassembly Instructions

Proper disassembly sequence to access internal components.

Front Panel: Remove knobs, front bezel screws, and carefully separate control board.

Main Unit: Remove bottom cover, side panels, and shield covers in sequence.

Circuit Boards: RF unit, Control unit, Display unit, Power supply unit. Connectors: Carefully note cable routing and connector orientations. Mechanical Parts: Chassis, heat sinks, and mounting hardware.

Troubleshooting Guide

Systematic troubleshooting procedures for common problems.

Turn off unit and disconnect power before internal inspection.
Check external connections and power supply first.
Follow signal flow from antenna to speaker.
Use service mode for diagnostic information.

Tip: Always start with simplest solutions before complex disassembly.

Parts List

Complete list of replacement parts with manufacturer part numbers.

Semiconductors: Transistors, ICs, diodes with original part numbers.
Passive Components: Resistors, capacitors, inductors values and tolerances.
Mechanical Parts: Knobs, connectors, hardware with specifications.
PCB Assemblies: Complete board assemblies and sub-assemblies.
Optional Units: Accessory boards and interface units.
Skip: Reference designators and alternate part numbers provided.
Cross-reference: Manufacturer equivalents where applicable.
Availability: Current production status and replacement guidance.

WARNING! Use only Kenwood-approved replacement parts. Substitutions may affect performance.

PCB Layouts

Detailed printed circuit board layouts for all major assemblies.

Wiring Diagrams

Complete interconnecting wiring diagrams and cable harness details.

Unplug unit before inspecting internal wiring. Use appropriate test equipment only.

CAUTION! Verify all connections before applying power. Incorrect wiring may cause damage.

Maintenance Schedule

Recommended maintenance intervals and procedures.

FCC Part 97: Amateur radio service regulations apply. Copyright © Kenwood Corporation; all rights reserved. For technical support, contact authorized Kenwood service centers. For parts and service information, visit www.kenwood.com or contact your regional service manager.

Safety Precautions

Symptom	Possible Cause	Corrective Action
No power	Power supply/fuse	Check DC input; replace blown fuse; verify power supply voltage.
No transmit	Protection circuits	Check antenna SWR; verify PA bias; inspect protection diodes.
Poor reception	RF circuits/alignment	Check antenna connection; align front-end; verify IF stages.
Frequency error	PLL circuit	Check reference oscillator; verify VCO tuning voltage.
Display issues	Control circuit	Check ribbon cables; verify display voltages; reset microprocessor.

Reset: Factory reset procedure available in service mode.

Service: Authorized Kenwood service centers only; www.kenwood.com