Kenwood TS-590SG Service Manual

The Kenwood TS-590SG is a high-performance HF/6m all-mode transceiver featuring 100W output power, advanced DSP filtering, built-in automatic antenna tuner, dual receive capability, and comprehensive connectivity options. This service manual provides detailed technical information for maintenance, repair, and service procedures. Below are key sections covering specifications, block diagrams, alignment procedures, troubleshooting, and schematics.

1. Technical Specifications 2. Block Diagrams 3. Alignment Procedures 4. Circuit Descriptions 5. Disassembly Instructions 6. Troubleshooting Guide 7. Parts List 8. Schematic Diagrams 9. PCB Layouts 10. Test Points 11. Service Notes

Technical Specifications

Complete technical specifications for the Kenwood TS-590SG transceiver.

ParameterSpecification
Frequency Coverage1.8-50 MHz (Amateur bands)
ModesSSB, CW, AM, FM, RTTY, PSK
Output Power5-100W (adjustable)
Receiver SystemDouble conversion superheterodyne
IF Frequencies1st IF: 69.011 MHz, 2nd IF: 24 kHz
SensitivitySSB/CW: 0.25 μV for 10 dB S/N
SelectivityDSP filters: 0.3-4.0 kHz (SSB), 0.05-4.0 kHz (CW)
Power Supply13.8V DC ±15% (negative ground)
Current ConsumptionReceive: 2A max, Transmit: 22A max
Dimensions280(W) × 105(H) × 280(D) mm
WeightApprox. 5.5 kg

Block Diagrams

System block diagrams showing signal flow and major components.

  1. RF Unit Block Diagram: Shows antenna input through RF amplifier and mixer stages.
  2. IF Unit Block Diagram: Details 1st and 2nd IF processing with DSP sections.
  3. Audio Unit Block Diagram: Audio processing and amplification stages.
  4. Control Unit Block Diagram: Microprocessor control and interface circuits.
  5. Power Supply Block Diagram: Voltage regulation and distribution.

WARNING! High voltages present in power supply section. Exercise extreme caution when servicing.

Alignment Procedures

Step-by-step alignment procedures for optimal performance.

  1. PLL Alignment: Adjust VCO and reference oscillators for proper locking.
  2. IF Alignment: Set IF amplifier stages and filter responses.
  3. RF Alignment: Adjust RF amplifier and mixer for proper gain and matching.
  4. Audio Alignment: Set audio levels and filter responses.
  5. Power Amplifier Alignment: Adjust bias and output matching networks.

CAUTION! Use proper test equipment and follow procedures exactly. Incorrect alignment may damage components.

Circuit Descriptions

Disassembly Instructions

Step-by-step disassembly procedure for service access.

Tools Required: Phillips screwdrivers, Torx drivers, anti-static equipment.

  1. Remove top cover: Remove 6 screws from top panel.
  2. Remove bottom cover: Remove 4 screws from bottom panel.
  3. Remove front panel: Disconnect ribbon cables and remove mounting screws.
  4. Remove main board: Disconnect all cables and remove mounting hardware.
  5. Remove RF unit: Carefully disconnect RF connections and remove shield covers.

Tip: Document cable positions and take photos during disassembly.

Troubleshooting Guide

Systematic troubleshooting procedures for common problems.

SymptomPossible CauseCorrective Action
No powerPower supply faultCheck DC input, fuses F1/F2, regulator ICs
No transmitPA circuit faultCheck PA bias, driver stages, protection circuits
No receiveRF/IF circuit faultCheck RF amplifier, mixers, IF stages
Poor sensitivityRF front-end faultCheck RF amplifier, antenna relay, filters
Frequency errorPLL faultCheck reference oscillator, VCO, PLL IC
Display problemsControl circuit faultCheck display connections, control CPU

Parts List

Complete parts list with component designations and specifications.

Part No.DescriptionQtyRemarks
X10-1230-01Main PCB Assembly1Complete assembly
X20-1450-01Front Panel Assembly1With display
X30-1670-01RF Unit Assembly1HF/6m section
X40-1890-01Power Supply PCB1Regulator section
X50-2010-01PA Unit Assembly1Final amplifier
IC1CPU: TMP87C800F1Main controller
IC2PLL: MB15E03SL1Frequency synthesizer
Q1RF Transistor: 2SC42261RF amplifier
F1, F2Fuse: 15A2Power input

Schematic Diagrams

Complete schematic diagrams for all circuit sections.

  1. Main Unit Schematic: Complete circuit diagram of main board.
  2. RF Unit Schematic: RF amplifier, mixer, and filter circuits.
  3. PLL Schematic: Frequency synthesizer and reference circuits.
  4. Audio Unit Schematic: Audio processing and amplifier circuits.
  5. Power Supply Schematic: Voltage regulation and distribution.
  6. Control Unit Schematic: Microprocessor and interface circuits.

WARNING! Schematics contain proprietary information. For authorized service use only.

PCB Layouts

Printed circuit board layouts and component placement diagrams.

Test Points

Test point locations and expected voltage/waveform measurements.

Test PointLocationNormal ValueRemarks
TP1Main PCB near IC1+5V DCCPU power supply
TP2RF Unit near Q1+8V DCRF amplifier supply
TP3PLL section2.5V P-PVCO control voltage
TP4Audio output1V RMSAudio output level
TP5Power supply+13.8V DCMain DC input
TP6IF section69.011 MHz1st IF frequency

Service Notes

Important service notes and technical updates.

Firmware Updates: Latest firmware available from Kenwood website. Update via CI-V interface.

Common Issues: - PA bias drift: Check thermal compensation circuits - Display fading: Replace backlight LEDs - Memory loss: Check backup battery - Tuner faults: Check relay contacts and matching networks

Safety: Always disconnect power before servicing. Use anti-static precautions. High voltages present in PA section.

Service Support: Contact Kenwood technical support for assistance: [email protected]

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