Simon,
This makes me wonder if your TX and RX are on the same frequency. Does the rig have an RIT perhaps? GL
73,
Rob WA9UAA

The 'In Depth Manual" spends a lot of time on the design philosophy and why the rig was designed the way it was. Please give it good read, especially if you are not going to use an amplifier.
Best,
Rob WA9UAA

Hi Jim,
If you can work backwards and identify the part you will be able to discover the mix. I would doubt they would be any good at HF but don't really know. The other issue is the weight. 
The bead balun kits sold by Palomar Engineers are quite good and not expensive.
73,
Rob WA9UAA

Good Day,
The error would seem to indicate that the processor in the radio is not passing self check. ie. it's the processor, something connected to it, or an interrupt being set (sent to the processor that halts all other activity). HTH
73,
Rob WA9UAA

Good Day,
I have been very well impressed with my Kenwood TS-590. With DATA on in SSB mode I have a choice of 1KHz through 2 KHz in 1 KHz increments and a couple of center frequencies for RTTY. The bandwidth runs from 2500 Hz down to about 50 Hz. It does a very good job. It is possible to run HRD and 1 USB cable between the rig and computer and do everything HRD does.
73,
Rob WA9UAA

Glenayre used to use .1 Ohm 1% resistors in both discrete and SMT components for TX current monitoring. I even had to change a few as they were out of spec. 
73,
Rob WA9UAA

I have felt it was an advantage to run my TS 480 HX at 100 watts because I'm not stressing the system to it's maximum output. Then of course, the extra power is there if you need it.
Best,
Rob WA9UAA

I use my MFJ 259B to preset my antenna tuner then use the rig at 30 watts to touch up the tuner. This greatly reduces the tuning time at any power level. 
Best,
Rob

Hi OM,
One of the best differences between the two rigs is the dedicated RF gain control on the TS 590 followed by the adjustable band pass DSP filters.  I'd say the range adjustable AGC is high on my list as well compared to the TS 480s Slow- Fast -Off settings. In my book the Adjustable Notch is next; though, not least, are the Band Stacking Registers. The noise reduction seems about the same,  I have had some power line noise here but not when I had TS 480 on the bench. The noise reduction worked best on CW. The receiver itself is, in comparison, the largest improvement. HTH
Best,
Rob 

Dan,
In loops, what you want is a full wave length loop up as high as possible. Granted, a full wave on 80 meters is 1005/ 3.5 mhz. which yields a circumference of 287 feet. The shape can be about any thing you can come up with; though, the greater the area inside the loop the better. A loop cut for 75 meters and using the AH-4 will get you on all the HF bands from 80 meters up through 10 meters. GL HTH
73,
Rob WA9UAA

Noting your test tech salery, you must have never worked for Glenayre Electronics!
Best,
Rob WA9UAA

Kim,
The real test is going to be if you can hear the noise on 80 Meters at a high enough level in order to null it out. My first answer is try it and see. You also might try a small tuner at the noise input of the MFJ 1026 and tune for maximum noise.
73,
Rob WA9UAA

One way to reduce losses is to put the tuner at the antenna. A coax fed remote tuner using a reversible 'L' matching system at the feed point would be efficient. 
73,
Rob WA9UAA

Hi OM,
There is a chance that the leads to the paddle are bypassed to ground to prevent stray charges from messing with the logic gates. The effect you have seen tells me that those capacitors are reaching the end of their life. A replacement is in order, a general recapping is recommended.
73,
Rob WA9UAA