Pioneer KEX-M8196ZT, KEX-M8396ZT Service Manual

ORDER NO.

CRT2393

PUB. NO. CRT2393

AUDIO SYSTEM

HEAD UNIT

Manufactured for TOYOTA
by PIONEER CORPORATION

ES300

VEHICLE DESTINATION PRODUCED AFTER ID No. TOYOTA PART No. PIONEER MODEL No.
LEXUS ES300 U.S.A.,CANADA August 1999 P1715 86120-33320 KEX-M8196ZT/UC

KEX-M8196ZT-91/UC

LEXUS ES300 MIDDLE EAST August 1999 P2724 86120-33241 KEX-M8396ZT-02/ES

KEX-M8396ZT-92/ES

ORDER NO.

CRT2456

PUB. NO.

CRT2456

AUDIO SYSTEM

HEAD UNIT

Manufactured for TOYOTA

by PIONEER CORPORATION

ES300

VEHICLE DESTINATION PRODUCED AFTER ID No. TOYOTA PART No. PIONEER MODEL No.

LEXUS ES300 MIDDLE EAST January 2000 P2726 86120-33390 KEX-M8396ZT-03/ES

KEX-M8396ZT-93/ES

KEX-M8396ZT-03,M8396ZT-93

NOTE:

- KEX-M8396ZT-93/ES is supplementary genuine part for a TOYOTA vehicle, and a Pioneer product for

recycling stock.

- Supplementary model is identical to the original except for the addition of following items.

Part No.

Description KEX-M8396ZT-93/ES

Polyethylene Bag CEG1026

Carton CHA2025

Contain Box CHL4051

Protector CHP1888,1889

- This service manual should be used together with the following manual(s):

Model Order No. Mech. Module Remarks

CX-529 CRT1507 2L Cassette Mech. Module:Mech.Description, Disassembly

KEX-M8396ZT-02/ES CRT2393

EXPLODED VIEWS AND PARTS LIST

EXTERIOR(Page 4)

- EXTERIOR SECTION PARTS LIST

Part No.

Mark No. Description KEX-M8396ZT-02/ES KEX-M8396ZT-03/ES

48 Grille Unit CXB5281 CXB5860
49 Door CAT2126 CAT2163
58 Panel CNS5175 CNS5954

PIONEER CORPORATION 4-1, Meguro 1-Chome, Meguro-ku, Tokyo 153-8654, Japan

PIONEER ELECTRONICS SERVICE INC. P.O.Box 1760, Long Beach, CA 90801-1760 U.S.A.
PIONEER ELECTRONIC [EUROPE] N.V. Haven 1087 Keetberglaan 1, 9120 Melsele, Belgium
PIONEER ELECTRONICS ASIACENTRE PTE.LTD. 253 Alexandra Road, #04-01, Singapore 159936

C PIONEER CORPORATION 1999

K-ZZS. DEC. 1999 Printed in Japan

2

KEX-M8196ZT,M8196ZT-91,M8396ZT-02,M8396ZT-92

- Dolby noise reduction manufactured under license from Dolby Laboratories Licensing Corporation.
"Dolby" and the double-D symbol are trademarks of Dolby Laboratories Licensing Corporation.

P 1 7 1 5

NOTE:

- KEX-M8196ZT-91/UC and KEX-M8396ZT-92/ES are supplementary genuine part for a TOYOTA vehicle,
and a Pioneer product for recycling stock.

- Supplementary model is identical to the original except for the addition of following items.

Part No.
Description KEX-M8196ZT-91/UC KEX-M8396ZT-92/ES
Polyethylene Bag CEG1026 CEG1026
Carton CHA2025 CHA2025
Contain Box CHL3842 CHL3841
Protector CHP1888,1889 CHP1888,1889

CONTENTS

1. SAFETY INFORMATION ............................................3

2. EXPLODED VIEWS AND PARTS LIST.......................4

3. BLOCK DIAGRAM AND SCHEMATIC DIAGRAM...10

4. PCB CONNECTION DIAGRAM ................................28

5. ELECTRICAL PARTS LIST ........................................45

6. ADJUSTMENT..........................................................56

7. GENERAL INFORMATION .......................................60

7.1 TEST MODE ......................................................60

7.2 ERROR NUMBERS INDICATION......................62

7.3 DIAGNOSIS.......................................................63

7.3.1 DIAGNOSIS MODE .................................63

7.3.2 DISASSEMBLY ........................................67

7.3.3 CONNECTOR FUNCTION DESCRIPTION ..68

7.4 PARTS................................................................69

7.4.1 IC ..............................................................69

7.4.2 DISPLAY...................................................71

7.5 SYSTEM BLOCK DIAGRAM.............................72

8. OPERATIONS AND SPECIFICATIONS.....................73

KEX-M8196ZT/UC

- This service manual should be used together with the following manual(s):

Model Order No. Mech. Module Remarks
CX-529 CRT1507 2L Cassette Mech. Module:Circuit Description, Mech.Description, Disassembly

P 2 7 2 1

KEX-M8396ZT-02/ES

ID No. P1715

ID No. P2724

3

KEX-M8196ZT,M8196ZT-91,M8396ZT-02,M8396ZT-92

1. SAFETY INFORMATION

This service manual is intended for qualified service technicians; it is not meant for the casual do-it-yourselfer.
Qualified technicians have the necessary test equipment and tools, and have been trained to properly and safely repair
complex products such as those covered by this manual.
Improperly performed repairs can adversely affect the safety and reliability of the product and may void the warranty.
If you are not qualified to perform the repair of this product properly and safely; you should not risk trying to do so
and refer the repair to a qualified service technician.

4

KEX-M8196ZT,M8196ZT-91,M8396ZT-02,M8396ZT-92

2. EXPLODED VIEWS AND PARTS LIST

2.1 EXTERIOR

- KEX-M8196ZT/UC

5

KEX-M8196ZT,M8196ZT-91,M8396ZT-02,M8396ZT-92

Mark No. Description Part No. Mark No. Description Part No.

- EXTERIOR SECTION PARTS LIST

1 Screw BMZ26P050FMC
2 Screw BMZ30P050FMC
3 Case CNB1980
4 Insulator CNM5987
5 Spacer CNM5293

6 Main Unit CWM6072
7 Chassis Unit CXB3159
8

Cassette Mechanism ModuleEXK3240

9 Screw IMS30P050FMC

10 MIC(MIC351) CPM1011

11 Screw BMZ30P060FMC
12 Screw(M3x5) CBA1409
13 Connector CDE5764
14 Connector(CN901) CKM1311
15 Plug(CN902) CKM1221

16 Connector(CN751) CKS2826
17 Connector(CN401) CKS3578
18 Connector(CN652,653) CKS3009
19 Plug(CN701,702) CKS3156
20 Antenna Jack(CN651) CKX1024

21 Holder(CN1) CNC2218
22 Holder CNC4981
23 Holder CNC7716
24 Holder CNC6058
25 •••••

26 FM/AM Tuner Unit CWE1523
27 Screw BPZ26P100FMC
28 Button(UP,DOWN) CAC5889
29 Button(EJECT) CAC6181
30 Button(1,2) CAC6177

31 Button(3,4) CAC6178
32 Button(5,6) CAC6179
33 Button(SCAN,P.SCAN) CAC6180
34 Button(AM) CAC6182
35 Button(FM1/2) CAC6019

36 Button(TAPE) CAC6020
37 Button(CD) CAC6021
38 Holder CNV5561
39 Holder CNV5560
40 Holder CNV3647

41 Holder CNV3648
42 LCD Unit CWM6074
43 Keyboard Unit CWM6073
44 Knob Unit CXB3157
45 Spring CBL-108

46 Knob Unit CXB3158
47 Spring CBL-108
48 Grille Unit CXB3160
49 Door CAT1990
50 Spring CBH1371

51 Cushion CNM6317
52 Earth Plate CNC8383
53 Rubber CNV5558
54 Rubber CNV5556
55 Rubber CNV5557

56 Holder CNC6774
57 Cushion CNM6411
58 Panel CNS5175
59 Screw BPZ20P060FMC
60 LCD CAW1528

61 Connector(CN1905) CKS2757
62 Holder CNV5559
63 Connector(CN1901,1902) CKS2666
64 Connector(CN1904) CKS2757
65 IC(IC921) PA2024A

66 Transistor(Q958,959) 2SB942
67 Volume(VR901-905) CCS1119
68 Volume(VR1901) CCS1226

NOTE:

- Parts marked by “*” are generally unavailable because they are not in our Master Spare Parts List.

- Screws adjacent to

∇ mark on the product are used for disassembly.

-

KEX-M8196ZT/UC

6

KEX-M8196ZT,M8196ZT-91,M8396ZT-02,M8396ZT-92

- KEX-M8396ZT-02/ES

7

KEX-M8196ZT,M8196ZT-91,M8396ZT-02,M8396ZT-92

Mark No. Description Part No. Mark No. Description Part No.

1 Screw BMZ26P050FMC
2 Screw BMZ30P050FMC
3 Case CNB1980
4 Insulator CNM5987
5 Spacer CNM5293

6 Main Unit CWM7069
7 Chassis Unit CXB3159
8

Cassette Mechanism ModuleEXK3240

9 Screw IMS30P050FMC

10 MIC(MIC351) CPM1011

11 Screw BMZ30P060FMC
12 Screw(M3x5) CBA1409
13 Connector CDE5764
14 Connector(CN901) CKM1311
15 Plug(CN902) CKM1221

16 Connector(CN751) CKS2826
17 Connector(CN401) CKS3578
18 Connector(CN652,653) CKS3009
19 Plug(CN701,702) CKS3156
20 Antenna Jack(CN651) CKX1024

21 Holder(CN1) CNC2218
22 Holder CNC4981
23 Holder CNC7716
24 Holder CNC6058
25 Shield Unit CXB3865

26 Tuner Unit CWE1457
27 Screw BPZ26P100FMC
28 Button(UP,DOWN) CAC5889
29 Button(EJECT) CAC6181
30 Button(1,2) CAC6177

31 Button(3,4) CAC6178
32 Button(5,6) CAC6179
33 Button(SCAN,P.SCAN) CAC6180
34 Button(AM/SW) CAC6183
35 Button(FM) CAC6022

36 Button(TAPE) CAC6020
37 Button(CD) CAC6021
38 Holder CNV5561
39 Holder CNV5560
40 Holder CNV3647

41 Holder CNV3648
42 LCD Unit CWM7071
43 Keyboard Unit CWM7070
44 Knob Unit CXB3157
45 Spring CBL-108

46 Knob Unit CXB3158
47 Spring CBL-108
48 Grille Unit CXB5281
49 Door CAT2126
50 Spring CBH1371

51 •••••
52 •••••
53 Rubber CNV5558
54 Rubber CNV5556
55 Rubber CNV5557

56 Holder CNC6122
57 Cushion CNM6411
58 Panel CNS5175
59 Screw BPZ20P060FMC
60 LCD CAW1528

61 Connector(CN1905) CKS2757
62 Holder CNV5559
63 Connector(CN1901,1902) CKS2666
64 Connector(CN1904) CKS2757
65 IC(IC921) PA2024A

66 Transistor(Q958,959) 2SB942
67 Volume(VR901-905) CCS1119
68 Volume(VR1901) CCS1226

-

EXTERIOR SECTION PARTS LIST

- KEX-M8396ZT-02/ES

8

KEX-M8196ZT,M8196ZT-91,M8396ZT-02,M8396ZT-92

2.2 CASSETTE MECHANISM MODULE

9

KEX-M8196ZT,M8196ZT-91,M8396ZT-02,M8396ZT-92

1 Screw BSZ20P040FMC
2 Washer CBF1037
3 Washer CBF1038
4 Washer CBG1003
5 Deck Unit EWM1008

6 Screw(M2×5) EBA1028
7 Screw(M2×2.5) EBA1037
8 Spring EBH1531
9 Spring EBH1589

10 Cushion ENM1034

11 Spring EBH1515
12 Spring EBH1587
13 Spring EBH1517
14 Spring EBH1547
15 Spring EBH1519

16 Spring EBH1537
17 Cord EDD1015
18 Photo-reflector(EGN2, 3) EGN1004
19 Photo-Interrupter(EGN1) EGN1005
20 Roller ENR1031

21 Shaft ELA1362
22 Roller ELA1348
23 Arm ENC1416
24 Arm ENC1397
25 Guide ENC1398

26 Holder ENC1417
27 Lever ENC1449
28 Arm ENC1401
29 Roller ENR1027
30 Belt ENT1027

31 Gear ENV1347
32 Collar ENV1508
33 Gear ENV1350
34 Flywheel ENV1410
35 Worm Gear ENV1439

36 Worm Wheel ENV1440
37 Gear ENR1028
38 Lever ENV1455
39 Arm ENV1445
40 Gathering PCB ENX1029

41 Gathering PCB ENX1041
42 Switch(S1) ESG1004
43 Motor Unit(M2) EXA1485
44 Chassis Unit EXA1494
45 Pinch Roller Unit EXA1472

46 Pinch Roller Unit EXA1473
47 Reel Unit EXA1484
48 Head Base Unit EXA1434
49 Lever Unit EXA1438
50 Gear Unit EXA1436

51 Frame Unit EXA1476
52 Lever Unit EXA1425
53 Head Assy(HD1) EXA1481
54 Motor Unit(M1) EXA1497
55 Washer HBF-179

56 Screw BMZ20P022FMC
57 Resistor(R1) RD1/4HM181J
58 Washer YE20FUC
59 Connector(CN251) CKS1711
60 Connector(CN252) CKS2127

61 Connector(CN253) CKS2129
62 •••••
63 Spring EBH1545
64 Switch(S2) ESG1004
65 Roller ENR1023

66 Cover ENC1412
67 Cover ENC1413
68 Spring EBH1546
69 Washer EBE1008
70 Washer YE15FUC

71 Lever Unit EXA1424
72 Spring EBL1026
73 Screw(M2×2) CBA1250
74 Capacitor(C1) CEA4R7M35LS2
75 Bracket ENC1472

76 Inductor(L1) ETH0001
77 Cushion ENM1036

Mark No. Description Part No. Mark No. Description Part No.

- CASSETTE MECHANISM MODULE SECTION PARTS LIST

10

KEX-M8196ZT,M8196ZT-91,M8396ZT-02,M8396ZT-92

A

1

234

B

C

D

12

34

3. BLOCK DIAGRAM AND SCHEMATIC DIAGRAM

3.1 BLOCK DIAGRAM (KEX-M8196ZT/UC)

11

KEX-M8196ZT,M8196ZT-91,M8396ZT-02,M8396ZT-92

5

6

7

8

A

B

C

D

5

6

7

8

CN701

CN702

CN401

CN751

CN902

PEE

AVC-LAN

ASL

KEYBOARD UNIT

D

B

TUNER CONTROL PCB

F

DECK UNIT

CN652

CN653

CN251

CN1901

CN1902

TAPE : -7.8dBs
(1kHz 0dB)

FM : -30dBs
AM : -30dBs

CD : +8.6dBs (1kHz 0dB)

R411
R412

1R8K
1R8K

470
470

UC

ES

M8396ZT-02/ES ONLY

A

MOTHER PCB

50K(W)

50K(W)

50K(W)

50K(W)

50K(W)

12

KEX-M8196ZT,M8196ZT-91,M8396ZT-02,M8396ZT-92

A

1

234

B

C

D

12

34

3.2 OVERALL CONNECTION DIAGRAM(GUIDE PAGE)

Note: When ordering service parts,be sure to refer to "EXPLODED VIEWS AND PARTS LIST"or"ELECTRICAL PARTS

LIST".

A-a A-b

A-a

A-b

A-b

A-a

Large size

SCH diagram

Guide page

Detailed page

A-a

A

CN1

CN901

RESET

TSW AMP

ANT

MUTE

8V REGURATOR

5V REGURATOR

8V REGURATOR

ILL DRIVELAMP DRIVE

E-VOL

EARTH PLATE

FM : -15.9dBs
AM : -14.3dBs
TAPE : -4.5dBs
CD : +5.0dBs

FM : -16.4dBs
AM : -14.9dBs
TAPE : -5.1dBs
CD : +4.4dBs

M8396ZT-02/ES ONLY

M8396ZT-02/ES ONLY

125µH

: The power supply is shown with the marked box.

Main Unit
Consists of

Mother PCB
Tuner Control PCB

13

KEX-M8196ZT,M8196ZT-91,M8396ZT-02,M8396ZT-92

5

6

7

8

A

B

C

D

5

6

7

8

A-b

A

CN701

CN702

CN401

CN751

RESET

KEYBOARD UNIT

D

B

TUNER CONTROL PCB

UNIT

CN652

CN653

CN1901

CN1902

TAPE : -7.8dBs

(1kHz 0dB)

FM : -30dBs

AM : -30dBs

M8396ZT-02/ES ONLY

A

MOTHER PCB

14

KEX-M8196ZT,M8196ZT-91,M8396ZT-02,M8396ZT-92

A

1

234

B

C

D

12

34

A-a

A-b

A-a

1

2

3

4

CN902

PEE

AVC-LAN

ASL

E-V

F

DECK UNI

CN251

FM : -15.9dBs

AM : -14.3dBs

TAPE : -4.5dBs

CD : +5.0dBs

CD : +8.6dBs (1kHz 0dB)

R411

R412

1R8K

1R8K

470

470

UC

ES

50K(W)

50K(W)

50K(W)

50K(W)

50K(W)

15

KEX-M8196ZT,M8196ZT-91,M8396ZT-02,M8396ZT-92

5

6

7

8

A

B

C

D

5

6

7

8

A-a

A-b

A-a

5

6

TSW AMP

ANT

MUTE

8V REGURATOR

8V REGURATOR

ILL DRIVELAMP DRIVE

M8396ZT-02/ES ONLY

Main Unit

Consists of

Mother PCB

Tuner Control PCB

16

KEX-M8196ZT,M8196ZT-91,M8396ZT-02,M8396ZT-92

A

1

234

B

C

D

12

34

A-a

A-b

A-b

1

2

3

4

17

KEX-M8196ZT,M8196ZT-91,M8396ZT-02,M8396ZT-92

5

6

7

8

A

B

C

D

5

6

7

8

CN1

CN901

5V REGURATOR

E-VOL

EARTH PLATE

FM : -16.4dBs

AM : -14.9dBs

TAPE : -5.1dBs

CD : +4.4dBs

M8396ZT-02/ES ONLY

125µH

: The power supply is shown with the marked box.

A-a

A-b

A-b

5

6

CN653

CN652

TUNER CONTROL PCB

A

CN401

A

CN401

FM : -30dBs
AM : -30dBs

R661
C666

33K

R22

27K

R022

UC

ES

C680

R039

R015

*** ***

***

B

M8396ZT-02/ES

R651

0R0

M8396ZT-02/ES ONLY

M8196ZT/UC ONLY

MAIN

ANTENNA

SUB

ANTENNA

FM DIVERSITY

18

KEX-M8196ZT,M8196ZT-91,M8396ZT-02,M8396ZT-92

A

1

234

B

C

D

12

34

3.3 TUNER CONTROL PCB

B

19

KEX-M8196ZT,M8196ZT-91,M8396ZT-02,M8396ZT-92

5

6

7

8

A

B

C

D

5

6

7

8

FM/AM TUNER UNIT (KEX-M8196ZT/UC)

TUNER UNIT (KEX-M8396ZT-02/ES)

C
C

FM : -26dBs
AM : -16dBs
(400Hz 30%)

M8396ZT-02/ES ONLY

M8396ZT-02/ES ONLY

M8396ZT-02/ES ONLY

C649
C650

R033
R033

R022

R022

UC

ES

***

***

R512
R513

4R7K

0R0

2R2K
2R2K

UC

ES

***

***

C664
C665

3900P
3900P

R018
R018

***

***

Main Unit
Consists of

Mother PCB
Tuner Control PCB

B

20

KEX-M8196ZT,M8196ZT-91,M8396ZT-02,M8396ZT-92

A

1

234

B

C

D

12

34

B

39K

56K

C

FM/AM TUNER UNIT

3.4 FM/AM TUNER UNIT (KEX-M8196ZT/UC)

C

21

KEX-M8196ZT,M8196ZT-91,M8396ZT-02,M8396ZT-92

5

6

7

8

A

B

C

D

5

6

7

8

C

B