Pioneer KEX-M8196ZT, KEX-M8396ZT Service Manual

5 (1)

Service

Manual

ES300 AUDIO SYSTEM HEAD UNIT

ORDER NO.

CRT2393

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

Manufactured for TOYOTA

 

by PIONEER CORPORATION

PUB. NO. CRT2393

Service

Manual

ES300 AUDIO SYSTEM HEAD UNIT

ORDER NO.

CRT2456

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

Manufactured for TOYOTA

 

by PIONEER CORPORATION

PUB. NO. CRT2456

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

 

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

KEX-M8196ZT/UC

KEX-M8396ZT-02/ES

P 1 7 1 5

P 2 7 2 1

 

ID No. P1715

ID No. P2724

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

- 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

- Dolby noise reduction manufactured under license from Dolby Laboratories Licensing Corporation.

"Dolby" and the double-D symbol are trademarks of Dolby Laboratories Licensing Corporation.

CONTENTS

1.

SAFETY INFORMATION ............................................

3

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

60

2.

EXPLODED VIEWS AND PARTS LIST .......................

4

7.1

TEST MODE ......................................................

60

3. BLOCK DIAGRAM AND SCHEMATIC DIAGRAM ...

10

7.2

ERROR NUMBERS INDICATION......................

62

4.

PCB CONNECTION DIAGRAM ................................

28

7.3

DIAGNOSIS .......................................................

63

5.

ELECTRICAL PARTS LIST ........................................

45

 

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

63

6.

ADJUSTMENT..........................................................

56

 

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

2

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.

3

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

2. EXPLODED VIEWS AND PARTS LIST

2.1 EXTERIOR

- KEX-M8196ZT/UC

4

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

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.

-EXTERIOR SECTION PARTS LIST

-KEX-M8196ZT/UC

Mark No. Description

Part No.

Mark No. Description

Part No.

1

Screw

BMZ26P050FMC

 

36

Button(TAPE)

CAC6020

2

Screw

BMZ30P050FMC

37

Button(CD)

CAC6021

3

Case

CNB1980

38

Holder

CNV5561

4

Insulator

CNM5987

39

Holder

CNV5560

5

Spacer

CNM5293

40

Holder

CNV3647

6

Main Unit

CWM6072

41

Holder

CNV3648

7

Chassis Unit

CXB3159

42

LCD Unit

CWM6074

8

Cassette Mechanism ModuleEXK3240

43

Keyboard Unit

CWM6073

9

Screw

IMS30P050FMC

44

Knob Unit

CXB3157

10

MIC(MIC351)

CPM1011

45

Spring

CBL-108

11

Screw

BMZ30P060FMC

46

Knob Unit

CXB3158

12

Screw(M3x5)

CBA1409

47

Spring

CBL-108

13

Connector

CDE5764

48

Grille Unit

CXB3160

14

Connector(CN901)

CKM1311

49

Door

CAT1990

15

Plug(CN902)

CKM1221

50

Spring

CBH1371

16

Connector(CN751)

CKS2826

51

Cushion

CNM6317

17

Connector(CN401)

CKS3578

52

Earth Plate

CNC8383

18

Connector(CN652,653)

CKS3009

53

Rubber

CNV5558

19

Plug(CN701,702)

CKS3156

54

Rubber

CNV5556

20

Antenna Jack(CN651)

CKX1024

55

Rubber

CNV5557

21

Holder(CN1)

CNC2218

56

Holder

CNC6774

22

Holder

CNC4981

57

Cushion

CNM6411

23

Holder

CNC7716

58

Panel

CNS5175

24

Holder

CNC6058

59

Screw

BPZ20P060FMC

25

•••••

 

60

LCD

CAW1528

26

FM/AM Tuner Unit

CWE1523

61

Connector(CN1905)

CKS2757

27

Screw

BPZ26P100FMC

62

Holder

CNV5559

28

Button(UP,DOWN)

CAC5889

63

Connector(CN1901,1902)

CKS2666

29

Button(EJECT)

CAC6181

64

Connector(CN1904)

CKS2757

30

Button(1,2)

CAC6177

65

IC(IC921)

PA2024A

31

Button(3,4)

CAC6178

66

Transistor(Q958,959)

2SB942

32

Button(5,6)

CAC6179

67

Volume(VR901-905)

CCS1119

33

Button(SCAN,P.SCAN)

CAC6180

68

Volume(VR1901)

CCS1226

34

Button(AM)

CAC6182

 

 

 

 

35

Button(FM1/2)

CAC6019

 

 

 

 

5

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

- KEX-M8396ZT-02/ES

6

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

-EXTERIOR SECTION PARTS LIST

-KEX-M8396ZT-02/ES

Mark No. Description

Part No.

Mark No. Description

Part No.

 

 

 

 

 

 

 

1

Screw

BMZ26P050FMC

36

Button(TAPE)

CAC6020

2

Screw

BMZ30P050FMC

37

Button(CD)

CAC6021

3

Case

CNB1980

38

Holder

CNV5561

4

Insulator

CNM5987

39

Holder

CNV5560

5

Spacer

CNM5293

40

Holder

CNV3647

6

Main Unit

CWM7069

41

Holder

CNV3648

7

Chassis Unit

CXB3159

42

LCD Unit

CWM7071

8

Cassette Mechanism ModuleEXK3240

43

Keyboard Unit

CWM7070

9

Screw

IMS30P050FMC

44

Knob Unit

CXB3157

10

MIC(MIC351)

CPM1011

45

Spring

CBL-108

11

Screw

BMZ30P060FMC

46

Knob Unit

CXB3158

12

Screw(M3x5)

CBA1409

47

Spring

CBL-108

13

Connector

CDE5764

48

Grille Unit

CXB5281

14

Connector(CN901)

CKM1311

49

Door

CAT2126

15

Plug(CN902)

CKM1221

50

Spring

CBH1371

16

Connector(CN751)

CKS2826

51

•••••

 

17

Connector(CN401)

CKS3578

52

•••••

 

18

Connector(CN652,653)

CKS3009

53

Rubber

CNV5558

19

Plug(CN701,702)

CKS3156

54

Rubber

CNV5556

20

Antenna Jack(CN651)

CKX1024

55

Rubber

CNV5557

21

Holder(CN1)

CNC2218

56

Holder

CNC6122

22

Holder

CNC4981

57

Cushion

CNM6411

23

Holder

CNC7716

58

Panel

CNS5175

24

Holder

CNC6058

59

Screw

BPZ20P060FMC

25

Shield Unit

CXB3865

60

LCD

CAW1528

26

Tuner Unit

CWE1457

61

Connector(CN1905)

CKS2757

27

Screw

BPZ26P100FMC

62

Holder

CNV5559

28

Button(UP,DOWN)

CAC5889

63

Connector(CN1901,1902)

CKS2666

29

Button(EJECT)

CAC6181

64

Connector(CN1904)

CKS2757

30

Button(1,2)

CAC6177

65

IC(IC921)

PA2024A

31

Button(3,4)

CAC6178

66

Transistor(Q958,959)

2SB942

32

Button(5,6)

CAC6179

67

Volume(VR901-905)

CCS1119

33

Button(SCAN,P.SCAN)

CAC6180

68

Volume(VR1901)

CCS1226

34

Button(AM/SW)

CAC6183

 

 

 

 

35

Button(FM)

CAC6022

 

 

 

 

7

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

2.2 CASSETTE MECHANISM MODULE

8

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

- CASSETTE MECHANISM MODULE SECTION PARTS LIST

Mark No. Description

Part No.

 

Mark No. Description

Part No.

1

Screw

BSZ20P040FMC

46

Pinch Roller Unit

EXA1473

2

Washer

CBF1037

47

Reel Unit

EXA1484

3

Washer

CBF1038

48

Head Base Unit

EXA1434

4

Washer

CBG1003

49

Lever Unit

EXA1438

5

Deck Unit

EWM1008

50

Gear Unit

EXA1436

6

Screw(M2×5)

EBA1028

51

Frame Unit

EXA1476

7

Screw(M2×2.5)

EBA1037

52

Lever Unit

EXA1425

8

Spring

EBH1531

53

Head Assy(HD1)

EXA1481

9

Spring

EBH1589

54

Motor Unit(M1)

EXA1497

10

Cushion

ENM1034

55

Washer

HBF-179

11

Spring

EBH1515

56

Screw

BMZ20P022FMC

12

Spring

EBH1587

57

Resistor(R1)

RD1/4HM181J

13

Spring

EBH1517

58

Washer

YE20FUC

14

Spring

EBH1547

59

Connector(CN251)

CKS1711

15

Spring

EBH1519

60

Connector(CN252)

CKS2127

16

Spring

EBH1537

61

Connector(CN253)

CKS2129

17

Cord

EDD1015

62

•••••

 

18

Photo-reflector(EGN2, 3)

EGN1004

63

Spring

EBH1545

19

Photo-Interrupter(EGN1)

EGN1005

64

Switch(S2)

ESG1004

20

Roller

ENR1031

65

Roller

ENR1023

21

Shaft

ELA1362

66

Cover

ENC1412

22

Roller

ELA1348

67

Cover

ENC1413

23

Arm

ENC1416

68

Spring

EBH1546

24

Arm

ENC1397

69

Washer

EBE1008

25

Guide

ENC1398

70

Washer

YE15FUC

26

Holder

ENC1417

71

Lever Unit

EXA1424

27

Lever

ENC1449

72

Spring

EBL1026

28

Arm

ENC1401

73

Screw(M2×2)

CBA1250

29

Roller

ENR1027

74

Capacitor(C1)

CEA4R7M35LS2

30

Belt

ENT1027

75

Bracket

ENC1472

31

Gear

ENV1347

76

Inductor(L1)

ETH0001

32

Collar

ENV1508

77

Cushion

ENM1036

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

 

 

 

 

9

1

 

2

 

3

 

4

 

 

 

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

3. BLOCK DIAGRAM AND SCHEMATIC DIAGRAM

3.1 BLOCK DIAGRAM (KEX-M8196ZT/UC)

A

B

C

D

10

1

2

3

4

5

 

6

 

7

 

8

 

 

 

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

A

B

C

D

11

5

 

6

 

7

 

8

 

 

 

 

 

 

1

 

2

 

3

 

4

 

 

 

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

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

 

 

 

Large size

 

 

 

SCH diagram

A-a

 

A-b

 

 

A-a

A-b

Guide page

Detailed page

A-a A-b

B

C

D

A MOTHER PCB

D KEYBOARD UNIT

A-a

CN1901

CN1902

 

 

 

 

CN701

CN702

 

CONTROLPCB

 

CN401

 

 

 

 

 

 

TUNER

 

M8396ZT-02/ES ONLY

 

 

 

 

FM : -30dBs

 

 

B

 

AM : -30dBs

 

 

CN652

CN653

 

 

 

 

CN751

 

 

UNITDECK

 

TAPE : -7.8dBs

 

 

 

(1kHz 0dB)

 

 

F

 

 

UC

ES

 

 

 

 

 

R411

1R8K

470

 

CN251

R412

1R8K

470

 

AVC-LAN

 

 

 

 

 

 

PEE

50K(W)

50K(W)

50K(W)

50K(W)

50K(W)

ASL

CD : +8.6dBs (1kHz 0dB)

CN902

12 A

1

2

3

4

Pioneer KEX-M8196ZT, KEX-M8396ZT Service Manual

5

 

6

 

7

 

8

 

 

 

 

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

A-b

A

LAMP DRIVE

ILL DRIVE

8V REGURATOR

Main Unit

 

Consists of

B

Mother PCB

 

Tuner Control PCB

 

RESET

TSW

AMP

ANT

M8396ZT-02/ES ONLY

MUTE

8V REGURATOR

FM : -15.9dBs

AM : -14.3dBs

TAPE : -4.5dBs

CD : +5.0dBs

FM : -16.4dBs

AM : -14.9dBs

TAPE : -5.1dBs

CD : +4.4dBs

E-VOL

5V REGURATOR

CN1

CN901

C

125 H

EARTH PLATE

M8396ZT-02/ES ONLY

D

: The power supply is shown with the marked box.

A 13

5

 

6

 

7

 

8

 

 

 

 

 

 

A

B

C

D

1

2

3

 

4

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

 

 

 

1

2

3

4

-a A-b

 

 

 

RESET

A

 

 

 

 

UNIT

CN1902

CN702

 

KEYBOARD

 

M8396ZT-02/ES ONLY

 

D

CN1901

CN701

 

 

PCB

FM : -30dBs AM : -30dBs

TAPE : -7.8dBs (1kHz 0dB)

 

MOTHER

CN401

CN751

A

14 A-a

CN653

 

CN652

 

BTUNERCONTROLPCB

UNIT

1

2

3

4

5

CD : +5.0dBs

TAPE : -4.5dBs

AM : -14.3dBs

FM : -15.9dBs

ES

470

470

UC

1R8K

1R8K

 

R411

R412

AVC-LAN

CN251

FDECKUNI

5

6

 

 

7

8

 

 

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

 

 

 

 

5

6

 

 

 

 

E-V

 

 

A-b

 

 

 

 

 

 

 

 

 

 

 

 

A-a

A

 

 

 

+8.6dBs (1kHz 0dB)

CN902

 

 

 

 

 

CD :

 

 

 

 

 

 

 

 

 

B

ASL

 

 

 

 

 

 

 

 

 

 

 

 

C

PEE

 

 

 

 

 

 

50K(W)

50K(W)

50K(W)

50K(W)

50K(W)

 

D

 

 

 

 

 

 

A-a

15

 

 

 

 

 

 

 

6

 

 

7

8

 

 

1

 

2

 

3

 

 

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

 

A-b

 

 

A

A-a

 

 

 

 

PCB

B

REGURATOR

Main Unit Consists of Mother PCB Tuner Control

 

 

 

8V

 

C

DRIVE

ILL

 

 

LAMP DRIVE

D

 

4

8V REGURATOR

MUTE

ANT M8396ZT-02/ES ONLY

AMP

TSW

16 A-b

 

 

 

ESET

1

2

3

4

1

2

3

4

5

125 H

EARTH PLATE

CN1

5V REGURATOR

15.9dBs

14.3dBs

: -4.5dBs

5.0dBs

6

7

 

8

 

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

 

 

 

marked box.

-a A-b

A

 

 

the

A

 

 

 

CN901

M8396ZT-02/ES ONLY

supply is shown with

 

 

 

 

: The power

 

 

 

 

 

 

B

FM : -16.4dBs AM : -14.9dBs TAPE : -5.1dBs

CD : +4.4dBs

 

 

 

C

E-VOL

D

 

5

6

A-b

17

5

6

7

8

1

 

2

 

3

 

4

 

 

 

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

3.3 TUNER CONTROL PCB

A

B TUNER CONTROL PCB

ANTENNA

MAIN

ANTENNA

SUB

B

M8196ZT/UC ONLY

C

FM : -30dBs

AM : -30dBs

D

CN652

A CN401

M8396ZT-02/ES ONLY

R651

0R0

FM DIVERSITY

M8396ZT-02/ES

UC ES

R661 33K 27K

C666 R22 R022

C680 R039 R015

*** ***

***

CN653

A CN401

18 B

1

2

3

4

5

 

6

 

7

 

8

 

 

 

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

A

C

C

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

TUNER UNIT (KEX-M8396ZT-02/ES)

 

 

UC

ES

 

C649

R033

R022

 

C650

R033

R022

 

C664

3900P

R018

M8396ZT-02/ES ONLY

C665

3900P

R018

***

***

***

***

B

96ZT-02/ES ONLY

FM : -26dBs

AM : -16dBs

M8396ZT-02/ES ONLY

(400Hz 30%)

 

 

 

M8396ZT-02/ES ONLY

 

 

***

 

UC

ES

***

 

 

R512

4R7K

2R2K

 

R513

0R0

2R2K

 

C

Main Unit

Consists of

Mother PCB

 

Tuner Control PCB

D

 

B 19

5

 

6

 

7

 

8

 

 

 

 

 

 

A

B

C

D

1

 

2

 

3

 

4

 

 

 

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

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

C FM/AM TUNER UNIT

B

56K

39K

20 C

1

2

3

4

5

 

6

 

7

 

8

 

 

 

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

B

A

B

C

D

C 21

5

 

6

 

7

 

8

 

 

 

 

 

 

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