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KEX-M8196ZT
Service Manual
76 pgs5.06 Mb1

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
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