Pioneer ES300 User manual

ORDER NO.
CRT2393
PUB. NO. CRT2393
AUDIO SYSTEM
HEAD UNIT
Manufactured for TOYOTA
by PIONEER CORPORATION
ES300
Service
Manual
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
Service
Manual
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
8Cassette 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
8Cassette 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
1234
B
C
D
1234
3. BLOCK DIAGRAM AND SCHEMATIC DIAGRAM
3.1 BLOCK DIAGRAM (KEX-M8196ZT/UC)

11
KEX-M8196ZT,M8196ZT-91,M8396ZT-02,M8396ZT-92
5678
A
B
C
D
5678

CN701 CN702
CN401
CN751
CN902
PEE
AVC-LAN
ASL
KEYBOARD UNIT
D
BTUNER CONTROL PCB
FDECK 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
AMOTHER PCB
50K(W)
50K(W)
50K(W)
50K(W)
50K(W)
12
KEX-M8196ZT,M8196ZT-91,M8396ZT-02,M8396ZT-92
A
1234
B
C
D
1234
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
5678
A
B
C
D
5678
A-b
A

CN701 CN702
CN401
CN751
RESET
KEYBOARD UNIT
D
BTUNER CONTROL PCB
UNIT
CN652
CN653
CN1901 CN1902
TAPE : -7.8dBs (1kHz 0dB)
FM : -30dBs AM : -30dBs
M8396ZT-02/ES ONLY
AMOTHER PCB
14
KEX-M8196ZT,M8196ZT-91,M8396ZT-02,M8396ZT-92
A
1234
B
C
D
1234
A-a A-b
A-a
1
2
3
4

CN902
PEE
AVC-LAN
ASL
E-V
FDECK 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
5678
A
B
C
D
5678
A-a A-b
A-a
5
6

ESET
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
1234
B
C
D
1234
A-a A-b
A-b
1
2
3
4

17
KEX-M8196ZT,M8196ZT-91,M8396ZT-02,M8396ZT-92
5678
A
B
C
D
5678
CN1
CN901
5V REGURATOR
E-VOL
EARTH PLATE
15.9dBs
14.3dBs : -4.5dBs
5.0dBs
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
ACN401
ACN401
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
1234
B
C
D
1234
3.3 TUNER CONTROL PCB
B