Sega AFTER BURNER CLIMAX User manual

OWNER'S MANUAL
IMPORTANT
¥ Before using this product, read this manual carefully to understand the
contents herein stated.
¥ After reading this manual, be sure to keep it near the product or in a
convenient place for easy reference when necessary.
420-0002-01UK
OWNER'S MANUALAFTER BURNER CLIMAX
© SEGA
Produced under license from Boeing Management Company. Boeing, McDonnell Douglas, McDonnell, Douglas, North American Aviation, their distinctive
airplane liveries, logos and product markings are among the trademarks owned by Boeing.
Produced under a license from Northrop Grumman Systems Corporation. F-14D Super Tomcat, F-5E Tiger II, A-10A Thunderbolt II, B-2A Spirit, and CVN-65
Enterprise are trademarks of Northrop Grumman Systems Corp. and are used under a license to Sega Corporation.
420-0002-01UK
1st Printing
OWNER'S MANUAL

CONTENTS
1BEFORE USING THIS PRODUCT...........................................................................................................2
1.1 INSPECTIONS IMMEDIATELY AFTER TRANSPORTING THE PRODUCT TO THE LOCATION .3
2INTRODUCTION TO THIS SERVICE MANUAL.......................................................................................5
3INSTALLATION AND SERVICE INSTRUCTIONS...................................................................................6
3.1 HANDLING AND INSTALLATION PRECAUTIONS..........................................................................6
3.2 COIN HANDLING...............................................................................................................................6
3.3 NAME OF PARTS..............................................................................................................................7
3.4 ACCESSORIES.................................................................................................................................8
3.4.1 INSTALLATION KIT....................................................................................................................8
3.4.2 SHIPPING THE GAME BOARD.................................................................................................9
3.5 ASSEMBLY INSTRUCTIONS..........................................................................................................10
3.5.1 APPLYING THE PLAY INSTRUCTIONS .................................................................................11
3.5.2 SECURING IN PLACE (LEG ADJUSTER ADJUSTMENT) .....................................................12
3.5.3 COIN HANDLING INSTALLATION...........................................................................................14
3.5.3.1 WIRING CONNECTIONS..................................................................................................15
3.5.4 CONNECTING THE POWER...................................................................................................16
3.5.5 ASSEMBLY CHECK.................................................................................................................17
3.6 MOVING THE MACHINE.................................................................................................................19
3.7 FUSES .............................................................................................................................................20
4MAINTENANCE ......................................................................................................................................21
4.1 CONTROL STICK............................................................................................................................22
4.1.1 HOW TO REMOVE THE CONTROL STICK............................................................................22
4.1.2 GREASING...............................................................................................................................25
4.1.3 VOLUME REPLACEMENT.......................................................................................................26
4.1.4 MICROSWITCH REPLACEMENT............................................................................................30
4.1.5 GUIDE PLATE REPLACEMENT..............................................................................................32
4.2 THROTTLE LEVER .........................................................................................................................33
4.2.1 GREASING...............................................................................................................................34
4.2.2 VOLUME ADJUSTMENT OR REPLACEMENT.......................................................................35
4.3 REPLACEMENT OF FLUORESCENT LAMPS...............................................................................39
4.4 PERIODIC INSPECTION.................................................................................................................40
4.5 TROUBLESHOOTING.....................................................................................................................42
4.5.1 ERROR MESSAGES................................................................................................................43
4.6 START/ CHANGE BUTTON LAMP REPLACEMENT.....................................................................46
4.7 GAMEBOARD..................................................................................................................................47
4.7.1 REMOVING THE BOARD ........................................................................................................47
4.7.2 COMPOSITION OF GAME BOARD.........................................................................................48
5GAME DESCRIPTION............................................................................................................................49
6EXPLINATION OF TEST AND DATA DISPLAY.....................................................................................62
7NETWORK PLAY....................................................................................................................................75
7.1.1 INSTALLATION PRECAUTIONS.............................................................................................76
7.1.2 CONNECTING THE COMMUNICATION CABLE....................................................................76
8APPENDIX A - ELECTRICAL SCHEMATIC...........................................................................................77
8.1 WIRE COLOURS.............................................................................................................................77
8.2 ELECTRICAL SCHEMATIC.............................................................................................................77

1 BEFORE USING THIS PRODUCT
To ensure the safe usage of the product, be sure to read the following before using the product. The following
instructions are intended for the use of QUALIFIED SERVICE PERSONNEL ONLY. After carefully reading and
sufficiently understanding the instructions should any activity be carried out on the product. Only qualified service
personnel should carry out maintenance on the product.
Terms such as WARNING!, CAUTION, and IMPORTANT! Are used where an explanation is given which requires
special attention, depending on the potential risk. SEGA is not responsible for injury or damage caused by use in a
manner contrary to the instructions stated in this document. In order to prevent accidents warning stickers and printed
instructions are applied in the places where a potentially hazardous situation relating to the product could arise. Be sure
to comply with these warnings.
Indicates that mishandling the product by disregarding this
warning will cause a potentially hazardous situation which can
result in death or serious injury.
Indicates that mishandling the product by disregarding this
caution will cause a potentially hazardous situation which
can result in personal injury and or material damage.
This is cautionary information which should be complied with when handling the product. Indicates that mishandling the
product by disregarding this will cause a potentially hazardous situation which may not result in personal injury but could
damage the product.
Be sure to turn off the power and disconnect from the mains supply before working on the machine.
Ensure that the correct fuse(s) is fitted to the machine.
Details of the correct fusing of the machine are enclosed in the Service Manual.
Ensure that only qualified Service Engineers perform any maintenance work on the machine.
Specification changes, removal of equipment, conversion and/or addition, not designated by SEGA are not permitted
and will invalidate this product’s CE conformity.
The parts of the product also include any warning labels or safety covers for personal protection etc. A potential hazard
will be created if the machine is operated while any parts have been removed. Should any doors, lids or protective
covers be damaged or lost, do not operate the product. SEGA is not liable in any whatsoever for any injury and/or
damage caused by specification changes not designated by SEGA.
Before installing the product, check for the Electrical Specification Sticker, SEGA products have a sticker on which the
electrical specifications are detailed. Ensure that the product is compatible with the power supply voltage and frequency
requirements of the location in which the machine is to be installed.
Install and operate the machine only in places where appropriate lighting is available, allowing warning stickers to be
clearly read.
To ensure maximum safety for both customers and operators, stickers and printed instructions describing potentially
hazardous situations are applied to places where accidents could occur. Ensure that where the product is operated has
sufficient lighting to allow any warnings to be read. If any sticker or printed warning is removed or defaced, do not
operate the machine, until it has been replaced by an identical item.
When handling the monitor, be very careful. (Applies only to product with monitor)
Some of the monitor (TV) parts are subject to high tension voltage. Even after turning off the power some components
are still occasionally subject to high tension voltage. Monitor repair and replacement should be performed by qualified
service engineers only.
In cases where commercially available monitors and printers are used only the contents relating to this product are
stated in this manual. Some commercially available equipment has functions and reactions not stated in this manual.
Read this manual in conjunction with the specific manual of such equipment.
Descriptions contained herein may be subject to change without prior notification.
The contents described herein are fully prepared with due care. However, should any question arise or errors be found
please contact SEGA.

3
1.1 INSPECTIONS IMMEDIATELY AFTER TRANSPORTING THE PRODUCT TO THE
LOCATION
•Inspection should only be carried out by QUALIFIED SERVICE PERSONNEL.
Normally, at the time of shipment, SEGA products are in a state to allowing usage immediately after
transporting to the location. Nevertheless, an irregular situation may arise during transportation preventing
this. Before turning on the power, check the following points to ensure that the product has been
transported safely.
•Are then any dented parts or defects (cuts, etc.) on the external surfaces of the product.?
•Are castors and leg adjusters present and undamaged?
•Do the power supply voltage and frequency requirements meet with the local supply?
•Are all wiring connectors correctly and securely connected? Unless connected in the correct direction,
connector connections cannot be made successfully. Do not insert connectors forcibly.
•Does the power cord have any cuts or dents?
•Do fuses meet the specified rating?
•Are such units such as monitors, control equipment, IC BD, etc. firmly secured?
•Are all earth wires connected?
•Are all accessories available?
•Can all doors and lids be opened with the accessory keys and/or tools?

4
CONCERNING THE STICKER DISPLAY CONCERNING WARNING STICKERS
SEGA product has stickers describing the product
manufacture number (Serial Number) and electrical
specification. If you require service assistance you will
require the Serial Number. Identical machines may
have different parts fitted internally. Only by quoting the
Serial Number will the correct parts be identified.
SEGA product has warning displays on stickers,
labels or printed instructions adhered/attached to or
incorporated in the places where hazardous
situations can arise. The warning displays are
intended for the accident prevention of customers
and service personnel.
SPECIFICATIONS
Installation Space (mm): 945 (W) x 1625(D)
Height (mm): 1873
Weight (kg): Approx. 260
Power, Max: 430W Rated Voltage (VAC):
Rated Current (A): 230 VAC 2.2A
Operating Temperature Range 5 - 40°C
Note: Descriptions in this manual are subject to change without prior notice.

5
2 INTRODUCTION TO THIS SERVICE MANUAL
SEGA ENTERPRISES LTD., supported by its experience in electronic high technology of VLSI’s,
microprocessors etc. and with a wealth of experience, have for more than 30 years been supplying various
innovative and popular games to the world market. This Service Manual is intended to provide detailed
descriptions together with all the necessary information covering the general operation of electronic
assemblies, electromechanicals, servicing controls, spare parts, etc. as regards MINI CLUB KART, a new
SEGA product. This manual is intended for those who have knowledge of electricity and technical expertise
especially in IC’s, CRT’s, microprocessors etc. Carefully read this manual to acquire sufficient knowledge
before working on the machine. Should there be any malfunction, non-technical personnel should under no
circumstances touch the interior systems. Should such a situation arise contact the nearest branch listed
below or our head office.
SEGA AMUSEMENTS EUROPE LTD./ SEGA SERVICE CENTRE
Suite 3A Oaks House,
12/22 West Street,
Epsom
Surrey
United Kingdom
KT18 7RG
Telephone: [phone]
Fax: [phone]

6
3 INSTALLATION AND SERVICE INSTRUCTIONS
•Installation and commissioning should only be carried out by QUALIFIED
SERVICE PERSONNEL.
3.1 HANDLING AND INSTALLATION PRECAUTIONS
When installing or inspecting the machine, be very careful of the following points and pay attention to
ensure that the player can enjoy the game safely.
The game must NOT be installed under the following conditions:
•Outside, the game is designed for indoor use only.
•In areas directly exposed to sunlight, high humidity, dust, excessive heat or extreme cold.
•In locations that would present an obstacle in the case of an emergency i.e. near fire equipment or
emergency exits.
•On unstable surfaces or surfaces subject to vibration.
•Where liquids, other than routine cleaning (do not use water jet), may come into contact with the game.
Important:
•This machine should only be installed by Qualified Service Personnel.
•Be sure to switch the supply power OFF and remove the mains supply plug from the machine before
any work is carried out on the machine.
•Do not attempt to repair the PCB’s (Printed Circuit Boards) yourself. This will void the warranty. The
PCB’s contain static sensitive devices that could be damaged.
•Always return a faulty part to your distributor with adequate packaging and protection.
•When removing the plug from the mains always grasp the plug not the cable.
•Do not use a fuse that does not meet the specified rating.
•Make sure all connections are secure before applying power.
•Do not clean using a pressure washer.
•Ensure that the mains lead is not damaged. If the mains lead is damaged in any
way there could be a danger of electric shock or a fire hazard.
•Ensure that the power supply is fitted with circuit protection. Using the power
supply without circuit protection is a fire hazard.
3.2 COIN HANDLING
Standard Sega machines are fitted with a C120 coin mechanism, however, as a service to our customers
Sega machines can be supplied with no coin mechanism or door allowing the customer to fit a coin
handling option from the approved list. Fit only the coin handling arrangements detailed below and follow
the instructions provided. Failure to fit the coin handling options detailed or failure to follow the installation
instructions will render the machine, under the CE marking directive, void.
Approved coin handling options:
•Money Controls C220 / SR3
•Generic mechanical
•Mars (MS111B1 and ME115)
•SECI RM4-G20

7
3.3 NAME OF PARTS
Width (mm) Length (mm) Height (mm) Weight (kg)
COCKPIT 945 1625 1522 239
BILLBOARD 758 560 353 13
When Assembled 945 1625 1873 Approx. 260

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3.4 ACCESSORIES
The machine is supplied with an installation kit. Please ensure the following parts are supplied:
3.4.1 INSTALLATION KIT
**1 ABX-2011UK INSTR CMODE L MULTI 1
**2 ABX-2012UK INSTR ATTACK R MULTI 1
**5 ECA-0001 SUPPORT BRKT 2
**6 420-0002-01UK SERVICE MANUAL ABX STD 1
**7 540-0009-01 WRENCH M8 TMP PRF 1
**8 540-0007-01 WRENCH M5 TMP PRF 1
**9 540-0006-01 WRENCH M4 TMP PRF 1
**13 OS1019 SELF SEAL BAG 9X12.3/4 2
**14 SAECE-XXX DECLARATION OF CONFORMITY 1
**17 601-11691-92 CARTON BOX LBG 1
**104 440-CS0186UK STICKER C EPILEPSY MULTI 1
**301 600-7269-0500UK CA LAN CAT5 500CM 1
Part No. 540-0006-01, 540-0007-01, 540-0009-01 - Tamper-proof TORX wrench.

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3.4.2 SHIPPING THE GAME BOARD
•When returning the GAME BOARD for repair or replacement, be sure to package
the entire ASSY SHIELD CASE in the original card transit box - THERE ARE NO
USER-SERVICEABLE PARTS INSIDE.
•Failure to return the GAME BOARD in this manner may invalidate the warranty.
Pack the ASSY SHIELD CASE in the original transit box as shown. Putting it upside down or packing
otherwise in the manner not shown can damage the GAME BOARD and other parts.

10
3.5 ASSEMBLY INSTRUCTIONS
•Perform the assembly by following the procedure herein stated. Failure to comply
with the instructions, for example, inserting the plug into an outlet at a stage not
mentioned in this manual can cause an electric shock
•Assembling should be performed as per this manual. Since this is a complex
machine, erroneous assembling can cause damage to the machine, or
malfunction to occur.
•Do not attempt to complete this work alone, a minimum of 2 people are required.
•Assembly should only be carried out by QUALIFIED SERVICE PERSONNEL.
When carrying out the assembly work, follow the procedure in the following five item sequence
STEP 1: APPLYING THE PLAY INSTRUCTIONS
STEP 2: SECURING IN PLACE
STEP 3: COIN HANDLING INSTALLATION
STEP 4: CONNECTION TO THE POWER SUPPLY
STEP 5: ASSEMBLY CHECK
Note that the parts contained within the installation kit are required for the assembly work.

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3.5.1 APPLYING THE PLAY INSTRUCTIONS
•This operation should only be carried out by QUALIFIED SERVICE
PERSONNEL.
Supplied in the installation kit are 2 sets of play instructions in 5 languages. Select the language of
your choice and apply in the following areas:
1. ABX-2011UK: Instructions CMODE L MULTI (on control panel)
2. 422-0870UK: Instructions ATTACK R MULTI (on control panel)
1 & 2

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3.5.2 SECURING IN PLACE (LEG ADJUSTER ADJUSTMENT)
•Make sure all of the leg adjusters are in contact with the floor. If they are not, the
machine may move and cause injury. This operation requires 2 people.
•This operation should only be carried out by QUALIFIED SERVICE
PERSONNEL.
This machine has four castors and four leg adjusters. When the installation position is decided, unscrew
the leg adjusters so that they raise each caster a minimum of 5mm from the floor. Make sure the machine
is level.
1. Move the machine to the installation position. When installing
against or close to a wall, be sure to allow an adequate space to
allow the player access to the machine.
2. Make the leg adjusters contact the floor. Adjust using a spanner as
shown below so that a minimum of 5mm exists between the
casters and the floor. Make additional adjustment so that the
machine is level.
3. After making adjustments, fasten the lock nut upward on all four
adjusters.
4. Install the SUPPORT BRACKETS on the left and right side of the frame. Remove the two M8 bolts
shown below and replace them to secure the SUPPORT BRACKETS.
Repeat procedure for both Left and Right sided
support plates.

13
VENTILATION: Ensure adequate ventilation is maintained as detailed below:
Image shown for illustration purposes.

14
3.5.3 COIN HANDLING INSTALLATION.
•This operation should only be carried out by QUALIFIED SERVICE
PERSONNEL.
When fitting the coin mechanism to the door please refer to the specific manufacturers installation
instructions for that coin mechanism. To fit the door to the machine, follow the procedure below.
•Loosen all of the bolts on the frame which secure the clips.
•Turn all clips in towards the door.
•Position the door into the aperture in the machine.
•Turn the clips around so that they will hold the door in the
machine.
•Tighten all of the bolts.

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3.5.3.1 WIRING CONNECTIONS.
COIN MECH LOOM INSTALLATION
C220B LM1006IDC
LM1006LAMP-0.1
•Attach the lamp holder to the bracket on the coin return
button.
•Attach one 15-way connector to the C220 coin mech.
•Attach the other 15-way connector to Validator A on the
credit board.
•Attach the 2-way connector to ‘LAMP’ on the VTS
board.
GENERIC
MECHANICAL
S
LM1008
LM1008-LAMP
•Fit the two lamp holders behind the coin return buttons.
•Attach the blue cable and orange cable to one mech’s
microswitch switch.
•Attach the blue/green cable and orange/green cable to
the other mech’s microswitch.
•Attach the 2-way mate and lok plug to the 2-way mate
and lok cap provided.
•Attach one 15-way connector to Validator A and the
other to Validator B on the credit board
MARS
MS111B1
MARS ME115
LM1007
LM1008-LAMP
•Fit the lamp holder to the bracket behind the coin return
button.
•Fit one of the 13-way connectors to the coin mech.
•Fit the other 13-way connector to Validator A on the
credit board. Note the 13-way connector is keyed and
this key must coincide with the key on the credit board.
SECI, C120 OWN LOOM AND
LM1006LAMP-0.1 •Attach the lamp holder to the bracket on the coin return
button.
•Attach the 2- connector to ‘LAMP’ on the VTS board.
•Attach the validator’s own loom to position A on the
credit board
VTS credit board assembly

16
3.5.4 CONNECTING THE POWER
•Be sure that the machine is not already connected to the mains supply before
attempting this operation
•This operation should only be carried out by QUALIFIED SERVICE
PERSONNEL.
1. Insert the mains lead into the wall socket.
2. Insert the IEC plug into the IEC socket on the
AC bracket.
3. Switch on the power supply at the wall.
4. Switch on the mains switch on the AC bracket.
5. Once power is turned on, the fluorescent
lamps in the top and rear billboards light
up. The Start System Screen displays
after a lapse of several seconds. It is
followed by the screen that indicates that
the network is currently being checked if
the communication mode has been set. If
there is a bad or improper
communication connection, each screen
will not proceed to the next, remaining on
the currently network-checked screen. If
this occurs, resolve the error according to
the instructions in this manual.
6. If the communication mode has not been
set or the communication check ends
normally failures are displayed, if found.
Resolve the errors according to the
instructions in this document. Pressing
the Start button while a failure is on-
screen allows you to go to the next
screen and start the game without
reaction.
7. Once all the above steps have been completed, the Advertise Screen displays and voices are output
through the left and right loudspeakers, unless you have set the machine so that no voices are output
during the Advertise mode.
This product retains the number of credits and the ranking data even after the power is turned off. It does
not retain data about the fractional number of coins (i.e. the number of coins not reaching one credit) or the
bonus adder count.

17
3.5.5 ASSEMBLY CHECK
•This operation should only be carried out by QUALIFIED SERVICE
PERSONNEL.
In the TEST mode ensure the assembly has been made correctly by performing the following checks.
Use test mode to confirm that assembly is proper, and that the LINDBERGH, connecting boards, and
input/output devices are normal.
Perform the following tests in test mode.
For tests (1) to (4), refer to the LINDBERGH service manual. For tests (5) to (7), see [9-3 Game Test
Mode].
The items displayed on the test screen for tests (5) and (6) vary depending on the setting for cabinet type in
the game setting screen.
(1) Information Display Screen
When “SYSTEM INFORMATION,” “STORAGE INFORMATION,” or “JVS TEST” has been selected on the
system test mode menu, system information, game information and information on JVS I/O board
connected to LINDBERGH are displayed.
If each category of information is displayed without anomalies, the LINDBERGH is normal.
(2) JVS Input Test Screen
When “INPUT TEST” has been selected on the JVS test screen, data input to the JVS I/O board is
displayed. On the product, this is the screen for the testing coin switch.
Insert a coin. If the display to the side of the switch changes the switch and wiring connections are normal.
(3) Monitor Test Screen
When “MONITOR TEST” has been selected on the system test mode menu, the screen for checking
monitor adjustment status appears.
Monitor adjustment is completed when the product is shipped from the factory, but you should observe the
test screen to determine whether further adjustment is necessary. Refer to Chapter 10 and adjust the
monitor if necessary.
(4) Speaker Test Screen
When “SPEAKER TEST” has been selected on the system test mode menu, the screen for checking
speaker sound output appears.
To confirm that audio output is normal, have test sound output from the game unit’s speaker.
(5) Input Test
When “INPUT TEST” has been selected on the game test mode menu, the screen for testing input device
appears. Test operate the input device by pressing each switch. If the display on the side of each input
device changes to “ON” and numerical values change smoothly in accordance with each operation, the
input device and its wiring connections are normal.

18
INPUT TEST SCREEN
OUTPUT TEST SCREEN
(6) Output Test
When “OUTPUT TEST” has been selected on the game test mode menu, the screen for testing lamps and
other output devices appears.
If each output device operates properly, the output device and its wiring connections are normal.
CALIBRATION SCREEN
(7) Calibration
Confirm that the operability of input devices and seat motions (Deluxe and Super Deluxe only) during game
play do not present any hindrances to play. Calibration is adjusted when the product is shipped from the
factory but it might need to be adjusted again because of vibrations during transport, etc.
If such things as operability are not satisfactory, select “CALIBRATION” on the game test mode menu and
check and adjust settings.

19
3.6 MOVING THE MACHINE
•When moving the machine, be sure to remove the plug from the power supply.
Moving the machine with the plug inserted can cause the power cord to be
damaged, resulting in a fire or electric shock.
•When moving the machine, remove the Support Brackets, retract the leg
adjusters fully and ensure the casters make contact with the floor. During
movement pay careful attention so that the casters or leg adjusters do not
damage any other cabling laid on the floor. Such damage could result in a fire or
electric shock.
•This operation should only be carried out by QUALIFIED SERVICE
PERSONNEL.