Sega RALLY 3 DELUXE User manual

SEGARALLY3DELUXE OWNERSMANUAL 420-0005-03UK

INTRODUCTION
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
INTRODUCTION
TABLE OF CONTENTS
Handling Precautions 01
Installation Precautions 04
Operation Precautions 06
Parts Descriptions 10
Accessories 11
Assembly and Installation 12
Precautions when moving 27
Game Description 29
Test and Data Display 41
Controller Unit 61
Monitor (Projector) 71
Coin Handling and VTS Bd 79
Lighting 87
Periodic Inspection 94
Troubleshooting 96
Game Board (Europa) 100
Network - Communication 102
Design Related Parts 108
Parts List 109
Colour Code Chart 150
Schematic Diagrams 151
STS Spare Parts 154

INTRODUCTION
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INTRODUCTION
SPECIFICATIONS
MACHINE DETAILS
Wdth : 1500 mm (59.1 nches)
Depth : 2810 mm (110.6 nches）
Heght： 2290 mm (90.2 nches)
Weght： 430 kg (948 lbs)
Power, Current： 720 W. 3 Amps
Voltage : 220 - 230 Vac 50Hz
Montor Type： Short Throw DLP (Reected).
Indcates mportant nformaton that, f gnored, may result n the mshandlng of the
product and cause faulty operaton or damage to the product.
Ths manual s ntended to provde detaled descrptons together wth all the necessary nformaton
coverng the general operaton of electronc assembles, electro-mechancals, servcng control, spare
parts, etc. for the product, “SEGA - RALLY DELUXE
Ths manual s ntended for the owners, personnel and managers n charge of operaton of the product.
Operate the product after carefully readng and su󱐰cently understandng the nstructons
.
In the unlkely event that the product does not functon correctly, DO NOT allow anyone other than
a techncan to touch the nternal system. Turn o󱐯 the power to the machne, makng sure to unplug
the electrcal cord from the outlet, and contact the o󱐰ce lsted below or the pont of purchase for ths
product.
Use of ths product s unlkely to cause physcal njures or damage to property. However, ponts that
requre specal attenton are ndcated by bold text, the word “IMPORTANT” and the symbol below.
SEGA AMUSEMENTS EUROPE, LTD.
Block C, 42 Barwell Busness Park, Chessngton, Surrey. KT9 2NY Unted Kngdom.
Telephone: [phone] Facsmle: [phone]
e-mal: ma[email protected] http://www.sega-amusements.co.uk
NOTE : The contents herein described are subject to change without notice.

v
INTRODUCTION
Parts replacement, mantenance nspectons and troubleshootng should be carred out by ste
mantenance personnel or other qualed professonals. Ths manual ncludes drectons for potentally
dangerous procedures whch should only be carred out by professonals wth the approprate
specalsed knowledge.
The ste mantenance personnel or other qualed professonals mentoned n ths manual are dened
as follows:
Ste mantenance personnel:
Indvduals wth experence n mantanng amusement equpment, vendng machnes, etc., workng
under the supervson of the owner/operator of ths product to mantan machnes wthn amusement
facltes or smlar premses by carryng out everyday procedures such as assembly, mantenance
nspectons, and replacement of unts/expendable parts.
Actvtes to be carred out by ste mantenance personnel:
Amusement equpment/vendng machne assembly, mantenance nspecton and replacement of unts/
expendable parts.
Other qualed professonals:
Persons employed by amusement equpment manufacturers, or nvolved n desgn, producton, testng
or mantenance of amusement equpment. The ndvdual should have ether graduated from techncal
school or hold smlar qualcatons n electrcal/electroncs/mechancal engneerng.
Actvtes to be carred out by other qualed professonals:
Amusement equpment/vendng machne assembly, repar/adjustment of electrcal/electronc/
mechancal parts.
Denition of 'Site Maintenence Personnel or Other Qualied Individuals
Procedures not descrbed n ths manual or marked as ‘to be carred out by ste
mantenance personnel or other qualed professonals’ should not be carred out by
personnel wthout the necessary skll or technology. Work carred out by unqualfed
persons may cause serous accdents, ncludng electrocuton.

HANDLING PRECAUTIONS
1
1
1 HANDLING PRECAUTIONS
When nstallng or nspectng the machne, be very careful of the followng ponts and pay attenton to
ensure that the player can enjoy the game safely.
Non-complance wth the followng ponts or napproprate handlng runnng counter to the cautonary
matters heren stated can cause personal njury or damage to the machne.
• Before performing work, be sure to turn the power off. Performing the work without
turning the power off can cause an electric shock or short circuit. In the case work should
be performed in the status of power on, this manual always states to that effect.
• To avoid an electric shock or short circuit, do not plug in or unplug quickly.
• To avoid an electric shock, do not plug in or unplug with a wet hand.
• Do not expose power cords or earth wires on the surface, (floor, passage, etc.). If exposed,
the power cords and earth wires are susceptible to damage. Damaged cords and wires can
cause an electric shock or short circuit.
• To avoid causing a fire or an electric shock, do not put things on or damage the power
cords.
• When or after installing the product, do not unnecessarily pull the power cord. If damaged,
the power cord can cause a fire or an electric shock.
• In case the power cord is damaged, ask for a replacement through where the product was
purchased from or the office herein stated. Using the cord as is damaged can cause fire, an
electric shock or leakage.
• Be sure to perform grounding appropriately. Inappropriate grounding can cause an electric
shock.
• Be sure to use fuses meeting the specified rating. Using fuses exceeding the specified
rating can cause a fire or an electric shock.
• Be sure that connections such as IC BD are made properly. Insufficient insertion can cause
an electric shock.
• Specification changes, removal of equipment, conversion and/or addition, not designated
by SEGA are not permitted.
• Failure to observe this may cause a fire or an electric shock. Non-compliance with this
instruction can have a bad influence upon physical conditions of the players or the
onlookers, or result in injury during play.
• SEGA shall not be held responsible for damage, compensation for damage to a third party,
caused by specification changes not designated by SEGA.
• If work or parts replacement not indicated in this manual is carried out, an accident may
occur. If it is necessary to carry out work not indicated in this manual, be sure to have it
done by the office indicated in this manual or by the point of purchase. Also, please inquire
regarding details of the work involved.
• Be sure to perform periodic maintenance inspections herein stated.

2
HANDLING PRECAUTIONS
1
• For the IC board circuit inspections, only the logic tester is allowed. The use of a multiple-purpose tester
is not permitted, so be careful in this regard.
• When cleaning the display surfaces, use a soft and dry cloth. Do not apply chemicals such as thinners,
benzene, etc.
• Static electricity from your body may damage some electronics devices on the IC board. Before handling
the IC board, touch a grounded metallic surface so that the static electricity can be discharged.
• Do not turn the power on and off continuously. Repeatedly turning the power on and off may cause
product malfunction or parts damage.
• Some parts are not designed and manufactured specically for this game machine. The manufacturers
may discontinue, or change the specications of such general-purpose parts. If this is the case, SEGA cannot
repair or replace a failed game machine whether or not a warranty period has expired.

HANDLING PRECAUTIONS
3
1
CONCERNING THE STICKER DISPLAY
This SEGA product has stickers attached
describing the product manufacture No. (Serial
No.) and Electrical Specications. It also has a
Sticker describing where to contact for repair
and for purchasing parts.
When inquiring about or asking for repairs,
mention the Serial No. and Name of Machine
indicated on the Sticker. The Serial Number
indicates the product register. Identical
machines could have different parts depending
on the date of production. Also, improvements
and modications might have been made after
the publication of this manual. In order to
ensure you order the correct parts, mention
the Serial No. when contacting the applicable
places.
CONCERNING THE WARNING LABELS
This SEGA product has warning displays on
stickers, labels and/or printed instructions
adhered/attached to or incorporated in the
places where a potentially hazardous situation
could arise. The warning displays are intended
for accident prevention for customers and
for avoiding hazardous situations relating to
maintenance and servicing work. Some portions
of the cabinet contain high voltage and may
cause accidents if touched.
When performing maintenance, be very
careful of the warning displays. It is especially
important that any complex repair and
replacement work not mentioned herein should
be performed by those technical personnel who
have knowledge of electricity and technical
expertise. In order to prevent accidents, caution

4
PRECAUTIONS REGARDING INSTALLATION LOCATION
2
Ths product s an ndoor game machne. Do not nstall t outsde. Even ndoors, avod nstallng n places
mentoned below so as not to cause a re, electrc shock, njury and/or malfuncton.
- Places subject to ran or water leakage, or places subject to hgh humdty n the proxmty of an ndoor
swmmng pool and/or shower, etc.
- Places subject to drect sunlght, or places subject to hgh temperatures n the proxmty of heatng unts,
etc.
- Places lled wth nammable gas or vcnty of hghly nammable/volatle chemcals or hazardous matter.
- Dusty places.
- Sloped surfaces.
- Places subject to any type of volent mpact.
- Vcnty of ant-dsaster facltes such as re exts and re extngushers.
- Areas where the temperature exceeds the applcable temperature (ambent temperature) range
of 5 to 30 degrees centgrade.
2 PRECAUTIONS REGARDING INSTALLATION LOCATION
2-1 LIMITATAION OF USE
Be sure to check the Electrcal Speccatons. Ensure that ths product s compatble wth the locaton’ s
power supply, voltage, and frequency requrements. A plate descrbng Electrcal Speccatons s
attached to the product. Non-complance wth the Electrcal Speccatons can cause a re and electrc
shock.
Ths product requres a breaker and earth mechansm as part of the locaton facltes. Usng the product
wthout these can cause a re and electrc shock.
Ensure that the ndoor wrng for the power supply s rated at 15 A or hgher (AC sngle phase 100V ~ 120V
area), and 7 A or hgher (AC 220V ~ 240V area). Non-complance wth the Electrcal Specfcatons can
cause a re and electrc shock.
Be sure to use an ndependent power supply equpped wth an earth leakage breaker. Usng a power
supply wthout an earth leakage breaker can cause an outbreak of re f a power surge occurs.
Puttng many loads on one electrcal outlet can cause generaton of heat and a fre resultng from
overload.
When usng an extenson cord, ensure that the cord s rated at 15 A or hgher (AC 100V ~ 120V area) and
7A or hgher (AC 220V ~ 240V area). Usng a cord rated lower than the speced ratng can cause a re and
electrc shock.
ELECTRICITY CONSUMPTION
MAX : 3A (AC 230V ~ 50HZ)

PRECAUTIONS REGARDING INSTALLATION LOCATION
5
2
• For the operaton of ths machne, secure a mnmum area of 2.6m [W] x 3.5m [D].
The dmensons of the base perphery are establshed n consderaton of ventlaton,
mantenance and customer passage. And f they fall and ht ther head, there could be a very
serous njury. Be sure to always secure enough space as prescrbed n ths manual.
• Be sure to provde su󱐰cent space speced n ths manual. Do not allow objects to block the
ventlaton ports. It can cause generaton of heat and a re.
• SEGA shall not be held responsble for damage or compensaton for damage to a thrd
party, resultng from the falure to observe ths nstructon.
In order to transport the
machne nto a buldng,
the mnmum necessary
dmensons of the openng
(of doors, etc,) are
1.2m, (W) and 1.7m, (H).
2-2 OPERATIONAL AREA
INSTALLATION SPACE
2-2 Fig 01 2-2 Fig 02
2-2 Fig 01
Before leavng the machne after Installaton, make sure that the Castor Lft Adjusters
are rmly postoned on the ground and that the machne s totaly stable.

6
PRECAUTION REGARDING PRODUCT OPERATION
3In order to avod accdents, check the followng before startng the operaton:
To ensure maxmum safety for the players and the customers, ensure that where the
product s operated has su󱐰cent lghtng to allow any warnngs to be read.
Operaton under nsuffcent lghtng can cause bodly contact wth each other,
httng accdent, and/or trouble between customers.
Be sure to perform approprate adjustment of the montor (projector). For operaton
of ths machne, do not leave montor’ s flckerng or devaton as s. Falure to
observe ths can have a bad nuence upon the players’ or the customers’ physcal
condtons.
It s suggested to ensure a space allowng the players who feel sck whle playng the
game to take a rest.
Check f all of the adjusters are n contact wth the surface. If they are not, the cabnet
can move and cause an accdent.
3 PRECAUTIONS REGARDING PRODUCT OPERATION
3.1 BEFOREOPERATION
Do not put any heavy tems on ths product. Placng any heavy tem on the product
can cause a fallng down accdent or parts damage
Do not clmb on the product. Clmbng on the product can cause a fallng down
accdent. To check the top porton of the product, use a step ladder.
To avod electrc shock, short crcut and / or parts damage,
do not put the followng tems on or n the perphery of
the product.
Flower vases, ower pots, cups, water tanks, cosmetcs,
receptacles or vessels contanng chemcals or water.
3-1 Fg 01
Ensure that all adjusters are n contact wth the oor.

PRECAUTIONS REGARDING PRODUCT OPERATION
7
3
Players hold the controller wth ther bare hands so t s recommended that wet towels
(paper towels) be provded.
● Durng daly cleanng be sure to check the surface of the steerng wheel, gear shfter
and other parts that the player touches wth hs hands for damage, cracks or loose
screws. If a player uses the machne whle t s damaged, cracked or has a loose
screw, the player may become njured.
● Durng daly cleanng, be sure to check the seat for any abnormalty, wetness, etc.
Falure to do ths may result n delberate tamperng or neglgence beng left unde-
tected.
● To avod njury, be sure to provde suffcent space by consderng the potentally
crowded stuaton at the nstallaton locaton. Insuffcent nstallaton space can
cause contact, collsons and or trouble between customers.
● Do not attempt to clean ths product usng pressursed equpment such as a jet
wash or hose. If for any reason ths product becomes wet, do not use untl t has
completely dred.
3.1 BEFOREOPERATION

8
PRECAUTION REGARDING PRODUCT OPERATION
3
● For safety reasons, do not allow any of the followng people to play the game.
・Those who need assstance when walkng.
・Those who have hgh blood pressure or heart problems.
・Those who have a neck or spnal cord problem.
・Those who have experenced muscle convulson or loss of conscousness whle
playng vdeo games, etc.
・Those who are ntoxcated or under the nuence of drugs.
・Pregnant women.
・Those who are not n good health.
・Those who do not follow the attendants nstructons.
・Those who cannot grasp the controller unt securely because of mmoblty n
ngers, hands or arms.
・Persons who dsregard the products warnng labels.
● Even players who have never been adversely affected by lght stmulus mght
experence dzzness or headaches dependng on ther physcal condton when
playng the game. Small chldren are especally lkely to experence these symptoms.
Cauton guardans of small chldren to keep watch on ther chldren durng play.
● Instruct those who feel sck durng pay to seek medcal advce or examnaton.
● To avod njury from fallng objects or electrc shock hazard from splt drnks, nstruct
the player not to place drnks or heavy tems on the product.
● To avod electrc shock hazard and short crcut hazard, do not allow customers to
put hand or ngers or any other extraneous matter n to the openngs of the product
or small openngs on or around the doors.
● To avod falls resultng n njury, mmedately stop the customer from leanng
aganst or clmbng on the product.
● To avod electrc shock and/or short crcut hazard, do not allow customers to unplug
the power plug wthout a justable reason.
● Ths product s ntended for 1 Player only. Playng the game by 2 or more Players
rdng on the seat together can cause fallng down and collson accdents by strkng
heads, hands or elbows.
● Persons other than the player should not
be allowed to touch the controls durng
play. They may brush aganst or collde
wth the controls or the player, possbly
resultng n accdent.
To avod njury and trouble, be sure to pay attenton to the behavor of vstors and players.
3.2 PAYINGATTENTIONTOCUSTOMERSDURINGOPERATION

PRECAUTIONS REGARDING PRODUCT OPERATION
9
3
Immedately stop such volent acts as httng and kckng the product. Such volent acts
can cause parts damage or cause the cabnet to fall over, resultng n njury.
● Customer should be warned not to place chldren on ther laps whle they
play the game. Dong so may cause the chld to become trapped between the
player and the control panel and/or cause the machne to tp over.
3.2 PAYINGATTENTIONTOCUSTOMERSDURINGOPERATION

10
Part Descrptons
4
4 PART DESCRIPTIONS
ITEM WIDTH (cm) DEPTH (cm) HEIGHT (cm) WEIGHT (kg)
DLP CABINET 1500 795 1700 160
MAIN CABINET 1100 2130 1320 210
BILLBOARD 1500 760 450 30
WHEN ASSEMBLED 1500 2785 2290 400
PROJECTOR SCREEN
SPEAKER POD
CONTROL PANEL
ASSEMBLY SEAT
ASSEMBLY HANDBRAKE
ASSEMBLY COIN TOWER
PROJECTOR HOUSING
ASSEMBLY BILLBOARD

ACCESSORIES
11
5
Conrm that the accessories list in the table below are present when setting up the product.
Accessories marked “Spare” in the note column are consumable items but included as spares.
TABLE 5A - ACCESSORIES
5 ACCESSORIES
SRS-INST-M ASSY INSTALLATION KIT SRS MDX
Level/Seq.No. Component Part Description
Component
Reference
Number
off
-------------- --------------------- ------------------------------- ----------------------------- ----------
**1 SRS-8200UK ASSY BILLBOARD SRS MDX 1
**4 SRS-8054UK JOINT BRKT MDX 2
**14 PK0450 BOX BILLBOARD SRS DX MK3 1
**101 440-CS0186UK STICKER C EPILEPSY MULTI 1
**104 LM1227 UK MAINS LEAD 10A WITH PLUG 1
**105 LM1246 EUROLEAD 10A EUROPEAN SOCKET 1
**106 CA LAN CAT5 500CM 1
**203 030-000825-SB M8X25 BLT W/S BLK (1)-8,(4)-2 16
**204 068-852216-0B M8 WSHR 22OD FLT BLK (1)-8,(4)-2 16
**402 420-0005-03UK SERVICE MANUAL SRS MDX 1
**403 OS1019 SELF SEAL BAG 9X12.3/4 3
**404 540-0006-01 WRENCH M4 TMP PRF 1
**408 DECLARATION OF CONFORMITY SAECE-xxx 1
**409 514-5078-5000 FUSE 5A T CERAMIC 20MM 1
MAINS LEADS
LM1227 (1xUK)
LM1246 (1xEURO)
DESCRIPTION OWNERS MANUAL
PT NUMBER (QTY) 420-0005-01UK
NOTE This Manual
Parts not labeled with part numbers are as
yet unregistered or cannot be registered.
Be sure to handle all parts with care, as some
parts are not available for purchase as
separate items.
KEY MASTER
220-9117 (2)
For opening/closing
the doors
KEY (2)
CASHBOX DOOR
TAMPER PROOF SCREW WRENCH
M4 540-0006-01 (1)
JOINT PLATE (Fitted)
SRS-8054UK (2)

12
ASSEMBLY & INSTALLATION
6
• Ths work should be carred out by ste mantenance personnel or other qualfed
professonals. Work performed by non-techncal personnel can cause a severe
accdent such as electrc shock. Falng to comply wth ths nstructon can cause a
severe accdent such as electrc shock to the player durng operaton. If no one wth
proper technologcal expertse s avalable, request servce from the o󱐰ce ndcated
n ths document or the pont of purchase so as to ensure safety.
• Perform assembly work by followng the procedure heren stated. Falure to comply
wth the nstructons can cause electrc shock.
• Perform assemblng as per ths manual. Snce ths s a complex machne, ncorrect
assemblng can cause an electrc shock, machne damage and/or mproper
functonng as per speced performance.
• When assemblng, more than one person s requred. Dependng on the assembly work,
there are some cases n whch workng by one person alone can cause personal
njury or parts damage.
• Ensure that connectors are properly connected. Improper connectons can cause
electrc shock.
• Be careful not to damage the wres. Damaged wres may cause electrc shock or short
crcut or present a rsk of re.
• Provde suffcent space so that assemblng can be performed. Performng work n
places wth narrow space or low celng may cause an accdent and assembly work
to be d󱐰cult.
• To perform work safely and avod serous accdent such as the cabnet fallng down, do
not perform work n places where step-lke grade d󱐯erences, a dtch, or slope exst.
• Do not leave power cords, ground wres or network cables n areas of heavy foot tra󱐰c.
Dong so may cause them to become damaged, possbly resultng n electrc shock
and/or short crcuts. When leavng wrng across a oor, always use a safety covers
to protect the wres. (Wrng dameter : Power Cables - approx 0.8, Network Cable
approx 0.5)
• The power cord for ths product has a ground termnal. Make sure to use ths ground
termnaton when pluggng t nto an ndoor outlet. Falure to ground the product
could lead to electrocuton. It can also cause malfuncton.
• Do not use connectors other than those connected to and used by the game board at
the tme of shpment. Do not connect wres to unused connectors. Ths could cause
the generaton of heat or smoke, or a burnout.
6 ASSEMBLY & INSTALLATION
• Wear approprate work clothng so that work can be performed safely. Use gloves and
safety shoes to prevent accdents or njures.
• When nstallng a wre protecton cover over a oor, use a materal shaped so that no
one passng by wll stumble over t. Usng a materal that could be stumbled over
mght lead to an accdental fall.
• Handle plastc parts wth care. Excessve weght or pressure may cause them to break
and the broken peces may cause njury.
• When openng/closng, attachng/removng doors or lds, be careful that your hands or
ngers etc, does not get caught n the apparatus.

ASSEMBLY & INSTALLATION
13
6
Installation and assembly of this product should take place in the following sequence.
6-2 FITTING THE BILLBOARD AND POP
6-4 INSTALLATION AND SECURING IN PLACE
6-5 CONNECTING POWER CABLE AND GROUND
6-6 CHECKING ASSEMBLY (SET UP)
6-1 GENERAL ASSEMBLY INFORMATION
6-3 FIXING THE MAIN CABINET TO THE DLP CABINET

14
ASSEMBLY & INSTALLATION
6
6-1 GENERAL ASSEMBLY INFORMATION
There are three MAIN Assembles suppled, that have to be tted together n order to
complete the bult of ths machne :
A - DLP Cabnet (Vdeo Cabnet Assembly)
B - Bllboard (Bllboard Assembly)
C - Man Cabnet (Seat and Control Assembly)
6-1 Fig 01
ASSEMBLY BILLBOARD
ASSEMBLY MAIN CABI
ASSEMBLY DLP

ASSEMBLY & INSTALLATION
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6
6-2 FITTING THE BILLBOARD AND POP
The BILLBOARD weighs 40Kgs (88.2lbs) therefore this installation should not
be attempted single handed. It is recommended that three persons under-
take this particular section of the installation.
WORK SHOULD NOT BE UNDERTAKEN ON TOP OF THE CABINET WITHOUT
THE USE OF A SUITABLE STEP OR FOOTSTOOL.
STEP 1
Using 2 people, a step ladder or step, place
the Assembly Billboard on top of the Display
Cabinet (g 01).
Maketheconnectionherebeforelowering
theBillboard.
6-2 Fig 01
6-2 Fig 02
6-2 Fig 03
STEP 2
Make the connections good before
lowering the Billboard in to place (g 02)..
STEP 3
Secure the Billboard to the top of the
Display Cabinet using the 6x M8 bolts and
washers supplied.