Mallory Ignition 646 User Manual
INSTALLATION INSTRUCTIONS
®
WINDOW RPM ACTIVATED SWITCH
PART NO. 646
Parts Included in this kit:
1 RPM Activated Switch Part No. 646
1 U shaped crimp-on wire terminal
1 #6 x 1/4" sheet metal screw
2 Velcro strips
CONTENTS
General Information ...................................................................... 1
Mounting Procedure ..................................................................... 1
Wiring Procedure .......................................................................... 1
How to Set the Window RPM Switch ........................................... 2
Wiring Diagrams for the RPM Activated Switch
Connecting to a HYFIRE® IV .....................................................2
Connecting to a HYFIRE® VII ....................................................3
Connecting to relays with a HYFIRE® VII ................................ 3
Connecting to a Timing Retard ................................................ 4
Connecting to a Timing Control ............................................... 4
Connecting to a Light ............................................................... 4
Connecting to an Electric (Shifter) Solenoid .......................... 5
Connecting to a Nitrous System .............................................. 6
Connecting to a Nitrous System and Timing Retard ..............6
Shifnoid Warning ....................................................................... 7
GENERAL INFORMATION
The Mallory 646 Window RPM Switch is an RPM switch that is triggered
from the tach terminal available on most aftermarket performance ignitions.
It will not only activate at a particular RPM, but can also be set to deactivate at a second, higher, RPM. It can be used on 4-12 cylinder engines.
NOTE: The Mallory 646 CANNOT be triggered from points or electronic distributor. It must be triggered from a tach output terminal.
The 646 features two independent sets of switch contacts that switch other
devices on or off when the selected RPM is reached. These contacts
switch a maximum current of 5 amps. To switch more than 5 amps, you
must use the RPM Activated Switch output to drive a high current relay,
such as a horn or headlight (see illustrations).
NOTE: The switch contacts are NOT connected electrically. This
allows you to turn one circuit on and another off at the same RPM.
MOUNTING PROCEDURE
Step 1
Disconnect the battery () cable to cut power to the system.
Step 2
Mount the unit in an area away from hot engine components or extreme
heat, such as exhaust manifolds, and away from moving parts, such as fans,
belts, and linkages.
Step 3
Mount the unit using supplied Velcro strips.
FORM 1008 (REV. A) 01/02
WIRING PROCEDURE
Step 1
Connect the BLACK WIRE to engine or chassis ground. You can use the
supplied U shaped terminal and #6 x 1/4" sheet metal screws to make
this connection. If you are connecting the RPM Activated Switch to an
aftermarket ignition system such as a Mallory HYFIRE
grounding location that the ignition uses. See Figures 2-4, pages 2-3.
®
, use the same
Step 2
Connect the RED WIRE to a 12-volt power supply, such as the ignition
switch. You can use the same wire that provides power for your ignition
as long as a ballast resistor is not wired in series with it. NOTE: Do NOT
connect the RED WIRE to the coil (+) terminal. Connect it to the
wire coming directly from the ignition switch. If your vehicle is
equipped with loom resistance wire, you must provide an alternate
power connection to the red wire.
Step 3
The GREEN WIRE must be connected to the ignition system tach output.
When using a Mallory ignition system, connect the GREEN WIRE
to the TACH terminal. See Figures 2-4, pages 2 and 3.
When using an aftermarket ignition with a TACH output, connect
the GREEN WIRE to the TACH terminal. Check manufactures ignition instructions to find this location.
Other aftermarket ignitions Connect the GREEN WIRE to the ta-
chometer lead terminal. Check manufacturers ignition instructions
to find this location.
Step 4
To connect a device that you want to switch ON at the RPM setting
youve selected, such as a shift light, connect one ORANGE WIRE to the
device and the other ORANGE WIRE to a 12-volt power supply. Connect
the remaining wire from the device to a ground. See Figure 5, page 4.
Step 5
To connect a device that you want to switch OFF at the RPM setting youve
selected, such as a nitrous solenoid, connect one PURPLE WIRE to the
device and the other PURPLE WIRE to a 12-volt power supply. Connect
the remaining wire from the device to a ground.
Step 6
Secure all wires to prevent contact with extreme heat, sharp objects, or
moving devices, such as fans, belts, and linkages.
Step 7
Recheck all wires and connections to ensure that they are correct before
applying power.
Step 8
Reconnect the battery () terminal cable. Start engine and check operation
of the RPM Activated Switch.
1MALLORY TECHNICAL SUPPORT (775) 882-6600 tech@mrgasket.com
HOW TO SET THE WINDOW RPM SWITCH
C – CYLINDER SELECT
L – LOW RPM
H – HIGH RPM
DOWN
UP
WINDOW RPM SWITCH
P/N 646
MODE
VALUE
MODE
On the front panel there are three buttons and an LED display. The
MODE button cycles through the low RPM setting, the high RPM
setting, and the cylinder number select. The UP and DOWN
buttons move the RPM in 100 RPM increments in either of the RPM
modes, and select 3-12 in the cylinder select mode.
The RPM range is 1000 to 16000 in 100 RPM increments. The high
setting (H) must be at least 200 RPM higher than the low (L) setting
for the switch to operate properly. The display shows RPM in
hundreds (for example, 76 would be 7600 RPM.
Set the cylinder select mode to the number of cylinders your engine
has (4-cycle only).
FIGURE 2
®
FIGURE 2
RPM ACTIVATED SWITCH WITH HYFIRE® IV
Connect ORANGE wires to a device
to be turned ON at a selected RPM
Connect PURPLE wires to a device to
be turned OFF at a selected RPM
To engine block or
chassis ground
To tachometer
BLACK
VALUE
MODE
MODE
UP
P/N 646
RED
C – CYLINDER SELECT
H – HIGH RPM
WINDOW RPM SWITCH
L – LOW RPM
DOWN
®
GREEN
Connect to 12 VOLT source
DO NOT connect to COIL +
Connect this harness according
to the instructions applicable to
the HYFIRE
®
being used.
To battery (+)
terminal
distributor or crank trigger
Used for magnetic pickup
®
HYFIRE® IV
IGNITION SYSTEM
To engine block or
chassis ground
MALLORY IGNITION 550 MALLORY WAY, CARSON CITY, NV 897012
To tachometer
Connect ignition coil and distributor/trigger
wires according to the HYFIREÆ VII instructions
applicable to the distributor/trigger being used
0 7 5
DO NOT connect to coil (+) terminal
DO NOT connect to coil (+) terminal.
Connect this wire to a switched 12 volt
source. Switch must be capable of
switching all of the current from the
ignition and device(s).
The ignition may draw up to 1/2 amp.
Minimum of 18GA wire should be used.
P/N 646
MODE
VALUE
L ñ LOW RPM
H ñ HIGH RPM
C ñ CYLINDER SELECT
MODE
WINDOW RPM SWITCH
UP
DOWN
BLACK
BLACK
FIGURE 3
RPM ACTIVATED SWITCH WITH HYFIRE® VII
RED
ORANGE WIRES ñ
Connect to a device to be turned
ON at a selected RPM.
®
PURPLE WIRES ñ
Connect to a device to be turned OFF at a
selected RPM. NOTE: Relays are required if
device being switched draws more than 5 amps.
To engine block or
chassis ground
FIGURE 4
RPM ACTIVATED SWITCH AND
RELAYS WITH HYFIRE® VII
0 7 5
These relays are shown as examples
only. Other relays may be used, such
as Blue Streak Part No. RY-48
Connect this wire to a device to be
turned OFF at a selected RPM.
Connect the other wire from the device to
GROUND. NOTE: Relays are required if the
device being switch requires more than 5 amps.
Connect this wire to a device to be
turned ON at a selected RPM.
Connect the other wire from the device to
GROUND. NOTE: Relays are required if the
device being switch requires more than 5 amps.
DO NOT connect these wires to COIL (+) terminal
Connect these wires to a switched 12 volt source.
Switch must be capable of switching all of the
current from the ignition and devices.
DO NOT connect to COIL (+) terminal
STANDARD
STANDARD
Connect ignition coil and distributor/trigger wires
according to the HYFIRE
the distributor/trigger being used
Æ
VII instructions applicable to
GREEN
RED
To engine block or chassis ground
To engine block or chassis ground
To engine block or chassis ground
To tachometer
H ñ HIGH RPM
L ñ LOW RPM
VALUE
MODE
DOWN
MODE
UP
P/N 646
C ñ CYLINDER SELECT
WINDOW RPM SWITCH
®
PURPLE
ORANGE
BLACK
3MALLORY TECHNICAL SUPPORT (775) 882-6600 tech@mrgasket.com
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