Mallory Ignition 6855M, 6856M User Manual [en, es, fr]

Hyre 6EZ and 6EZ RPML

Instruction Manual

Part#: 6855M, 6856M

HYFIRE®6EZ and 6EZ RPML SERIES

ELECTRONIC IGNITION CONTROL

PART NOS. 6855M (6EZ) and 6856M (6EZ RPML)

PLEASE READ THESE INSTRUCTIONS COMPLETELY BEFORE STARTING THE INSTALLATION

INSTALLATION INSTRUCTIONS

FORM 1604 03/04

GENERAL INFORMATION

The features of the HYFIRE®6EZ and HYFIRE®6EZ RPML are the same, with one exception: the HYFIRE®6EZ RPML includes a single stage RPM limiter.You can set various RPM limits using switches that are accessible through the rectangular cut-out in the end bracket. See page 4 of this instruction form for more information about the rev limiting features of the HYFIRE

6EZ RPML.

Battery

The HYFIRE

6EZ Series Ignition Control operates on any negative ground, 12 volt electrical system with a distributor. It will also work with 16 volt batteries and can withstand a momentary spike of 24 volts in case of jump starts. This system delivers full voltage with a supply of 10-18 volts, and operates with a supply voltage as low as 8 volts. If your application does not use an alternator, allow at least 15 amp/hour for every half hour of operation. If you crank the engine with the same battery or other accessories, such as an electric fuel or water pump, increase the amp/hour rating.

Coils

The ProMaster

Performance Coil will deliver optimum performance with your HYFIRE®6EZ Ignition Control. The stock coil on the vehicle is also retained.

NOTE: Do not install the HYFIRE®6EZ Ignition Control in any vehicle that is originally equipped with a CD ignition control.

Spark Plugs and Wires

High quality, spiral wound wire and proper routing are essential to the operation of the HYFIRE®6EZ Ignition Control. This type of wire provides a good path for the spark to follow while minimizing electromagnetic interference (EMI).

NOTE: Do not use solid core spark plug wires with the

HYFIRE®6EZ Ignition Control.

Routing

Wires should be routed away from sharp edges, moving objects, and heat sources. Wires that are next to each other in the engine’s firing order should be separated. For example, in a Chevy V8 with a firing order of 1-8-4-3-6-5-7-2, the #5 and #7 cylinders are positioned next to each other on the engine as well as in the firing order. Voltage from the #5 wire could jump to the #7 wire. This could cause detonation and engine damage. For added protection against cross-fire, Mallory offers PRO SHIELD insulated sleeving. Pro Shield is a glass woven, silicone coated protective sleeve that slides over your plug wires. It also helps reduce damage from heat and sharp objects.

MISCELLANEOUS INFORMATION

Sealing

Do not attempt to seal the HYFIRE®6EZ Ignition Control. All of the circuits of a HYFIRE®6EZ receive a conformal coating of sealant that protects the electronics from moisture. Sealing the HYFIRE

6EZ will not allow any moisture that seeps in through the grommets to drain and may result in corrosion.

1 HYFIRE®6EZ Ignition Control 1 ProMaster e Performance Coil 1 Coil Wire Kit 8 #10 Sheet Metal Screws

4 10-32 X 7/8 Screws 4 10-32 nuts 2 Ring Terminals, Insulated

PARTS INCLUDED:

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mark the location of the mounting holes. Use a 1/8" drill bit to drill the holes. Use the supplied self-tapping screws to mount the box.

The ProMaster

Performance Coil can be mounted in any position. We recommend placing it within 24" of the distributor for ease of wiring.

Welding

To avoid any damage to the HYFIRE

6EZ Ignition Control when welding on the vehicle, disconnect the positive (red) and negative (black) power cables of the HYFIRE®6EZ Ignition Control. It is also a good idea to disconnect the tachometer ground wire as well.

Distributor Cap and Rotor

We recommend installing a new distributor cap and rotor when installing the HYFIRE®6EZ Ignition Control. Be sure the cap is clean inside and out, especially the terminals and rotor tip. On vehicles with smaller caps, it is possible for the air inside the cap to become electrically charged causing crossfire which can result in misfire. You can prevent this by drilling a couple of vent holes in the cap. Drill the holes between terminals at rotor height, facing away from the intake. If needed, place a small piece of screen over the holes to act as a filter.

Hyfire®6EZ Diagnostic LED (Not available with rev limiting ignition 6EZ RPML). On the end panel of your Hyfire 6EZ ignition there is a small hole. Behind this hole is a red LED indicator. The LED will flash when receiving a proper trigger signal from the vehicle. If, after a normal power-up, the LED doesn’t flash when cranking the engine, you should check your triggering circuit for problems. If the LED flashes when the engine is cranked, but there is still no spark, the problem lies somewhere else.

Hyfire®6EZ Cylinder Selection

Your HYFIRE®6EZ Ignition comes from the factory set up for 8 cylinder operation. If you want to use this

ignition with a 4 or 6 cylinder engine, you must first remove the four screws that hold the endplate with the LED hole. Once the endplate is removed, you’ll see the end of the circuit board. Look for the two-section switch. To select 4 cylinder mode, move the switch marked "1" to the "ON" position. To select 6 cylinder mode, move the switch marked "2" to the "ON" position. If both switches are "OFF", or both are "ON", the ignition will run in the 8 cylinder mode. See Figure 1.

MOUNTING

The HYFIRE®6EZ Ignition Control can be mounted in any position. If you mount it in the engine compartment, keep it away from moving objects and heat sources. Do not mount the unit in a closed area, such as the glovebox.When you find a suitable location to mount the unit, make sure all wires of the ignition reach their connections. Hold the ignition in place and

LABELS FOR

"CYLINDER SELECT"

ON CIRCUIT BOARD

DIAGNOSTIC

LED

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WIRING See Figure 2

Remove the factory coil wire and set it aside. Leave all other wiring on the distributor and coil in place. Connect one of the 2 supplied coil wires from the factory coil tower to the high tension tower on the end of the HYFIRE®6EZ Ignition Control.

Take the other supplied coil wire and connect it from the new Mallory coil to the distributor.

Connect the Red wire from the harness to the battery positive (+) terminal.

Connect the Black wire from the harness to the battery negative (-) terminal.

Plug the harness connector into the matching connector on the ignition control.

Note: All of the wires of the HYFIRE®6EZ Ignition Control may be shortened as long as quality connectors are used or soldered in place.

BLACK (LARGE 14 GA)

TO BATTERY NEG (

)

RED (LARGE 14 GA)

TO BATTERY POS (

)

NEW COIL WIRE

COIL WIRE

STOCK COIL

NEW COIL

TO DISTRIBUTOR

PART No. 6855

WIRE FUNCTIONS

Power Leads

The two heavy gauge wires (14 gauge) that deliver battery voltage to the ignition:

Heavy Red Connects directly to the battery positive (+)

terminal or to a positive battery junction. It could also be connected to the positive side of the starter solenoid.

NOTE: Never connect this

wire to the alternator.

Heavy Black Connects directly to the battery negative (-)

Orange/Black Plugs into the coil connector. These are the

only wires that make electrical contact with the ProMaster

Performance Coil.

ROUTING WIRES

Route all wires away from heat sources, sharp edges, and moving objects. Route the trigger wires separate from the other wires and spark plug wires. If possible, route them along a ground plane, such as the block or firewall, which creates an electrical shield. The magnetic pickup wires should be routed separately and twisted together to help reduce extraneous interference.

WARNING: The HYFIRE®6EZ Ignition Control is a capacitive discharge ignition. High voltage is present at the coil primary terminals. Do not touch these terminals or connect test equipment to them.

Connector

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Rotary Switch Switch #1 Switch #1

Position DOWN UP

0 4,500 8,500 1 4,750 8,750 2 5,000 9,000 3 5,250 9,250 4 5,500 9,500 5 5,750 9,750 6 6,000 10,000 7 6,250 10,250 8 6,500 10,500

9 6,750 10,750 A 7,000 11,000 B 7,250 11,250 C 7,500 11,500 D 7,750 11,750 E 8,000 12,000 F 8,250 NO LIMIT

Number of

Cylinders Switch #2 Switch #3

4 UP Down

6 Down UP

8 Down Down

RPM Limiter Settings 6EZ RPML Only See Figure 3 Note the sticker attached to the end plate of the HYFIRE®6EZ

RPML. This sticker shows settings for number of cylinders and RPM limits. In case the sticker becomes damaged or otherwise unreadable, the settings are shown at right.

Setting Switch #4 Not used

PRESTART CHECKLIST

• The only wires connected to the new coil terminals should be the orange connected to coil positive (+) and black connected to coil negative (–).

• Power leads are connected directly to the battery positive and negative terminals.

• Both coil wires are seated into place.

• The engine is equipped with at least one ground strap to the chassis.

TROUBLESHOOTING

This section offers several tests and checks you can perform to ensure proper installation and operation of the HYFIRE®6EZ Ignition Control. If you experience a problem with your HYFIRE

6EZ, first check for proper installation and poor connections. You can eliminate many problems by checking these items. If you have any questions concerning your HYFIRE®6EZ Ignition Control contact the Mallory Technical Service Department at

216.688.8300, Monday through Friday, 8:30 am to 5:30 pm

Eastern time.

Misses and Intermittent Problems

Experience has shown that if your engine is misfiring or hesitating at higher RPM, it is usually not an ignition problem. Most common causes include a coil or plug wire failure, arcing from the cap or boot plug to ground or spark ionization inside the cap. Perform the following checks:

FIGURE 3

• Inspect the plug wires at the cap and at the spark plug for a tight connection. Visually inspect for cuts, abrasions, or burns. The higher energy of the new ignition can create an arching problem if the spark plug wires have deteriorated. This will make the engine miss.

• Inspect the primary coil wire connections. Because the HYFIRE®6EZ Ignition Control receives a direct 12 volt source from the battery, there will not be any voltage at the coil positive (+) terminal, even with the key turned on. During cranking, or while the engine is running, very high voltage will be present and no test equipment should be connected.

WARNING: Do not touch the coil terminals during cranking or while the engine is running.

• Make sure that the battery is fully charged and the connections are clean and tight. If you are not running an alternator, this is an imperative check. If the battery voltage drops below 10 volts during a race, the HYFIRE®6EZ Ignition Control output voltage will drop.

• Is the engine running lean? Inspect the spark plugs and the entire fuel system.

• Check all wiring connections for corrosion or damage. Remember to use proper connections followed by soldering, then seal the connections completely.

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