Mallory 646 User manual

1MALLORY TECHNICAL SUPPORT [phone] [email protected]
®
WINDOW RPM ACTIVATED SWITCH
PART NO. 646
INSTALLATION INSTRUCTIONS
FORM 1008 (REV. A) 01/02
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.
t will not only activate at a particular RPM, but can also be set to de-
activate at a second, higher, RPM. t can be used on 4-12 cylinder engines.
NOTE: The Mallory 646 CANNOT be triggered from points or elec-
tronic 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.
WIRING PROCEDURE
Step 1
Connect the BLACK W RE 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. f you are connecting the RPM Activated Switch to an
aftermarket ignition system such as a Mallory HYF RE®, use the same
grounding location that the ignition uses. See Figures 2-4, pages 2-3.
Step 2
Connect the RED W RE 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 W RE must be connected to the ignition system tach output.
 When using a Mallory ignition system, connect the GREEN W RE
to the TACH terminal. See Figures 2-4, pages 2 and 3.
 When using an aftermarket ignition with a TACH output, connect
the GREEN W RE to the TACH terminal. Check manufactures ig-
nition instructions to find this location.
 Other aftermarket ignitions  Connect the GREEN W RE to the ta-
chometer lead terminal. Check manufacturers ignition instructions
to find this location.
Step 4
To connect a device that you want to switch ON at the RPM setting
youve selected, such as a shift light, connect one ORANGE W RE to the
device and the other ORANGE W RE 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 youve
selected, such as a nitrous solenoid, connect one PURPLE W RE to the
device and the other PURPLE W RE 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.
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
General Information ...................................................................... 1
Mounting Procedure ..................................................................... 1
Wiring Procedure .......................................................................... 1
How to Set the Window RPM Switch ........................................... 2
Wiring Diagrams for the RPM Acti ated 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
CONTENTS

MALLORY IGNITION 550 MALLOR WA , CARSON CIT , NV 897012
HYFIRE®IV
IGNITION SYSTEM
®
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 Connect to 12VOLT source
DO NOT connect to COIL +
RED
C – CYLINDER SELECT
L – LOW RPM
H – HIGH RPM DOWN
UP
WINDOW RPM SWITCH
P/N 646
MODE
VALUE
MODE
®
BLACK
To engine block or
chassis ground
GREEN
To tachometer
Connect this harness according
to the instructions applicable to
the HYFIRE
®
being used.
To battery (+)
terminal
Used for magnetic pickup
distributor or crank trigger
To engine block or
chassis ground
HOW TO SET THE WINDOW RPM SWITCH
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).
C – CYLINDER SELECT
L – LOW RPM
H – HIGH RPM DOWN
UP
WINDOW RPM SWITCH
P/N 646
MODE
VALUE
MODE
®
FIGURE 2
FIGURE 2
RPM ACTIVATED SWITCH WITH HYFIRE® IV

3MALLORY TECHNICAL SUPPORT [phone] [email protected]
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.
075
Connect ignition coil and distributor/trigger
wires according to the HYFIRE
Æ
VII instructions
applicable to the distributor/trigger being used
To tachometer
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.
BLACK
RED
DO NOT connect to coil (+) terminal
BLACK
To engine block or
chassis ground
ORANGE WIRES ñ
Connect to a device to be turned
ON at a selected RPM.
C ñ CYLINDER SELECT
L ñ LOW RPM
H ñ HIGH RPM DOWN
UP
WINDOW RPM SWITCH
P/N 646
MODE
VALUE
MODE
®
FIGURE 3
0 7 5
STANDARD STANDARD
Connect ignition coil and distributor/trigger wires
according to the HYFIRE
Æ
VII instructions applicable to
the distributor/trigger being used
GREEN
C ñ CYLINDER SELECT
L ñ LOW RPM
H ñ HIGH RPM DOWN
UP
WINDOW RPM SWITCH
P/N 646
MODE
VALUE
MODE
®
To tachometer
RED
DO NOT connect to COIL (+) terminal
PURPLE
ORANGE
BLACK
Connect the other wire from the device to
GROUND. NOTE: Relays are required if the
device being switch requires more than 5 amps.
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 OFF at a selected RPM.
Connect this wire to a device to be
turned ON at a selected RPM.
To engine block or chassis ground
To engine block or chassis ground
To engine block or chassis ground
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.
These relays are shown as examples
only. Other relays may be used, such
as Blue Streak Part No. RY-48
FIGURE 4
RPM ACTIVATED SWITCH WITH HYFIRE® VII
RPM ACTIVATED SWITCH AND
RELAYS WITH HYFIRE® VII

MALLORY IGNITION 550 MALLOR WA , CARSON CIT , NV 897014
PURPLE WIRES
(NOT USED)
ORANGE WIRES (NORMALLY OPEN -
CLOSES/“ON” AT THE RPM SETTING)
TO 12V SOURCE
ORANGE18AWG
WIRE
PART NO. 646
PART NO. 646
PART NO. 646
PURPLE
WIRES
(NOT
USED)
RED, GREEN AND BLACK
WIRES: SEE PAGES 5-12
ORANGE WIRES (NORMALLY OPEN -
CLOSES/“ON” AT THE RPM SETTING)
TO 12V SOURCE
ORANGE18AWG
WIRE
(#21)
REMOTETIMINGCONTROL
IGNITION SYSTEM
PART NO. 631
PURPLE WIRES
(NOT USED)
RED, GREEN AND
BLACK WIRES: SEE
TO 12V SOURCE
ORANGE WIRES
TO 12V SOURCE
ORANGE WIRES
ORANGE WIRES:
OR
NOTE: TO TURN LIGHTS “OFF” AT RPM SETTING - EXCHANGE THE ORANGE WIRES AND THE PURPLE WIRES.
RED, GREEN AND BLACK
WIRES: SEE PAGES 5-12
HIGH SPEED RETARD
PART NO.
618-1
(ZERO)
0
1
3
5
7
9
1
1
1
3
1
5
FIGURE 5 TIMING ETA D ON AT PM SETTING

5MALLORY TECHNICAL SUPPORT [phone] [email protected]
MANUAL SHIFTING: TURN
SWITCH “OFF”
TOGGLE SWITCH
PART NO. 26074
PART NO.646
PART NO.646
PART NO.646
TO 12V SOURCE
ORANGE OR PURPLE WIRES
RED, GREEN AND BLACK
WIRES: SEE PAGES 5-12
RED, GREEN AND BLACK
WIRES: SEE PAGES 5-12
RED, GREEN AND BLACK
WIRES: SEE PAGES 5-12
MANUAL SHIFTING: TURN SWITCH “OFF”
TOGGLE SWITCH
PART NO. 26074
TO 12V SOURCE
ORANGE OR PURPLE WIRES
MANUAL SHIFTING: TURN SWITCH “OFF”
TOGGLE SWITCH
TO 12V SOURCE
ORANGE OR PURPLE WIRES
HR - 106
1 3 5
USE ORANGE WIRES TO TURN
“ON”AT LOW RPM SETTING.
USE PURPLEWIRESTOTURN
“OFF” AT LOW RPM SETTING.
USE ORANGE WIRES TO TURN
“ON”AT LOW RPM SETTING.
USE PURPLEWIRESTOTURN
“OFF” AT LOW RPM SETTING.
USE ORANGE WIRES TO TURN
“ON”AT LOW RPM SETTING.
USE PURPLEWIRESTOTURN
“OFF” A
FIGURE 6 ELECT IC (SHIFTE ) SOLENOID

MALLORY IGNITION 550 MALLOR WA , CARSON CIT , NV 897016
PART NO.646
RED,GREEN AND BLACK
WIRES: SEE PAGES 5-12
PURPLEWIRES
(NOT USED)
ORANGEWIRES
TO 12V SOURCE:
“ON” ONLY WITH THE NITROUS
ARMING SYSTEM
HR - 106
GAS
SOLENOID NITROUS SOLENOID
PART NO.646
TO 12V SOURCE:
“ON” ONL
Y WITH THE NITROUS
ARMING SYSTEM
RED,GREEN AND BLACK
WIRES: SEE PAGES 4-11
PURPLEWIRES
(NOT USED)
HR - 106
GAS
SOLENOID NITROUS SOLENOID
ORANGE
18AWGWIRE
ORANGEWIRES
NOTE: THE NITROUS SYSTEM WILL TURN "OFF" AT UPPER RPM SETTING.
NOTE: THE NITROUS SYSTEM WILL TURN "OFF" AT UPPER RPM SETTING.
HIGH SPEED RETARD
PART NO.
618-1
(ZERO)
0
1
3
5
7
9
1
1
1
3
1
5
FIGURE 7
FIGURE 8
NIT OUS SYSTEM ON
AT PM SETTING
NIT OUS SYSTEM AND TIMING ETA D ON AT PM SETTING

7MALLORY TECHNICAL SUPPORT [phone] [email protected]
PURPLE WIRES
NOT USED
PART NO. 646
BLACK WIRE
GROUND
GREEN WIRE
TACH TERMINAL
RED WIRE
12V IGN. SWITCH
ORANGE WIRES
OPTIONAL
SWITCH
B&M PRO
RATCHET SHIFTER
NEUTRAL SAFETY
TO 12V
TO STARTER
SWITCH
TO 12V
SHIFNOID
INTERFACE RELAY
COMMON
NORMALLY OPEN
NORMALLY CLOSED
87A
87
(NOT USED)
86 85
30
FIGURE 9
SHIFNOID WI ING FO B&M ATCHET SHIFTE
W/SN5070 SOLENOID

MALLORY IGNITION 550 MALLOR WA , CARSON CIT , NV 897018
FORM 1008
(REV. A) 01/02
Made in U.S.A.
Printed in U.S.A.
MALLORY IS A DIVISION OF HE MR. GASKE PERFORMANCE GROUP
550 MALLORY WAY, CARSON CI Y, NEVADA 89701
[phone] FAX [phone]
www.mrgasket.com