Shimano BL-4600 Manual - Page 2

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SI-8JY0A-002-00

General Safety Information

WARNING

– To avoid serious injuries:

• Improper use of your bicycle's brake system may result in a loss of control or

an accident, which could lead to a severe injury. Because each bicycle may

handle differently, be sure to learn the proper braking technique (including

brake lever pressure and bicycle control characteristics) for your bicycle.

Consult your bicycle dealer and the bicycle's owners manual, and practice

your riding and braking technique.

• The BL-4600/BL-R780 brake levers are equipped with a mode switching

mechanism to make them compatible with V-BRAKE brakes, caliper brakes,

cantilever brakes and roller brakes.

If the incorrect mode is selected it may cause either excessive or

insufficient braking force to occur, which could result in dangerous

accidents. Be sure to select the mode in accordance with the

instructions given in the mode switching table.

Mode position

Applicable brake

V position

The V indicates the mode

position for compatibility with

• V-BRAKE brakes

V-BRAKE brakes.

C/R position

The C indicates the mode

position for compatibility with

• Caliper brakes

caliper brakes and cantilever

brakes.

• Cantilever brakes

The R indicates the mode

• Roller brakes

position for compatibility with

roller brakes.

• If the front brake is applied too strongly, the wheel may lock and the bicycle

may fall forward, and serious injury may result.

• Use the ST-4600/4603, BL-4600/R780 with the BR-4600. Do not use the BR-

4600 in combination with previous STI levers for road riding or with the BL-

R770/BL-R550 brake levers for flat handlebars, otherwise the braking

performance provided will be much too strong.

• Securely tighten the caliper brake mounting nuts to the specified tightening

torque.

· Use lock nuts with nylon inserts (self-locking nuts) for nut-type brakes.

· For sunken nut type brakes, use sunken nuts of the appropriate length

which can be turned six times or more; when re-installing, apply sealant

(locking adhesive) to the nut threads.

If the nuts become loose and the brakes fall off, they may get caught up in

the bicycle and the bicycle may fall over. Particularly if this happens with the

front wheel, the bicycle may be thrown forward and serious injury could

result.

• Brakes designed for use as rear brakes should not be used as front brakes.

• Obtain and read the service instructions carefully prior to installing the

parts. Loose, worn or damaged parts may cause the bicycle to fall over and

serious injury may occur as a result. We strongly recommend only using

genuine Shimano replacement parts.

• Be careful not to allow any oil or grease to get onto the brake shoes. If any

oil or grease do get on the shoes, you should replace the shoes, otherwise

the brakes may not work correctly.

• Check the brake cable for rust and fraying, and replace the cable

immediately if any such problems are found. If this is not done, the brakes

may not work correctly.

• Always make sure that the front and rear brakes are working correctly before

you ride the bicycle.

• The required braking distance will be longer during wet weather. Reduce

your speed and apply the brakes early and gently.

• If the road surface is wet, the tires will skid more easily. If the tires skid, you

may fall off the bicycle. To avoid this, reduce your speed and apply the

brakes early and gently.

• Read the Service Instructions for the Brake Systems carefully before use.

• Read these Technical Service Instructions carefully, and keep them in a safe

place for later reference.

Note

• If using SHIMANO's road brake shoes in combination with ceramic rims, the

brake shoes will wear more quickly than normal.

• If the brake shoes have worn down until the grooves are no longer visible,

they should be replaced.

• Different brake shoes have their own characteristics. Ask the place of

purchase for details when purchasing the brake shoes.

• Parts are not guaranteed against natural wear or deterioration resulting from

normal use.

• For maximum performance we highly recommend Shimano lubricants and

maintenance products.

• For any questions regarding methods of handling or maintenance, please

contact the place of purchase.

Technical Service Instructions

SI-8JY0A-002

BR-4600

Caliper Brake

In order to realize the best performance, we recommend

that the following combination be used.

Series

TIAGRA

ST-4600 / ST-4603, BL-4600 / BL-R780

Brake lever

Caliper Brake

BR-4600

Brake cable

Installation of the brake lever

1. Installation to the handlebar

<ST-4600 / 4603>

Secure the assembly with the installation nut on the outside of

the bracket. Pull the bracket cover back and use a 5 mm Allen

key to tighten the bolt.

Bracket cover

5 mm Allen key

Installation nut

Tightening torque:

6 – 8 N·m {52 – 69 in. lbs.}

<BL-4600 / R780>

Use a 4 mm Allen key to install.

3. Lever stroke adjustment

Tightening torque:

6 - 8 N·m {53 - 69 in. lbs.}

4 mm Allen key

Use a handlebar grip with a

maximum outer diameter of

32 mm.

When installing the components to carbon frame/handle bar

surfaces, verify with the manufacturer of the carbon frame/parts

for their recommendation on tightening torque in order to

prevent over tightening that can cause damage to the carbon

material and/or under tightening that can cause lack of fixing

strength for the components.

2. Installation of the brake cable

<ST-4600 / 4603>

Tilt the lever in (as when shifting) to make it easier to pass the

cable through the cable hook.

Note: The front lever cannot be tilted

to the inside until lever

pushed once or twice.

Pull

Lever b

Tilt

• To increase the lever

Pass the inner cable through as shown in the illustration, and

Remove the pad spacer (A)

then set the inner cable drum into the cable hook.

and install the bump rubber.

Cable hook

* Apply a small amount of grease to the projections when installing

Inner cable drum

Temporarily secure the outer casing to the handlebar (by using

tape or similar material).

Outer casing

Tape

Installation of the brake

Then wrap the handlebar with handlebar tape.

1. Installation of the brake itself

Note:

Cut the cable at the length at which it is not pulled tight

when the handlebar is turned all the way to the left and

right.

<BL-4600 / R780>

Cable hook

• Mode switching

Outer casing

C/R position

Inner cable drum

Outer casing

Cable hook

Inner cable drum

2. Brake shoe setting position

<ST-4600 / 4603>

Pad spacer (A)

Pad spacers (A) + (B)

4º

8º

Initial condition:

4º

7.5 mm

14 mm

Pad spacer (A)

Pad spacer (B)

Bump rubber

• To decrease the lever

stroke

Insert pad spacer (B) as far as

it will go and so that the

3. Cable connection

projections fit into the holes in

pad spacer (A).

the pad spacer and the bump rubber.

4. Centering of the brake shoe

<BL-4600 / R780>

Make a minor adjustment by using the centering adjustment

2 mm Allen key

5.6 mm

screw.

22 mm

Compress the arch‚ and set while the shoe is in firm contact

with the rim.

Tightening torque:

8 – 10 N·m {69 – 87 in. lbs.}

5. Readjustment of the shoe clearance

5 mm Allen key

Turn the cable adjustment bolt to readjust the shoe clearance.

The usual position during

installation is when the head

of the centering adjustment

screw is as shown in the

illustration.

6. Check

Depress the brake lever about 10 times as far as the grip and

check that everything is operating correctly and that the shoe

After adjusting the brake shoe position so that the shoe surface

clearance is correct before using the brakes.

and the rim surface are as shown in the illustration, tighten the

shoe fixing bolt.

Direction of

rim rotation

<ST-4600 / 4603>

Direction of

Toe-in

rim rotation

0.5 mm

Note:

The BR-4600 allows the angle of contact between the shoe

<BL-4600 / R780>

and the rim (toe-in) to be adjusted. Adjusting the toe-in

makes it possible to obtain smoother braking operation.

1 mm or more

Shoe fixing bolt

4 mm Allen key

Tightening torque:

5 – 7 N·m {43 – 61 in. lbs.}

Set the quick release lever to the closed position; then adjust

One Holland, Irvine, California 92618, U.S.A. Phone: +1-949-951-5003

the shoe clearance (as shown in the illustration below) and

secure the cable.

Industrieweg 24, 8071 CT Nunspeet, The Netherlands Phone: +31-341-272222

Cable bolt tightening torque:

6 – 8 N·m {52 – 69 in. lbs.}

3-77 Oimatsu-cho, Sakai-ku, Sakai-shi, Osaka 590-8577, Japan

* Service Instructions in further languages are available at :

http://techdocs.shimano.com

Please note: specifications are subject to change for improvement without notice. (English)

Centering adjustment

screw

3 mm Allen key

Open

Closed

Quick release lever

Cable adjustment bolt

Depress about

10 times

Depress about

10 times