Brake Adjustment Details for Case 586G

[MikePhua]

Background of the Machine
The Case 586G is part of the G Series 3 rough-terrain forklifts (models 585G, 586G and 588G) produced by Case Construction Equipment (a brand of CNH Industrial).
Some key specifications:

• Rated lift capacity around 6,000 lb (≈2,722 kg) for the 586G model.
  
• Operating weight for 2-wheel drive version about 14,285 lb (≈6,480 kg).
  
• Engine output about 80 net hp (≈60 kW) for the model.
  
• Among its features: roller mast design and self-adjusting wet-disc brakes for increased component life and reduced maintenance.
  

In other words, when working on brake adjustment for the machine, it is important to understand that the system is not the typical shoe and drum set-up – it uses wet-disc style brakes, sealed and designed for minimal maintenance. Because of that, the treatment of “adjustment” is different than older systems.

Key Brake System Terms (Glossary)

• Wet-disc brakes: A braking system where discs (rotors) and pads operate fully sealed in a bath of oil or hydraulic fluid; the fluid cools the discs and prevents contamination.
  
• Self-adjusting: A mechanism that automatically takes up wear of brake pads/discs so that manual adjustment of clearance is not required under normal service.
  
• Parking brake: A brake function intended to hold the machine stationary when parked; may be spring-applied/hydraulically released or a separate mechanism.
  
• Brake pedal free-travel / “play”: The distance the pedal moves before the braking force begins to apply. Excessive free travel means delayed braking.
  
• Axle brake oil / fluid level: For wet-disc systems, brake fluid (or oil) bath level and condition are critical, not just pad thickness.
  
• Drag: Slight friction or contact in the brake system when wheel is turned by hand; used as a diagnostic tweak for shoe/linings in drum systems, less so for sealed wet-disc systems.
  

When and Why to Check Adjustment
Although the 586G uses a self-adjusting wet-disc brake system, you still can encounter issues where braking feels weak, pedal travel is long, or the parking brake won’t hold. In these cases adjustment or system inspection is needed. Common symptoms:

• Brake pedal travels significantly before braking engages.
  
• Machine creeps or rolls when parking brake is set.
  
• Brakes feel “soft” or require repeated pedal travel to get full effect.
  
• Unusual brake fluid leakage, contamination, or overheating.
  Maintenance literature confirms wet-disc brakes require far less service but system integrity still matters.
  

There’s a small anecdote: A contractor parked his 586G overnight on a slight incline. In the morning the machine had shifted slightly despite the parking brake being applied. Upon inspection, the brake-oil level in the axle was low; replenishing fluid and cycling the brake restored full holding power. This underlines that even “self-adjusting” systems still need proper fluid maintenance.

Step-by-Step Brake Adjustment and Inspection Procedure
Below is a recommended sequence specifically tailored to the 586G as a wet-disc self-adjusting system.

1. Park and secure the machine
   • Lower the forks to the floor and set the transmission in neutral.
     
   • Apply parking brake and chock wheels if on incline for safety.
     
   • Shut down engine and remove key.
     
2. Check brake fluid/oil bath level
   • Locate the axle housing or brake bath fill plug (manufacturer manual will specify).
     
   • Level should be at the specified mark; add the correct fluid if low.
     
   • Check for contamination: water ingress, excessive sludge or metal particles. Replace fluid if compromised.
     
3. Inspect seals and external components
   • Look for external leaks around axle, hubs, or brake housing covers.
     
   • Check for damaged vent plugs or missing sealing bolts.
     
   • Ensure the parking-brake actuator (spring/hydraulic or cable) functions smoothly.
     
4. Check pedal free-travel and linkage
   • With the engine off, press the brake pedal and note distance before feeling firm resistance. Compare to service manual spec (often under ½–¾ inch free travel).
     
   • Adjust linkage stop bolt if present so that pedal travel is within spec, and brake begins before excessive pedal travel.
     
5. Brake performance test
   • Start engine, select forward gear at low idle, slowly release parking brake and attempt to move – machine should resist motion strongly.
     
   • Bring machine to a slow forward speed, apply service brake — it should stop smoothly, with no “grab” or long pedal travel.
     
   • Set parking brake, count to five, attempt gentle forward motion; the machine should not creep.
     
6. Full load test
   • Under safe conditions, lift rated load or simulate equivalent, and retest braking. The system should still hold and stop effectively.
     
   • Monitor for brake fade (pedal travel increasing as brakes heat up) — improper oil level or contamination may cause this.
     
7. Document and schedule check-ups
   • Record brake bath oil change date, inspection findings, pedal travel data.
     
   • Since the system is self-adjusting, plan fluid changes and seal inspections at regular intervals (for example every 1,000 hours) or per manufacturer guidance.
     

Troubleshooting Common Issues & Solutions

• Excessive pedal travel / weak braking → likely causes: low brake fluid level, air in brake bath, worn or contaminated discs, linkage misadjustment. Solution: top up fluid, bleed if air-entrained, inspect discs and seals, adjust pedal linkage.
  
• Parking brake won’t hold on incline → causes: parking actuator malfunction (spring or hydraulic), worn internal components, bath fluid low or overheated. Solution: test actuator, replace faulty parts, verify bath level and fluid condition.
  
• Brake fade under heavy use → typically wet-disc bath contaminated (oil degraded) or overheating due to excessive slipping. Solution: drain and refill with new fluid, verify load capacity and operator technique (avoid riding brakes).
  
• Brake drag (wheels hard to turn when brake released) → even though system is sealed, internal seals may be sticking, bath fluid may be overfilled, or linkage stop bolt incorrectly set. Solution: inspect for seized components, check bath level, correct linkage stop.
  
• External leaks around axle housing → bad seals, loose cover bolts, or damaged vent. Solution: replace seals, tighten bolts to spec, ensure vent is clean.
  

Additional Recommendations for the 586G Owner/Technician

• Use only the brake-bath fluid type specified by the manufacturer; substituting improper fluid can degrade seal life or brake performance.
  
• Avoid excessive brake slipping (i.e., riding the brake) especially on rough terrain – this generates heat and can shorten life of the wet-disc assembly despite the “maintenance-free” claim.
  
• Keep operator training in mind: Proper braking technique reduces wear (e.g., decelerate early rather than heavy braking at last moment).
  
• Maintain service access: The 586G series was built with ground-level service access in mind. Good access means easier inspections and thus better long-term performance.
  
• Archive records of brake inspections and any parts replaced — when resale value or later owner audits occur, documented maintenance adds credibility.
  

Summary
While the 586G uses a modern self-adjusting wet-disc brake system, it still demands regular inspection: fluid level and condition, pedal travel, and external components. Proper linkage adjustment, fluid maintenance and test-drives with load will ensure that the braking system functions safely and effectively. Skipping these checks can lead to delayed braking response, inadequate parking-brake hold or brake fade under heavy loads. Treat brake adjustment not as a one-time job but as part of the ongoing preventive-maintenance plan.