Diamond Brake FAQs
Diamond Technology Brake FAQ’s
How do Diamond Technology Brakes provide improved brake modulation with smoother stops?
The unique properties of Diamond Technology Brakes improve the quality of stopping. Brake jerking, grabbing and shuddering are replaced with consistently smooth and controlled decelerations and stops. In terms of braking, “modulation” refers to the amount of fine control the driver has over a range of brake force that is directly related to how much brake pedal pressure is applied. The majority of “normal” braking occurs with relatively light pedal pressure to gradually slow the vehicle, sometimes to a complete stop. When conditions warrant more severe slowing and stopping, the driver will apply greater pressure to the brake pedal in order to maintain vehicle control and safety. A “panic stop” is an emergency condition that requires all of the brake force available to immediately stop the vehicle. Modulated brakes allow the driver to know every time just how the vehicle will slow and stop according to how much he or she steps on the brake pedal. There are no surprises or unpredictable brake events. A light brake application results in gradual slowing without grabbing. A heavy brake application results in a rapid stop without violent shaking or dangerous fading. Equally important to a responsive brake application is the ability for the brakes to release when necessary. Diamond Technology Brakes reduce the residual heat gain inside the wheel end, thereby allowing brake components to retain their original characteristics longer. Friction glazing is reduced or eliminated while drums and rotors maintain a more “friction friendly” surface allowing for dramatically improved brake performance and longevity.
How do Diamond Technology Brakes reduce noise where other brakes do not?
Brake noise - annoying squealing, screeching, howling and scraping sounds are the result of vibrations, mechanical waves that oscillate through various physical mediums; ending up, unfortunately, at our ear drums. Reducing vibration at various locations often reduces brake noise. Replacing loose and/or worn bushings, fasteners and other parts help to rectify components affected by vibration. However, when it comes to brakes, abating noise is often a trickier proposition that requires eliminating the resonance (vibration) problem at its origination. Heat energy is the natural by-product of braking. Too much heat will change the characteristics of the components at the friction couple, namely brake linings, drums and rotors. When overheated, brake friction tends to harden and crystallize as resins within the lining “bleeds” to the surface. Additionally the drum or rotor transforms as it heats, precipitating graphite from within the cast iron structure. Thermal expansion and contraction occurs. Hardened “martensitic” hot spots are created at the surface, as well as small cracks or “heat checks”. The once-new condition of the materials at the friction couple deteriorates, causing accelerated galling of brake lining and metal. Heat and wear increase as the brake’s stopping power degrades, thus requiring the driver to apply even more brake pressure to slow and/or stop the vehicle. The chain reaction proceeds. Glazed and crystallized brake lining in contact with a hardened and uneven cast iron surface creates an unfavorable friction couple that is adverse to smooth, modulated, quiet braking. Like fingernails on a blackboard the two incompatible materials will produce a pandemonium of the shrillest racket imaginable. The unique properties of Diamond Technology Brakes reduce the residual heat gain inside the wheel end, thereby allowing brake components to retain their original characteristics longer. Friction glazing is reduced or eliminated while drums and rotors maintain a more “friction friendly” surface. The problem of brake noise is eradicated at the source.
How do Diamond Technology Brakes eliminate brake “sticking”?
Brake “sticking” is the phenomenon that occurs when various metals found within certain frictions oxidize and adhere to rusting cast iron drums and rotors. This condition becomes a problem, particularly on non-powered axles like steer, trailer, tag, pusher and center axles (on articulating transit buses). When the corrosion becomes severe, the materials at the friction couple coalesce and the stuck brakes will cause the wheel(s) to lock, rendering the vehicle unmovable. Corrosion and rust is a pervasive reality in transit brakes. The incidence of stuck wheels is always greater in environments where certain catalysts (e.g. water and salt) come into contact with the brakes. In winter climates this circumstance worsens when ice and snow become a caustic soup mixed with various types of chlorides (salts) that attack nearly everything under the bus. The corrosion rates are further accelerated when they come into contact with elevated brake temperatures. When the vehicle is parked (with brakes applied) for an extended period of time of two days or more it is not uncommon to find a bus that cannot be driven until the “frozen” brakes are repaired, often a time-consuming and costly situation. Diamond Technology Brakes solves the problem of brake sticking. Corrosion inhibitors are introduced into the cast iron drums and rotors during the manufacturing process. Further, because Diamond Technology Brakes lower the overall operating temperatures at the wheel end, corrosion rates are reduced when compared with hotter environments.
How does the Diamond Technology Brakes program achieve fewer wheel seal failures?
Leaking seals are perhaps one of the most common problems in brake maintenance. It is a well-documented fact that over 90% of wheel seal failures are the result of improper installation. Power Brake understands this reality, which underscores the necessity for comprehensive training for all technicians and supervisors. The success of any brake maintenance program extends well beyond furnishing high quality components. Parts must be properly installed according to Original Equipment standards and maintained to industry-accepted recommended practices. As the saying goes, “A chain is only as strong as its weakest link”; so follows the Diamond Technology Brakes philosophy regarding brake maintenance. Therefore, Power Brake is committed to providing certified training to every Diamond customer. In fact, we require it. The “magic” to reducing wheel seal failures resides within the skilled and properly trained technician.
Diamond Technology Brakes reduce vehicle down time.
Fewer brake jobs mean vehicles stay on the road longer, generating revenue and serving your customers. Diamond Technology Brakes have been documented to double and, in many cases, triple brake life. It is that simple.
What are the burnishing requirements of Diamond Technology Brakes?
Brake friction manufacturers each have their suggested procedures for the burnishing of a new brake shoe friction to a brake drum or a brake pad to a brake rotor. Some of these recommended practices are quite extensive and time-consuming. For our purposes the final result of burnishing is simply the elimination of smoke (from contaminants) and noise (from vibration), while at the same time establishing required brake torque and a balanced brake system. This process requires building enough even heat into the friction so as to burn away any surface phenolics and contaminants. Some brake manufacturer’s state that brake drums and/or rotors be “seasoned” through a gentle burnish to reduce stresses inherent in the cast iron. Others assert that a film of friction material be transferred to the brake drum during this process for successful braking, employing in some cases a 500°F burnishing procedure. Diamond Technology Brake drums and rotors do not require this provision. Diamond drums and rotors are post-finished at the factory to enhance the burnishing process. Immediately following a brake job drive the vehicle at 20 mph with slight pressure on the brake pedal (minimum drum/rotor temperature to be 250 – 300 degrees F). Following this, take a short non-braking drive to allow for cooling of the brake shoe or brake pad. After cooling, conduct several 25 mph stops to confirm adequate brake torque and immediately record wheel 5 temperatures. Temperatures should be within 20 degrees F left to right, and 50 degrees F front to rear. In the event there is not sufficient brake torque, re-adjust the brakes, repeat the burnishing steps and conduct the 25 mph stopping procedure. This will complete the burnish process.
Diamond Technology Brakes reduce inventory carrying costs.
No longer are hundreds of extra parts required to perform brake maintenance. Diamond Technology Brakes axle kits require a single part number per axle. Each kit is equipped with all of the components necessary to perform a complete brake job. Because the entire kit is warrantied for 100,000 miles, it is required that each item in the assorent be replaced. This eliminates technician discretionary parts replacement and standardizes brake maintenance procedures. The needs for large numbers of potentially overstocked items are no longer necessary. Diamond Technology Brake axle kits erase any risk of wasting precious financial resources in stockpiled inventory which becomes obsolete as aging vehicles are retired from the fleet