2Pileco Diesel HammerThe Pileco Diesel hammer is a time proven design using the impact atomization principle. The Diesel pile hammers are self contained and do not require an additional power source.PILECO Diesel Hammers are reliable and always ready to operate Air-cooled; extreme heat and cold are not a problemThe capacity of the Diesel oil and lubricant tank allows several hours of constant pile driving.PILECO Diesel Hammers are adjustable The adjustable fuel pump serves to regulate the jumping height, and thereby the impact energy.The PILECO Diesel Hammer is environmentally friendly Following alternate fuels can be used without any pump or valve conversion to reduce pollution - soybean oil refined or oilseed rape (colza oil) - estherized soybean oil or oil serape oilseed rape - kerosene and JP-8 fuel
3Where the Pileco Diesel Hammers come from? Hammers are built to Pileco specifications using the time proven design along with many additional improvementsHammers are produced by Wuxi Xinren Universal Machinery Co. Ltd. – a manufacturer that has more than nine years experience in building D62 size hammers and larger (i.e. D80, D100, D125, D160, D180, D225, D250 and the D280)The main factoryA hammer cylinder being Machined in a lathe
4Where the Pileco Diesel Hammers come from? The hammer cylinder in a mill.Hammers ready for shipmentThe foundryA hammer being testedThe new factory opened in May 2004, using modern machining methods to produce high quality equipment.
7Functional operation of a Pileco Diesel Hammer Raising of piston (starting)
8Functional operation of a Pileco Diesel Hammer Raising of piston (starting)For starting the Diesel hammer, the piston (ram) is raised by means of a mechanical tripping device and is automatically released at a given height.
9Functional Operation of a Pileco Diesel Hammer Injection of Diesel fuel and compression
10Functional operation of a Pileco Diesel Hammer Injection of diesel fuel and compressionAs the piston falls through the cylinders it activates a lever on the back of the fuel pump, which injects a measured amount of diesel fuel onto the top of the impact block. Shortly after this, the exhaust ports are closed.
11Functional operation of a Pileco Diesel Hammer 3. Impact and atomizationFunctional operation of a Pileco Diesel Hammer
12Functional operation of a Pileco Diesel Hammer Impact and atomizationCompressing all the air between the exhaust ports and the top of the impact block, the piston continues falling until it strikes the top of the impact block. The heat generated by the compression of air in the presence of atomized fuel, causes an explosion of the fuel, throwing the piston upward and forcing the impact block downward against the pile
13Functional operation of a Pileco Diesel Hammer Exhaust
14Functional operation of a Pileco Diesel Hammer ExhaustWhile moving upwards, the piston will pass and open the exhaust ports. Exhaust gases will escape and the pressure in the cylinder will equalize
15Functional operation of a Pileco Diesel Hammer Scavenging
16Functional operation of a Pileco Diesel Hammer ScavengingThe piston continues its upward momentum which draws in fresh air for the next cycle, cools the cylinders, and releases the pump lever. The pump lever returns to its starting position, so that the pump will again be charged with fuel. Gravity stops the upward motion of the piston and it starts falling through the cylinders once again.
17Pileco Diesel HammersThis is a comparison of the quality and materials used for the diesel hammers made by Pileco and the competition.
18The Piston Pileco Others The piston is cast with the most advanced special casting technique in the world ---cast from the bottom, which creates a piston with less impurities and a higher density of 7.2T/M3.Special metal elements are also added for additional strength. The gating (sprue) and the feeder of the piston are longer so that more part of the gating (sprue) and feeder are removed.This ensures the quality of the part of the piston that can be used. The piston has stable and reliable quality, but its cost is RMB3, higher than the piston made in Guangdong.OthersThe piston is cast with simple casting technique ---cast from the top, which causes the piston have more impurities and unstable performances.There are not any special metal elements added. The toughness and wear resistance properties are bad.Less part of the gating (sprue) and feeder are removed, which can’t guarantee the quality of the part of the piston that can be used.So, the cost of the piston is 25% lower than the piston made by Pileco.OthersPileco
19Impact Block Pileco Impact Block Pileco Others The impact block is precision forged with the material 50CRMoA.It is finish machined after being heat treated twice after which it is sent to a heat treatment factory for nitrogen treatment.The impact block has reliable quality, stable property and longer service life.The cost of nitrogen treatment is USD1.00/kg, which is more expensive.Nitrogen treating increases the toughness of the steel providing a longer life of the block.OthersThe impact block is ordinary forged.The material used for it is 50CRMo, which is not purified steel/ virgin steel.The impact block is not nitrogen treated after the heat treatment of quenching and tempering and finish machining.The cost of the impact block is 22% lower than the impact block made by Pileco.Pileco Impact Block
20Upper CylinderThe metal used to fabricate all tanks of upper cylinder is 2 ~ 3mm thinner than the metal used to fabricate the tanks of Wuxi hammers.The inside wall of tanks is not spayed with stainless steel.All welding seams are weld by hand. Fillet welding seams are not welded on the rolling table / welding manipulator.There is oxide on the inside wall of fuel and oil tanks due to heat treatment. Other factories needs to clean up the oxide after heat treatment and weld again.There is always a welding seam left finally that is not heat treated to eliminate welding stress and it will crack easily after long-term use.The cost of the upper cylinder is 32% higher than Pileco8mm
21Upper Cylinder10mmThe thickness of metal used to fabricate the fuel and oil tanks of upper cylinder for small hammer is 2mm thicker than that of the hammers made by others.The thickness of the metal used to fabricate fuel and oil tank of the upper cylinder for large hammer is 3mm thicker than that of the hammers made by others.The inside wall of the tanks all are hot spayed with a metal powder of stainless steel. The purpose of spaying stainless steel is to prevent any oxide. This will provide a smooth fuel and oil passage ways thus ensuring that the fuel and oil systems are not blocked.All seams are welded using an argon arc weld. This is to ensure that they are welded thoroughly. All seams are heat treated after they all are welded. This ensures the welded width and strength.They are welded on rolling table. The surface is then given a shot blasting after heat treatment to ensure the quality.This ensures a stable and reliable weld. The welded seams of tanks will not crack easily after long term use.
22Lower CylinderPilecoSpecial metal elements are added to the material of the lower cylinder.This is to create a dense material. The weight of the casting feeder is 1/5 of the weight of lower cylinder roughcast.The material of cylinder sleeve is #60 special steel, which is a hard metal and has good wear resistance after it is forged and heat treated.OthersThe casting feeder of the lower cylinder is very small (saving material), so the roughcasts of lower cylinder all are loose and have small defects.There are not sleeves for the hammers sold in China.For the lower cylinders sold to foreign countries, one section of cylinder sleeve is used with standard material of #45 steel, and the other section of sleeve is used with common material of 16mm steel pipe which is not wear resistant.
23Piston Ring Pileco Others The casting is the special roughcasting shell of piston ring cast by Shanghai Hudong Foundry.The material quality is controlled by the foundry and engineer Xu Zu Liang, and then it is sent to the appointed piston ring factory to be machined in secrecy.The surface of the piston ring is coated with hard chrome. The piston ring is a better quality product.OthersThe material of piston ring is very common, and it is cast and machined by small factory.Its surface is not coated with hard chrome.The piston ring has low cost and is not serviceable.
24Inner Endring Pileco Other The material of the inner endring is #60 special steel. It is machined after heat treatment (two times) and eliminating stress (one time).It is then sent to the special heat treatment factory for nitrogen treatment.This is to ensure accuracy and hardness.The inner endring is wearable and serviceable and is a better quality item.OtherThe inner endring is made of common composition brass and is not heat treated.It is not wearable and serviceable.It is low cost and not serviceable
25PumpsPileco Fuel PumpThe fuel pump body and cover as well as the oil pump body are made by Shanghai Hudong Foundry.The casting quality of them is controlled by the foundry. The material quality is very reliable.The pump element used for fuel pump and the cylinder used for oil pump all are precision ground, the clearance is ~ 0.011mm.All the hoses used for pumps are Parker hoses.The injective valves are machined using special machine tool to ensure the accuracy and exchangeability.Pileco Oil Pump
26PumpsThe fuel pump body and cover as well as the oil pump body are cast by common small foundry.They are loose fitting.The pump element in fuel pump and cylinder in oil pump are not precision ground and the accuracy of them is ~ 0.02mm.All the hoses used for pumps are common rubber hoses.The injective valves are machined using common machine tool, which have poor exchangeability and stability.
27Honing of the upper & Lower Cylinders PilecoPileco Vertical Honing MachineOthersPrecision honing of the inside walls of upper and lower cylinders all are made on the common horizontal honing machine.This is done in an outside factory.Because the honing machine is horizontal, the orientation is not uniform and the accuracy is poor.Precision honing of the inside walls of upper and lower cylinders all are done on the special vertical honing machine we own.The honing time is very long and the honing accuracy is very high.
28Presentation Quality Others The appearance of hammers is rougher due to various reasons such as casting and welding.
29Presentation Quality The presentational quality is much better. We have made a higher standard of quality in our product.The presentational quality of all future hammers is constantly being improved.
30Pile Driving Systems with A Diesel Hammer Swinging leadSwinging lead spotter supportedFixed lead spotter supportedFixed lead with three axis boom point connector and vertical travelCaisson type leadLarge diameter lead systems for vertical piles
31Swinging Leads Characteristics: Most economical onshore pile driving Lead is free hanging at a 3 line crane boomLines for lead, hammer and pile)Lead steps in the ground allow to swing the upper end in every direction
32Swinging Leads Spotter Supported Characteristics:Lead is free hanging at a 3 line crane boom ( lines for lead, hammer and pile)Hydraulic spotter allows to swing the lead more exactly and quicker to the ram pointLead steps can set in the ground allow to swing the upper end in every direction
33Fixed Extended Leads – Spotter Supported Characteristics:Lead is attached with a boom point connector to the crane boom tip and at the lowerEnd supported by a hydraulic adjustable spotterExact positioning to ram point possible while also adjusting to the exact batter2 line head block for hammer and pile lineUpgrade the system with additional pile line and auger drilling equipment possible
34Vertical Travel Leads Spotter Supported Characteristics:Lead is attached with a boom point connector to the crane boom tip and at the lower end supported by a hydraulic adjustable spotterExact positioning to ram point possible while also adjusting to the exact batterWide range of batter piling possible, because the lead can lowered down to the ground and below2 line head block for hammer and pile line as minimum versionUpgrade the system with additional pile line and auger drilling equipment possible
35Caisson Type Leads Characteristics: Lead and hammer with helmet are one unit hanging at crane or derrickLead is supported by the pile only while driving, batter piling is possiblePile adaptors can be used for large diameter piles
36Large Diameter Lead Systems for Vertical Piles Characteristics:Special lead frames for large pipe piles up to 120” diameterLead is supported by the pile only while driving
37Telescopic Lead Mobilram System Characteristics:Adapter sled for Telescopic Lead – Mobilram Systems are useful in case where pile driving with vibratory hammers is not anymore efficient or where restrictions are given