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The n. 1 inUndercarriage5,000,000 Track Shoes 1,100,000 Rollers
100,000 Track Chains 320,000 Idlers and Sprockets220,000 Tons of
product 12,000 Containers of product
A Company ofThyssenKrupp Group
BERCO S.p.A.
Berco Product LineThe Widest Choice
BMPMININGPRODUCTS
BSDSPECIAL DEVICES
BMRMEDIUM RANGE
BTSTRACKSYSTEMS
MINI UNDERCARRIAGE& UTILITIES
BMU
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CONTENTS
MOVING YOUR BUSINESS AHEAD
YOUR BEST UNDERCARRIAGE VALUESince 1920 Berco has offered an
innovative, reliableand economical solution to any undercarriage
need.Whether for the original equipment manufacturers(OEM) or the
aftermarket, for a special machine or amini-excavator, for a
bulldozer or a miningexcavator, Berco can offer you the right
answer to yourspecific requirement. Superior engineering,
innovative technology,comprehensive know how and
state-of-the-artmanufacturing guarantee the total quality of
theproducts and services offered to you.Original Equipment Quality,
Aftermarket Value
THE COMPETENT PARTNER YOU CAN RELY ONCustom made solutions and
project engineeringsupport is available upon request.Our team of
engineers can help you choose or designthe most effective and
efficient solution to your specificundercarriage need. They can
help you reduce development andengineering time, tooling expenses
and facility costs,while adding value to your business.Berco, The
choice of the leading OEMsi
MOVING YOUR BUSINESS AHEAD
page 2
THE WIDEST CHOICEpage 3
MAKINGA SUPERIOR PRODUCT
page 4
STATE OF THE ART PRODUCTION
page 5
BMPBerco Mining Products
page 6
BMRBerco Medium Range
page 8
BMUBerco Mini Undercarriage
page 10
BTSBerco Track Systems
page 12
BSDBerco Special Devices
page 14
All products shown in this document originate from Berco
exclusively.Any references to Caterpillar (the Caterpillar word
signs) are mentioned to communicate thatthe aforemenioned products
are only suitable for Caterpillar machines with the
correspondingmodel designation.
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3
THE WIDEST CHOICEOF UNDERCARRIAGE COMPONENTS AND SYSTEMS FOR
TRACK TYPE MACHINES
TRACK SHOES More than 66 different profiles Hot rolled, cast and
hot forged shoes More than 5,000 configurations Variable width, mud
holes, clipped corners, chamfered holes
IDLERS Cast, forged and fabricated types More than 500
configurations Low temperature (-50C) version available
ROLLERS Single flange, double flange and inner flange rollers
More than 1,000 configurations Low temperature (-50C) version
available
TRACK CHAINS Dry, sealed & greased, sealed & lubricated
chains Heavy Duty version More than 11,000 configurations Suitable
for XR, XL, LGP and TSK undercarriages
SPROCKETS & SEGMENTS Weld-on rim, bolt-on rim, full hub and
segmented type 3,4,5 and 6 teeth segments More than 130 segment
configurations More than 1,100 sprocket configurations
SPECIAL APPLICATIONS Undercarriage for special applications:
large conveyor, pipelinehandling, pavers, milling machines, logging
equipment, directionaldrills, mining equipment, etc.
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ISO9001
4
ADDING VALUE TO YOUR BUSINESSState-of-the-art 3D modeling,
Finite Element Analysis(FEM) and Rapid Prototyping enables to
design,optimize and evaluate a component before it is built.
Artificial Intelligence techniques are currently beingdeveloped
to automatically inspect 100% ofcomponents. Reliability Test on
components arecarried out to determine life and performance in
avariety of field applications.
Berco Metallurgy Laboratory employs advancedmachines such as an
electron microscope withmicroanalysis, a spectrophotometer,
tribometers forwear tests, MTS presses for static and fatigue
tests(also at extreme temperatures -70C 250C) onmaterials and
components.
Huge efforts are also devoted to the development ofNew Materials
and improvement of the Heat TreatingProcesses, to guarantee longer
product life andsuperior products.
Photo-elasticity and Strain Gauge techniques arecommonly used
for stress and fatigue analysis onindividual and assembled
components.
Berco adds value not only to the products but also toYour
Business.
MAKING A SUPERIOR PRODUCT
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ISO14001
AUTOMATED PROCESSES AUTOMATIC QUALITYThe entire production
process is fully automated andcomputer controlled via Computer
ManufacturingTechnology systems. This guarantees a highly
reliableprocess and constant quality of the products.
THE RIGHT PRODUCT AT THE RIGHT TIMEA vast variety of raw
materials and flexible manufacturinggive the competitive advantage
of short lead times whilematching your specific need. Thats what we
also callCustomer Satisfaction.
HEAT TREATED TO TREAT YOU EVEN BETTERQuality materials and
state-of-the-art manufacturing arenot enough to guarantee the
quality of the finished products.Thats why the heat treating
processes are carried outmaking sure that all process parameters
(temperaturegradients, time, quenching temperature, etc.) are
constantlymonitored online. Hardening and tempering upgrade
mechanical properties forsuperior wear resistance, stress relieving
guarantees perfectgeometry and excellent resistance for longer
product life.
STATE OF THE ART PRODUCTION
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RH 120C Greased unsealed track chain Chain pitch 350 mm (13.78)
Double grouser forged shoe,width 800 mm (311/2)
Track roller assembly,single flange, with oil fillplug on
collars andlocking pins, reinforcedshaft dimensions
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BMPMINING PRODUCTSBerco Mining Products offers an efficient,
reliableand economical range of solutions for miningoperations,
catering for the undercarriage needs ofopen pit mining, quarrying
or earthmoving inlarge-scale land reclamation.Superior engineering
and technology,comprehensive know-how and
state-of-the-artmanufacturing ensure the total quality of
theproducts and services offered.Our team of engineers is available
to help youchoose or design the most effective and
efficientsolution to your specific undercarriage needs.
THE WIDEST CHOICEA complete line of undercarriage componentsfor
track-type machine classes ranging from 50to 400 ton and 215.9-350
mm (81/2-13.78)chain pitchDry, greased, sealed & lubricated
chain versions.Arctic (-50C) version and track chains with
life-time seal groups uponrequestForged shoes forheavy
dutyapplicationsTrack chains forspecialapplications: largeconveyor
systems,pipeline handling, etc.
FORGED SHOESForged shoes for extremeapplications, wheregreatest
mechanical andwear resistance propertiesare needed
CLASS D10N/RPitch 260 mm - 101/4
CLASS D9N/R - D275Pitch: 240 mm - 9.44
CLASS D8K - D155Pitch: 228.6 mm - 9
CLASS D375Pitch 280 mm - 11
THE WIDEST CHOICE OFUNDERCARRIAGE FOR EXCAVATORS Components for:
CAT345, 350, 365, 375, E650, 5080;Demag H65, H85, H95, H121; Case
CX800; HitachiEX550, EX600, EX700, EX750, EX800, EX1000,EX1100,
EX1800, EX2500; Komatsu PC650, PC710,PC750, PC800, PC1100, PC1800,
PC3000, PC4000;Liebherr R954, R964, R974, R984, R994; Link
BeltLS7400; Terex O&K RH30, RH40, RH60, RH90,RH120C; Poclain
300, 400, 600, 1000; SumitomoSH800 and other machines
Chain pitch from 215.9 to 350 mm (81/2-13.78)
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7TRACK CHAINS WITH BPR For D9L, D9N, D9R, D10N, D10R, D11N,
D11R,D275, D375, D455 and D475 machines
Lubricated track chains with snap rings in all joints (BPR)
BPR - Berco Pin Retention - improves operating lifeof
components. The snap rings on the pin endsprovide a perfect
sealability of the track chains. Sideloads can be partially
supported by this device
D10 and D11 lubricated track chains with new seal Oversized pin:
a new design for D11 track chain alsoavailable
THE WIDEST CHOICE OFUNDERCARRIAGE FOR DOZERS Components for: CAT
D8, D9, D10, D11classes; Dresser TD25, TD40; FiatallisFD30, FD40,
FD50; Deere 1050C;Komatsu D135, D155, D275, D355,D375, D455, D475;
LiebherrPR751, PR752 and other machines
Chain pitch from 215.9 to 317.5 mm (81/2-121/2)
Track links are forged, quenched andtempered, rail surface
inductionhardened to increase the wear resistance(HRC>45)
Extreme service single grouser shoes available
CLASS D11N/R - D475Pitch 317,5 mm - 121/2
300 TON CLASS EXCAVATORPitch 350 mm - 13.78
LIEBHERR R984C (BMP 280) Track group, greased, sealed, chain
pitch 280 mm (11)
Double grouser shoes, open center, clippedcorner, shoe width 750
mm (291/2)
Track roller assembly, single flange Bolt-on 12 teeth sprocket
rim,diameter 1131 mm (441/2)
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8SPROCKETS AND SEGMENTS Sprockets for 7-50 ton class excavators
andsegments for D3-D8 class dozers
Nine chain pitch versions from 140 to228.6 mm (5.51-9)
Single shot induction hardened onentire tooth profile or with
differentialquenching for excellent resistance towear and
fatigue
Through hardened segments for highsurface hardness (HRC>50)
and toughcore (HRC 45)
BMRMEDIUM RANGEThe Berco Medium Range offers an
innovative,reliable and economical set of solutions to
yourundercarriage needs, catering for OriginalEquipment
Manufacturers (OEMs), theAftermarket, bulldozers, excavators, old
machinesor special designs and providing you with the rightanswer
to your specific requirements.
THE WIDEST CHOICEA complete line of undercarriage componentsfor
track-type machine classes ranging from 7 to50 ton and 140-228,6 mm
(5.51"-9) chainpitchDry, greased, sealed or lubricated
chainversions, heavy duty chains, more than 11,000configurationsAny
configuration available with single, double,triple grousersCast,
forged or fabricated idler types, more than500 configurationsSingle
flange, double flange or inner flangerollers, more than 1,500
configurationsMore than 600 configurations of sprockets andsegments
Low and high temperature versions for
extremeapplicationsUndercarriage for special applications:conveyor,
pipeline handling, milling machines,forest machines, etc
IDLERS Fabricated idlers with hot rolled rim for 7-50 tonclass
excavators and for D3-D8 class dozers
Induction hardenedrail surface forexcellent resistanceto wear
and fatigue Heavier componentsfor improved stability Forged idlers
forheavy dutyapplications
TRACK SHOES Cast steel shoes for specialapplications: swamp type
(1), flattype (2), bent ends shoes,polyurethane track shoes (3)
andmore
Through hardened and stress relievedto guarantee excellent wear,
highstrength and resistance to bending andbreakage, resulting in
longer life
CLASS D6MPitch: 190 mm - 71/2
CLASS D5MPitch: 171.5 mm - 63/4
CLASS D3 - D4 B/CPitch: 155.5 mm - 61/8
Undercarriage for sugarcane harvester
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2
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9GREASED TRACK CHAINS FOR EXCAVATORS AND HEAVY DUTYAPPLICATIONSA
completely new sealing system, consisting of a W shape polyurethane
seal, especially designed tokeep grease in joints and abrasive
particles out of them Internal pin & bushing wear reduction,
withconsequent life extension for 20% and more ifcompared with the
standard sealed chains on thesame application
Reduction of sneaky tracks phenomenon, as resultof more
laterally stable chains, thus reducing wear ofrelated parts, such
as links, rollers, guides
Improved rebuildability of the track chain Noise and maintenance
costs reduction and lessmachine fuel consumption: improved
travellingperformances
CLASS D8N/R/TPitch: 215.9 mm - 81/2
CLASS D7N/RPitch: 215.9 mm - 81/2
CLASS D6R/TPitch: 203.2 mm - 8
BERCO HEAVY DUTY TRACK CHAINSFOR D4-D7 CLASS MACHINESHeavy duty,
sealed & lubricated track chains have beenspecifically designed
for increased pin & bushingretention. Track link incorporates
greater pin-to-linkand bushing-to-link contact areas while
additionallink wear material increases component life.
ROBUSTUSTM, THE NEW ROTATING
BUSHING TRACK SYSTEM
In the new system ROBUSTUSTM the bushing rotateswhen in contact
with the sprocket, reducing the bushingand sprocket friction and
wear and thus enabling longerlife.As a consequence, it is not
necessary to turn bushingsand pins and replace sprocket segments
during thewhole life of the undercarriage.
Wider track link rail, provides an extendedrunning surface
area
Wear perfectly balanced through all components Berco Pin
Retention Reinforced hardware to improve joint stabilityNew concept
of seal design
The new system is fully compatible with existing framesand
standard components: (D6H and D5H machines ),older machines can be
easily upgraded to increase theirproductivity and the life of the
undercarriage.In the same way ROBUSTUSTM is forward-compatiblewith
the new generation undercarriages equipped withparallel or twin
links.Berco field tests proved that the new systemincreases the
track life of 35 percent, with amaximum of 6,000 hours of operation
withoutmaintenance; and this means cutting operatingcosts up to 25
percent.
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10CLASS T300
Pitch: 101.6 mm - 4
F25C - HEAVY DUTY TRACK CHAINSPECIALLY DESIGNED FOR
PAVINGMACHINESSealed and greased track chain pitch 125 mm
(4.92),with w-shaped polyurethane seals, reinforced track linkwith
strut for extremely heavy-duty applications andheavy vehicles, four
different shoes:
Flat, hot forged, 300 mm (11.81) Rubberized (polyurethane) shoe,
300 mm Triple grouser shoe, 300 mm, open center upon request Single
grouser shoe, 300 mm, open center upon request
BMUMINI UNDERCARRIAGE & UTILITIESThe Berco Mini
Undercarriage program offers aninnovative, reliable and economical
set of miniundercarriage solutions, catering for miniexcavators,
horizontal drilling machines, smalldozers or paving machines and
providing you withthe right answer to your specific requirements.
Bercocan supply a complete range of interchangeablecomponents for
rubber track belts or traditional steeltrack chains, guaranteeing
the best possible valuefor money. Superior engineering,
innovativetechnology (e.g. patented monoblock cast ironchains),
comprehensive know-how and state-of-the-art manufacturing ensure
the total quality of theproducts and services offered.
THE WIDEST CHOICEA complete line of undercarriage components
formini excavators class machines ranging from 1 to6 ton, Compact
Track Loader (CTL) and otherCompact Utilities Track chains with
90-140 mm pitch (3.54-5.51")Traditional steel chains with welded or
bolt-onshoes Interchangeability from steel to rubber
andviceversaClamp-on rubber pads or rubberized shoesavailable
Single grouser shoe Flat type shoe
Triple grouser shoe
CLASS T150Pitch: 90 mm - 3.54
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11CLASS T500
Pitch: 135 mm - 5.31CLASS FL4
Pitch: 140 mm - 5.51CLASS F25C HD
Pitch: 125 mm - 4.92
Undercarriage for CTL
4 rollers, rubber version
Undercarriage for CTL
5 rollers, steel version
NEW STEELUNDERCARRIAGECOMPONENTSRecent evolutions in the market
of MiniExcavators have led Berco to developnew undercarriage
components for thisrange of machines. In particular, for 3 and
5-ton classmachine components, it was possible toengineer new parts
suitable to guaranteemore resistance to wear and
betterperformances.The first big advantage of chains,
rollers,idlers consists in the raw material choice:instead of using
austempered cast iron(ADI) it has been used a special steelalloy.As
a consequence, the manufacturingprocess can benefit of both
forgingtechnique and faster and more efficientmachining operations.
Moreover, it is also possible to applyinduction hardening to
undercarriageparts more subject to wear thusincreasing wear life
and performances
during operation.
Berco has developed a newsolution based on a
trackedundercarriage, available in bothrubber tracks and
traditionalsteel track chain. The range,which already featured
twoversions rubber tracks andtraditional steel track chain. In
cooperation with his partnersBerco can offer:- Track Frames- Front
Idlers- Rear Idlers- Track Rollers- Sprocket & Final Drive-
Rubber Tracks
RUBBER TRACKSThe rubber track belts,strengthened with steel
cables,have metal inserts, giving amaximum cruising speed of
about 14 km/h. The rubber tracksolution provide good grip in a
greatvariety of working conditions and ensuregreat mobility even in
difficult situationslike muddy soils, great slopes, etc. Allthis
make the rubber tracked skid steera much more versatile and
productivemachine compared to the traditionalwheeled version.
STEEL TRACK CHAINSThe steel track chains, compared to therubber
tracks, provide a much higherwear resistance, higher grip
(traction)and longer durability (up to 4 timeshigher). It is the
recommended solutionfor heavy-duty operations, harshenvironment
(steel scrap yards,demolishing sites, etc.) and anytime it isnot
necessary to change often the work-site.
UNDERCARRIAGE COMPONENTS FOR FOR COMPACT TRACK LOADERS
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BTSCOMPLETE TRACK SYSTEMSThe Berco Complete Track Systems
division is the idealsolution for all OEMs that now, more than
ever, areexpressing the need for complete 'turnkey'
undercarriagesystems.Berco is able to supply compete track
systems(undercarriage components, hydraulics, frames andgearboxes),
finished and ready for installation onmachines directly on
manufacturers' own assembly lines.
Berco has a vast range of products and, when requestedfor
special applications, develops sets of componentsspecifically
tailored to customers' needs. All this makes Berco a supplier with
a level of reliabilityand skill that clearly distinguishes them
from othersystems integrators, who merely find generalcomponents on
the market and 'put them together'.Berco Complete Track Systems is
able to supply safe,reliable systems, soundly based on the
hallmarkcharacteristics of the Berco brand: extensive
know-how,flexible design responding rapidly and effectively
tocustomers' needs and, finally, the ability to support thecustomer
at every stage, from design right through toinstallation.Berco's
great competence and flexibility in engineeringand production allow
them to develop, design and supplyundercarriage systems for a wide
range of applications,such as pavers, rock boring machines, rice
and sugar-cane combine harvesters, mini-excavators, etc.
The Berco Complete Track Systems engineering staff usethe same
calculation methods in the development of newmachines in
co-engineering projects with OEMs as in thedesign and verification
of the welded structures in theirown production systems. These
methods include FEManalysis on frames, dynamic and vibrational
analysis,CAD-3D design and construction drawings forproduction. All
this guarantees high quality standardsand the ability to satisfy
even the most exacting andcomplex needs of the customer.
These solid engineering skills are combined with aremarkable
production capability, now spread over fivefactories and
characterised by leading edge technologyand highly automated
production lines.This production capability guarantees the
qualitydemanded by the customer, on schedule.
Finally, a continuously expanding network of
branches,strategically located all over the world, is able to
supplyon a just-in-time basis and guarantee a speedy andefficient
after-sales service.
GENERIC UNDERCARRIAGE FRAMES
MOBILE CRUSHING PLANT FRAMES
Standard layout dimensions are presented Custom-tailored design
on request Sideframe or carbody supply Wide choice of gear-boxes
and hydraulic motors isavailable
Optional swing bearing plate and swivel joints areavailable
Standard layout dimensions are shown Custom-tailored design on
request Wide choice of gear-boxes and hydraulic motors
isavailable
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RICE COMBINE HARVESTER DRILLING RIG FRAMES
ROAD MILLING MACHINES MINI EXCAVATORS
ASPHALT PAVERS
Mini excavators, utility-use or special applicationmachines
Standard layout dimensions are presented Metal track chains with
2-grousers, 3-grousers,rubber pads or rubber belt options
Custom-tailored design on request Sideframe only or the whole
carbody supply. Wide choice of gear-boxes andhydraulic motors is
available
Optional swing bearingplate and swiveljoints areavailable
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CEM7000 Electromechanical Wrench
OPERATING SPECS
Max. torque on socket shaft 7,000 Nm5,160 lbfft
Max. final tightening angle 360
Socket shaft rotation speeds 8.5-145 rpm(2-speed), in either
direction
Socket shaft motor power 6 HP4.5 kW
Max. admitted width 1,200 mm track chain + shoes 471/4
Max. admitted height 370 mm track chain + shoes 141/2
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BSDSPECIAL DEVICESThe Berco Special Devices offers a
completesolution to your undercarriage maintenanceneeds, with a
range of specific operationsincluding pin & bushing turning,
roller lubrication,track shoe fastening or on-site machine
servicing.Superior engineering and technology,comprehensive
know-how and state-of-the-artmanufacturing ensure the total quality
of theequipment offered. Berco offers turnkey solutions,
custom-madedesign and supply of complete workshop andrepair
facilities, training and technicalsupport.
THE WIDEST CHOICE PT350 stationary hydraulic press forthe
assembly/disassembly ofmedium and large-size track chains
(e.g.Komatsu D575, O&K RH120C, LiebherrR994B and Caterpillar
D11 track chains)PT250 stationary hydraulic press formedium and
small-size chainsPP50 and PP100 portable presses powerfuland
versatile tools for assembly and disassemblyof track chains,
sprockets, rollers, shafts,transmission components, etcComplete
line of tools for servicing variousundercarriage sizes, available
upon requestDCL and DCL-D track control and lubricatingdevices for
checking the vacuum in oil seals andinjecting oil into lubricated
chains, rollers andidlers (DCL-D model)CEM7000 electromechanical
track shoe wrenchfor screwing and unscrewing the shoe bolts
ontracked vehicle chains, both large and small. Theelectronic
torque-turn control ensures highlyreliable and consistent bolt
torquing results. Thehigh torque developed facilitates bolt
removaleven in the most difficult situations (e.g. rust) The ACC
and ACC/S-SP track winder aredesigned for winding medium and
small-sizechains, whereas theACC/S-SP isspecifically designedfor
the larger sizes
DCL/DCL-D Lubrication Device
OPERATING SPECS
Max. vacuum759 mm/Hg29,88Hg
Vacuum pump capacity at atm.pressure
66 dm3/min2,3 ft3/min
Oil pump max. delivery3 dm3/min183 in3/min
Pressure setting3 bar43 lbf/in2
Oil tank capacity75 dm3
2,6 ft3
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PT250-PT350 Hydraulic Track Presses
OPERATING SPECS PT250 PT350
Max ram force 1,803 kN (184 tf) 3,185 kN(325 tf)203 sh ton 358
sh ton
Max operating pressure 31.5 Mpa (315 bar) 35 Mpa (350 bar)4,570
lbf\in2 4,980 lbf\in2
Ram rod diameter 230 mm 270 mm9.05 10 5/8
Max ram stroke 160 mm 190 mm6.30 71/2
PP100-PP50 Portable Hydraulic Track Presses
OPERATING SPECS PP100 B/S PP50 B/S
Max. ram force 911.4 kN (93 tf) 490 kN (50 tf)102.4 sh ton 54.7
sh ton
Max. traction of rams 715.4 kN (73 tf) 323.4 kN (33 tf)80.6 sh
ton 36.3 sh ton
Max. operating pressure 70 Mpa (700 bar) 70 Mpa (700 bar)10,000
lbf/in2 10,000 lbf/in2
Max. ram stroke 350 mm 280 mm13 3/4 11
Oil capacity 4.64 dm3 2 dm3
283 in3 122 in3
ACC - ACC/S-SP Track Winders
OPERATING SPECS ACC ACC/S-SP
Rotation speed 3 giri/min 1,7 rpmin both directions
4 HP 4 HP
3 kW 3 kW
Max. mass admitted 3.600 kg 8.200 kgonto spindle 7.936 lb 18.040
lb
Max track shoe width admitted 762 (1.000) mm 1.460 mm(with
optional device) 30 (40) 571/2
Motor rating
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BERCO S.p.A.Via 1 Maggio, 23744034 Copparo (FE) ItalyTel. +39
0532 864 111Fax +39 0532 864 [email protected]
ISO 9001 Cert. n. 0029/4
ISO 14001 Cert. n. 0009A/2
Your Berco Dealer:
01102.WR432GB00C
Published by Berco Communications Dept.
All manufacturerss nam
es, num
bers, sym
bols and descriptions are used for reference purposes only. All
parts listed are of
Berco original production.The specifications and processes
described in this brochure are subject to change without notice