Berco Mining Products

The Widest Undercarriage Choice

MOVING YOUR BUSINESS AHEAD

The n. 1 in
Undercarriage
6,000,000 Track Shoes
1,300,000 Rollers
180,000 Track Chains
320,000
250,000
12,000
Idlers and Sprockets
Tons of product
Containers of product
3BMP
MINING
PRODUCTS

A Company BERCO S.p.A.

of ThyssenKrupp
Technologies
MOVING YOUR WE CARE
BUSINESS AHEAD
YOUR BEST UNDERCARRIAGE VALUE CUSTOMER SERVICE
Since 1920 Berco has offered an innovative, We have a large dealer network covering more
reliable and economical solution to any than 90 countries in the world. They have been in
undercarriage need. Whether for the original business for decades, they know the business and
equipment manufacturers (OEM) or the they know it from their customers’ point of view.
aftermarket, for a special machine or a mini- They understand customers’ needs and they
excavator, for a bulldozer or a mining know that their success is tied to their customers’
excavator, Berco can offer you the right answer successes.
to your specific requirement. We support our dealers with our professional
Superior engineering, innovative technology, sales force. We train them, and provide them with
comprehensive know how and state-of-the-art the right marketing tools and advanced
manufacturing guarantee the total quality of the technological systems. We have developed a
products and services offered to you. computer based integrated system BOPIS (Berco
“Original Equipment Quality, Aftermarket Value” Online Product Information System) enabling a
dealer technician to use a laptop computer from
AN EXPERT PARTNER YOU CAN RELY ON the field to consult our database and easily find
Custom made solutions and project the right answer.
engineering support is available upon request. We back you, wherever you are. We work with
Our team of engineers can help you choose or our dealers to establish a parts and service
design the most effective and efficient solution presence near you, in order to always have the
to your specific undercarriage need. right product at the right time in the right place. It
is customer satisfaction that has built our Berco
They can help you reduce development and
Track Record.
engineering time, tooling expenses and facility
costs, while adding value to your business. CUSTOMER SATISFACTION
“Berco, The choice of the leading OEMs” Considering that more than 50% of your
maintenance costs will go into maintaining the
undercarriage, it is not surprising that Berco
represents the best choice when the time comes
for the replacement. And the best choice is
confirmed by the large number of Satisfied
Customers that Keep Choosing Berco
LEADERSHIP
IN ENVIRONMENTAL DEVELOPMENT
Not only do we care about our customers
supplying quality products manufactured under
ISO 9001:2000 certified processes, but, also, we
care about the Environment.
Since Jan 2000 Berco is ISO 14001 certified and
has adopted Environmental Procedures
throughout the entire manufacturing process. We
have an Environmental Strategy and we
continuously check on the progress made toward
the set objectives.
Getting More out of Less. Reduction of energy
consumption, improved use of materials and
minimization of waste, allows for a lower impact
on the environment.
We have favored environmental friendly
transportation like trains and boats and have
begun redesigning our packaging to use
recyclable materials. We have changed our
painting processes to an environmentally friendly
water-based paint and we have reduced the
amount of polluting emissions. We have adopted
a closed loop cooling system to reuse water from
our heat treating instead of emitting it into the
enviroment.

ISO 9001 - ISO 14001

3 BMP
MINING PRODUCTS
Berco Mining Products offers an efficient, reliable and
economical range of solutions for mining operations,
catering for the undercarriage needs of open pit
mining, quarrying or earthmoving in large-scale land
reclamation.
Superior engineering and technology, comprehensive
know-how and state-of-the-art manufacturing ensure
the total quality of the products and services offered.
Our team of engineers is available to help you
FORGED SHOES
choose or design the most effective and efficient Forged shoes for extreme applications,
solution to your specific undercarriage needs. where greatest m echanical and wear
resistance pr operties are needed
THE WIDEST CHOICE
• A complete line of undercarriage components for
track-type machine classes ranging from 50 to 300
ton and 215.9-350 mm (81/2”-13.78”) chain pitch
• Dry, greased, sealed & lubricated chain versions.
• Arctic (-50°C) version and track chains with life-time
seal groups upon request
• Forged shoes for heavy duty applications
• Track chains for special applications: large conveyor
RH 120C
systems, pipeline handling, etc. • Greased unsealed track chain
• Chain pitch 350 mm (13.78”)
• Double grouser forged shoe, width
800 mm (311/2”)
• Track roller assembly, single
THE WIDEST CHOICE flange, with oil fill plug on
collars and locking
OF UNDERCARRIAGE FOR EXCAVATORS pins, reinforced
• Components for: CAT345, 350, 365, 375, E650, 5080; shaft dimensions
Demag H65, H85, H95, H121; Case CX800; Hitachi
EX550, EX600, EX700, EX750, EX800, EX1000, EX1100,
EX1800; Komatsu PC650, PC710, PC750, PC800,
PC1100, PC1250, PC1800; Liebherr R954, R964, R974,
R984, R994; Link Belt LS7400; Terex O&K RH30, RH40,
RH60, RH90, RH120C; Poclain 300, 400, 600, 1000;
Sumitomo SH800 and other machines
• Chain pitch from 215.9 to 350 mm (81/2”-13.78”)
 BERCO: THE CHOICE OF THE LEADING OEMS

LIEBHERR R984C TRACK CHAINS WITH BPR

• Track group, greased, sealed, • For D9L, D9N, D9R, D10N, D10R,
chain pitch 280 mm (11”) D11N, D11R, D275, D375, D455 and
• Double grouser shoes, open center, clipped corner, shoe D475 machines
width 750 mm (291/2”) • Lubricated track chains with snap
• Track roller assembly, single flange rings in all joints (BPR)
• Bolt-on 12 teeth sprocket rim, • BPR - Berco Pin Retention - improves
diameter 1131 mm (441/2”) operating life of components. The
snap rings on the pin ends provide a
perfect sealability of the track chains.
Side loads can be partially supported
by this device
• D10 and D11 are available with
lifetime seal groups, for applications
in which the life of the seal becomes
the critical factor for the life of the
chain

THE WIDEST CHOICE OF UNDERCARRIAGE

FOR DOZERS
• Components for: CAT D8, D9, D10, D11 classes; Dresser
TD25, TD40; Fiatallis FD30, FD40, FD50; Deere 1050C;
Komatsu D135, D155, D275, D355, D375, D455, D475;
Liebherr PR751, PR752 and other machines
• Chain pitch from 215.9
to 317.5 mm (81/2”-121/2”)
• Track links are forged, quenched and tempered,
rail surface induction hardened to increase
the wear resistance (HRC>45)
• Extreme service single grouser shoes
available
3 BMP
MINING PRODUCTS
TRACK CHAINS
Special heavy duty, sealed & lubricated track chains have
been accurately designed for increased pin & bushing
retention. The links incorporate greater pin-to-link and bushing-to-
link contact areas while additional link wear
material increases component life.
Exclusive heat treatment gives Berco links consistent
surface hardness, unmatched hardened depth and
strong core hardness for increased component life.
Berco pins & bushings are dimensionally matched to
the links and manufactured to provide excellent track
joint reliability, while the specific design ensures
maximum sealability.
BPR, Berco Pin Retention (available for some track chains)
improves operating life of components. The snap rings on
the pin ends provide a perfect sealability of the track chains.
Side loads can be partially supported by this device
D10 and D11 are also available with lifetime seal groups, for
applications in which the life of the seal becomes the critical
factor for the life of the undercarriage.
All this results in excellent wear resistance, strength and
durability for superior sealability and longer life.
• Links are forged from deep hardening boron steels with
certified hardenability based on Berco specification
• Links are either quenched and tempered or through
hardened for strong core hardness, superior strength and
higher pin & bushing retention
• Rail surface induction hardened (HRC>53) to the wear limit
(HRC>45)
• Final furnace tempering reduces link chipping and spalling
• Bushings are treated in a special furnace for high
temperature carburizing
• Pins are deep hardened for best resistance to wear and
fatigue
• Precision designed and accurately machined for proper fit,
higher reliability and longer life

CLASS D8N/R CLASS D9L (PC600) CLASS D155

Pitch: 215.9 mm - 81/2” Pitch: 228.6 mm - 9” Pitch: 228.6 mm - 9”
 BERCO: THE CHOICE OF THE LEADING OEMS

ROLLERS
Rollers feature reinforced flanges and have been designed
and manufactured for longer life in the most severe
applications.
Berco’s differential quenching or through hardening
processes upgrade mechanical properties for increased wear
life, superior structural support and resistance to
deformation.
Berco’s exclusive seal groups help to ensure lifetime
lubrication for extended life and to reduce your costs.
Berco offers a complete range of rollers to meet your work
environment requirements.
• Hot forged in two halves to obtain best internal grain
texture (higher resistance)
• Specific medium alloyed boron steel for high hardenability
•Heat treatment of the roller shell guarantees superior
hardened depth (hardness >50 HRC) and rail wear
resistance, while maintaining internal shell surfaces (in
contact with hubs and bushings) hardness at 40 HRC, for
extreme resistance to fatigue and shock stresses caused by
the most severe applications
• Induction hardening and superior finishing of the shafts
• Large bearing and bushings area for high resistance to
radial loads
• Sizeable oil capacity and perfect sealing
• Berco heavy duty seal groups (Cromium Vanadium cast iron
type with surface hardness HRC 65) ensure anti-wear, anti-
sizing and anti-rusting properties
• Berco exclusive artic type seal groups ensure excellent
performance up to -40°C
• Maintenance free, for longer life and perfect operation
under any working condition
• Precision designed and carefully manufactured for perfect
alignment, perfect fit of bushings and final assembly of the
components

CLASS D9N/R CLASS D275 CLASS D10N/R (PC800)

Pitch: 240 mm - 9.44” Pitch: 240 mm - 9.44” Pitch 260 mm - 101/4”
3 BMP
MINING PRODUCTS
IDLER GROUPS TENSIONING DEVICE
Berco track Idler Groups are manufactured for For the higher class machines, a hydraulic unit
superior wear resistance. Whether cast, forged replaces the standard spring assembly. It is
or fabricated, Berco idlers provide superior connected to the machine power
structural support. unit and to an accumulator
Special heat treatment ensure through special
proper hardness level, providing hydraulic valves.
long wear resistance. Berco “duo Accurate cylinder
cone” seal groups ensure lifetime shell, piston
lubrication eliminating idler design and hi-
maintenance and reducing operating pressure seals
costs. ensure maintenance
Berco offers a complete variety of idler groups to free operation.
meet your work environment requirements.
• Heavy duty ring-rolled rail rims
• Low alloyed boron steels with certified
TRACK SHOES
hardenability based on Berco specification In extreme applications, products with exceptional
(fabricated version) properties are needed. To satisfy the needs of
• Induction hardened rail surface diameter these highly demanding customers, Berco has
• High tread surface hardness (HRC > 50) also developed a range of forged shoes.
• Minimum hardened depth 8 mm A fully automated forging line, employing a
• Tempered to resist cracking and chipping 32.1 ton press, followed by machining and heat
• Idlers can be supplied alone or fully assembled treat processes, deliver a product with the greatest
with brackets, adjuster and tensioning device mechanical and wear resistance properties.
• Precision design and accurately machined for Berco offers the widest variety of track shoes and
proper fit, higher reliability and track shoe options (clipped corners, open center,
longer life etc.) to meet the requirements of every work
environment.
• Low alloyed boron steels with
certified hardenability based
on Berco specification
• Through hardened and
stress relieved for high strength
and resistance to bending and
breakage
• Surface hardness HRC 47 for superior
wear resistance and longer life
• Precision designed and carefully manufactured
for proper fit

CLASS D375 (PC1100) CLASS D11N/R

Pitch 280 mm - 11” Pitch 317,5 mm - 121/2”
 BERCO, THE CHOICE OF THE LEADING OEMS

SPROCKETS SEGMENTS
Deep induction hardened and excellent depth Segments are through hardened for improved
pattern on entire tooth profile provide long wear wear resistance. High, surface depth and core
life. Either from cast steel or from hot forging, hardness mean Berco segments provide long
Berco sprockets guarantee maximum resistance wear life, resistent to bending, breakage and
and durability even in the most severe maximum hardware retention. The bolt-on design
applications. Accurate machining of hubs and reduces your machine downtime.
flanges provide perfect interchangeability. • Hot forged for optimum internal
• Cast steel or hot forged steel for optimum grain flow
internal grain flow • Through hardened for high surface hardness
• Single Shot Induction hardening for high surface (HRC > 50) and tough core (HRC 45)
hardness (HRC > 50) • Specific low alloyed boron steel for high
• Effective hardened depth 4÷10 mm at HRC45 hardenability
• Specific low alloyed boron steel (low alloyed • Precise design and accurate machining
steel for cast version) for high hardenability of the mounting surfaces ensures best
• Tempered to resist cracking and chipping performance
• Optimized design to reduce stress concentration
areas
• Uneven tooth design extends wear life
• Accurate machining of the mounting surfaces
ensures best performance
• Sprockets, sprocket rims and bolt-on type

D475 (PC1800) 300 TON CLASS EXCAVATOR

Pitch 317,5 mm - 121/2” Pitch 350 mm - 13.78”
MAKING
A SUPERIOR PRODUCT
ADDING VALUE TO YOUR BUSINESS
State-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
being developed to automatically inspect 100% of
components. Reliability Test on components are
carried out to determine life and performance in a
variety of field applications.
Berco Metallurgy Laboratory employs advanced
machines such as an electron microscope with
microanalysis, a spectrophotometer, tribometers
for wear tests, MTS presses for static and fatigue
tests (also at extreme temperatures -70°C ÷
250°C) on materials and components.
Huge efforts are also devoted to the development
of New Materials and improvement of the Heat
Treating Processes, to guarantee longer product
life and superior products.
Photo-elasticity and Strain Gauge techniques
are commonly used for stress and fatigue analysis
on individual and assembled components.
Berco adds value not only to the products but
also to Your Business.
STATE OF THE ART
PRODUCTION
With a capacity of over 250,000 tons of finished AUTOMATED PROCESSES
product, Berco manufactures more than 180,000 AUTOMATIC QUALITY
track chains, 6,000,000 track shoes, The entire production process is fully automated
1,300,000 rollers and 320,000 idlers and and computer controlled via Computer
sprockets per year. Manufacturing Technology systems. This
Track links are forged, quenched, tempered, guarantees a highly reliable process and constant
machined and induction hardened on the rail quality of the products.
surface. Bushings are turned and drilled in double
spindle lathes, case hardened, ground and
THE RIGHT PRODUCT
superfinished (lapped) for longer seal life. AT THE RIGHT TIME
A vast variety of raw materials and flexible
Track shoes are either hot rolled or forged for manufacturing give the competitive advantage of
optimum internal grain flow and stronger core short lead times while matching your specific
resistance, through hardened and stress relieved need. That’s what we also call Customer
for perfect geometry and excellent resistance to Satisfaction.
bending.
Complete track chains are then assembled in a HEAT TREATED
fully automatic transfer line (Berco Design) where TO TREAT YOU EVEN BETTER
all important parameters (torque, lubrication, seals Quality materials and state-of-the-art
positioning, etc.) are monitored. manufacturing are not enough to guarantee the
quality of the finished products. That’s why the
Rollers are forged in two halves, welded in
heat treating processes are carried out making
automated welding stations, through hardened,
sure that all process parameters (temperature
machined and finally assembled with shafts,
gradients, time, quenching temperature, etc.) are
hubs, collars and seal groups.
constantly monitored online.
Sprockets are forged for optimum internal grain
Hardening and tempering upgrade mechanical
flow and stronger core resistance, machined and
properties for superior wear resistance, stress
induction hardened on the entire tooth profile.
relieving guarantees perfect geometry and
Idlers are fabricated by automated welding of hot excellent resistance for longer product life.
rolled rail rims (one piece) with heat treated forged
hub and high resistance side plates. Painting
completes the process while final inspection on
the finished products guarantees the Total Quality
of all components.
 00507.WR430GB00B

Berco original production.The specifications and processes described in this brochure are subject to change without notice
All manufacturers’s names, numbers, symbols and descriptions are used for reference purposes only. All parts listed are of
ISO 9001 Cert. n. 0029/2
ISO 9001 Cert. n. 1327/0
ISO 9001 Cert. n. 0092/2

ISO 14001 Cert. n. 0009A/0

Published by Berco Marketing & Communications Dept.

BERCO S.p.A. Your Berco Dealer:

Via 1° Maggio, 237
44034 Copparo (FE) Italy
Tel. +39 0532 864 111
Fax +39 0532 864 259
info@berco.com
www.berco.com