WR412GB00C 15-04-2010 11:56 Pagina 1

Idler Groups
The Widest Choice

A Company of
ThyssenKrupp
BERCO S.p.A.
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Berco
Moving Your Business Ahead

Leadership in Getting the Most from Berco Process Control

Undercarriage your Undercarriage Berco builds value &
For about 90 years Berco’s Since 1920 Berco has durability into every
leadership and research has continued to innovate and undercarriage component.
resulted in the greatest improve undercarriage Berco controls processes
undercarriage value. performance. High-quality critical to durability and
Quality is the critical link materials and careful value, such as: design, raw
that assures the maximum manufacturing processes material, heat treating,
productivity of your ensure that Berco manufacturing and because
machine. No one has undercarriage components Berco has control over
invested more than Berco are reliable, durable and these processes,
to assure dependable wear at a predictable rate. our undercarriages wear at
High Quality Longer life and controllable a predictable rate and can
Undercarriage. Berco wear mean that you be managed as a system.
starts with the highest get maximum
quality steel, then controls undercarriage performance
hardened depth along with at the lowest operating
other performance features. cost. At Berco we call it
As a result Berco’s “Best Undercarriage
undercarriage is second to Value”.
none for extended wear life
and value.
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Idler Groups
The Widest Choice

Berco Idler Groups

Berco track Idler Groups are manufactured for
superior wear resistance. Whether cast, forged or
fabricated, Berco idlers provide superior structural
support and resurfacing capabilities. Special heat
treatment ensures proper hardness level,
providing long wear resistance. Berco’s seals
groups ensure lifetime lubrication eliminating
idler maintenance and reducing operating costs.
Berco offers the widest variety of idler groups to
meet the requirements of your work environment.

Your Best Undercarriage Value

• Low alloyed boron steels with certified hardenability
based on Berco specification (for fabricated versions)
• Low alloyed cast steel (cast version)
• Heavy duty ring-rolled tread rims (for fabricated versions)
• Induction hardened tread diameter
• High tread surface hardness (HRC > 50) for reduced wear
and longer life
• Tempered to resist cracking and chipping
• Precise design and manufacturing for proper fit
• Easy resufacing
• Idlers can be supplied alone or fully assembled with
brackets, adjuster and tension device
• The choice of the leading OEMs

The Widest Choice

• Cast, forged and fabricated (double or single flange) types
• Ultra low temperature (-50°C) version available
• More than 500 different configurations
• For track-type machines ranging from 1 to 400 ton
• The choice of the leading OEMs

Customer Satisfaction
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
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Idler Groups
Quality Components

Section of a fabricated front

idler group showing the
hardened pattern of the tread
diameter rim and of the
shaft and the lubrication
clearance.

Front idler shaft section Shafts, Bushings and

showing hardened areas Seal Groups.
and lubrication clearances. All components are
manufactured in fully
automated production systems
and computer controlled via
Computer Manufacturing
Technology systems (CIM). This
guarantees a highly reliable
processes ensuring consistent
and excellent quality.
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Adding Value to Our Products

Adding value to Your Business

FEM analisys of an idler shell FEM analisys of a bracket 3D modeling of an idler group

Making a Superior Product

It all begins in the design stage,
Berco Research & Reliability Test on components
Development engineers (ex. rollers) are carried out to
employ state of the art determine life and performance
computer design. The use of in a variety of field applications.
3D modeling and finite element
analysis (FEM) allow us to Artificial Intelligence and
design and evaluate a Vision techniques are currently
component before it is built. being developed to
automatically inspect 100% of
Our Rapid Prototyping components. This reduces Rapid prototyping
enables Berco’s engineers to defects (ex. after forging or
optimize a design before heat treatment) attributable to
spending money in tooling. manufacturing to almost zero.

Berco Metallurgy Laboratory Huge efforts are also devoted

employs advanced machines to the development of
such as an electron microscope New Materials and
with microanalysis, a improvement of the
spectrophotometer, tribometers Heat Treating Processes, to
for wear tests, MTS presses for guarantee longer product life
Electron microscope with
static and fatigue tests on and Superior Products. microanalysis
materials and components.
Having supplied leading OEMs
Photo-elasticity and strain for decades, Berco’s
gauge techniques are Engineers and product
commonly used for stress and specialists can help you design
fatigue analysis on individual and manufacture the right
and assembled components. undercarriage, using high tech
software, tools and expertise.
Stress analysis at extreme Berco can also help you reduce
temperatures (-70°C ÷ 250°C) development and engineering
are also carried out. time, tooling expenses and
facility costs. Berco Adds
Value not only to our products
but also to Your Business.

Stress analysis at extreme

temperatures
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State of the Art Production

State of the Art Components

Ring rolling of tread rims

With a capacity of over 25,000 ton of finished product the
Berco Idler Department manufactures more than 130,000
Idler Groups per year.
Fabricated Idlers: from the central raw material
warehouse the steel bars are transferred to the induction
heating/hot shearing and pre-forming stations and then to
the multi-spindle ring rolling mill (Berco’s design) where
idler tread rims are produced in one operation. Rims are
then machined and transfered to the FMS lines where they
are welded by robots to the forged hubs and side plate(s).
Induction hardening of the tread diameter follows and final
assembly (with shaft, bushings and seals) in a fully
automated FMS line complete the process.
Cast Idlers are machined in vertical lathes in the tread
diameter and in the hub area. Induction hardening and
final assembly followed by painting completes the process.
Online control at each stage of manufacturing and final
inspection of the finished product guarantees
the Total Quality of all components.
Heat Treated Automated Processes
to Treat You Even Better Automatic Quality
Quality materials and state-of- The entire production process is
art manufacturing are not fully automated and computer
enough to guarantee the quality controlled via Computer
of the finished products. That’s Manufacturing Technology
Ring rolling of tread rims why the heat treating of idlers is system. This guarantees highly
carried out with all process reliable processes and constant
parameters (temperature quality of the products.
gradients, time, quenching
temperature, etc.) that are The Right Product at
constantly monitored online. The Right Time
Hardening and tempering A vast variety of raw materials
upgrade mechanical properties and flexible manufacturing give
for superior wear resistance and the competitive advantage of
excellent mechanical resistance short lead times while matching
for longer product life. Shafts your specific need.
are induction hardened and That’s what we also call
surface finished to guarantee Customer Satisfaction.
longer bushing life and excellent
mechanical properties.
Automated welding line
Automated shaft manufacturing line FMS line for automated assemby of Idler Groups Induction hardening of shafts
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We Care

Leadership in Environmental Customer Service

Development
We have a large dealer network
Not only do we care about our covering 70 countries in the
customers supplying quality world. They have been in
products manufactured under business for decades, they
ISO 9001 certified processes, know the business and they
but also we care about the know it from their customers’
Environment. point of view. They understand
customers’ needs and they
Since Jan 2000 Berco is know that their success is tied to
ISO 14001 certified and has their customers’ successes.
adopted Environmental
Procedures throughout the entire We support our dealers with our
manufacturing process. We have professional sales force. We
anEnvironmental Strategy and train them, we provide them
we continuously check on the with the right marketing tools
progress made toward the set and advanced technological
Objectives. systems. We have developed a
computer based integrated
Getting More out of Less. system BOPIS (Berco Online
Reduction of energy consumption, Product Information System)
improved use of materials and enabling a dealer technician to
minimization of waste, allows for a use a laptop computer from the
lower impact on the environment. field to consult our database
We have given preference to and easily find the right answer.
environmentally friendly
transportation like trains and boats We back you, wherever you
and we have begun redesigning are. We work with our dealers to
our packaging in order to use establish a parts and service
recyclable materials. We have presence near you, in order to
changed our painting processes always have the right product at
and now use environmentally the right time in the right place.
friendly water-based paint, with a It is customer satisfaction that
reduction in the amount of has built our Berco Track
pollutant emissions. We have Record.
adopted a closed loop cooling
system that reuses the water from
our heat treatment processes
instead of emitting it into the
environment.
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01003.WR412GB00C Published by Berco Communication Dept.

ISO 9001 Cert. n. 0029/5

ISO 14001 Cert. n. 0009A/3

All manufacturers’s names, numbers, symbols 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

BERCO S.p.A. Your Berco dealer:

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