Berco Mini Undercarriage

The Widest Choice

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

MOVING YOUR BUSINESS AHEAD

BMU
MINI UNDERCARRIAGE & UTILITIES

A Company of ThyssenKrupp

BERCO S.p.A.

MOVING YOUR BUSINESS AHEAD

YOUR BEST UNDERCARRIAGE VALUE
Since 1920 Berco has offered an innovative, reliable and economical solution to any undercarriage need. Whether for the original equipment manufacturers (OEM) or the aftermarket, for a special machine or a miniexcavator, for a bulldozer or a mining excavator, Berco can offer you the right answer to your specific requirement. Superior engineering, innovative technology, comprehensive know how and state-of-the-art manufacturing guarantee the total quality of the products and services offered to you. Original Equipment Quality, Aftermarket Value

WE CARE
CUSTOMER SERVICE
We have a large dealer network covering more than 90 countries in the world. They have been in business for decades, they know the business and they know it from their customers point of view. They understand customers needs and they know that their success is tied to their customers successes. We support our dealers with our professional sales force. We train them, and provide them with the right marketing tools and advanced technological systems. We have developed a computer based integrated system BOPIS (Berco Online Product Information System) enabling a dealer technician to use a laptop computer from the field to consult our database and easily find the right answer. We back you, wherever you are. We work with our dealers to establish a parts and service presence near you, in order to always have the right product at the right time in the right place. It is customer satisfaction that has built our Berco Track Record.

AN EXPERT PARTNER YOU CAN RELY ON

Custom made solutions and project engineering support is available upon request. Our team of engineers can help you choose or design the most effective and efficient solution to your specific undercarriage need. They can help you reduce development and engineering time, tooling expenses and facility costs, while adding value to your business. Berco, 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

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

BMU

MINI UNDERCARRIAGE & UTILITIES

The Berco Mini Undercarriage program offers an innovative, reliable and economical set of mini undercarriage solutions, catering for mini excavators, horizontal drilling machines, small dozers or paving machines and providing you with the right answer to your specific requirements. Berco can supply a complete range of interchangeable components for rubber track belts or traditional steel track chains, guaranteeing the best possible value for money. Superior engineering, innovative technology (e.g. patented monoblock cast iron chains), comprehensive know-how and state-of-theart manufacturing ensure the total quality of the products and services offered.

F25C - HEAVY DUTY TRACK CHAIN SPECIALLY DESIGNED FOR PAVING MACHINES
Sealed and greased track chain pitch 125 mm (4.92), with w-shaped polyurethane seals, reinforced track link with strut for extremely heavy-duty applications and heavy 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

THE WIDEST CHOICE

A complete line of undercarriage components for mini excavators class machines ranging from 1 to 6 ton, Compact Track Loader (CTL) and other Compact Utilities Track chains with 90-140 mm pitch (3.54-5.51") Traditional steel chains with welded or bolt-on shoes Interchangeability from steel to rubber and viceversa Rubberized shoes are available

Single grouser shoe

Flat type shoe

Triple grouser shoe

CLASS T150 Pitch: 90 mm - 3.54

CLASS T300 Pitch: 101.6 mm - 4

NEW STEEL UNDERCARRIAGE COMPONENTS

Recent evolutions in the market of Mini Excavators have led Berco to develop new undercarriage components for this range of machines. In particular, for 3 and 5-ton class machine components, it was possible to engineer new parts suitable to guarantee more resistance to wear and better performances. The first big advantage of the track chain consists in the raw material choice: instead of using austempered cast iron (ADI) it has been used a special steel alloy. As a consequence, the manufacturing process can benefit of both forging technique and faster and more efficient machining operations. Moreover, it is also possible to apply induction hardening to track chain parts more subject to wear thus increasing wear life.

UNDERCARRIAGE COMPONENTS FOR FOR COMPACT TRACK LOADERS

Berco has developed a new solution based on a tracked undercarriage, available in both rubber tracks and traditional steel track chain. The range, which already featured two versions rubber tracks and traditional steel track chain. In cooperation with his partners Berco can offer: - Track Frames - Front Idlers - Rear Idlers - Track Rollers - Sprocket & Final Drive - Rubber Tracks RUBBER TRACKS The rubber track belts, strengthened with steel cables, have metal inserts, giving a maximum cruising speed of about 14 km/h. The rubber track solution provide good grip in a great variety of working conditions and ensure great mobility even in difficult situations like muddy soils, great slopes, etc. All this make the rubber tracked skid steer a much more versatile and productive machine compared to the traditional wheeled version. STEEL TRACK CHAINS The steel track chains, compared to the rubber tracks, provide a much higher wear resistance, higher grip (traction) and longer durability (up to 4 times higher). It is the recommended solution for heavy-duty operations, harsh environment (steel scrap yards, demolishing sites, etc.) and anytime it is not necessary to change often the worksite.

Undercarriage for CTL 5 rollers, steel version

Undercarriage for CTL 4 rollers, rubber version

CLASS F25C HD Pitch: 125 mm - 4.92

CLASS T500 Pitch: 135 mm - 5.31

CLASS FL4 Pitch: 140 mm - 5.51

BMU

MINI UNDERCARRIAGE & UTILITIES

TRACK CHAINS WITH WELDED SHOES
Specific design ensures interchangeability between steel and rubber track belts, either at machine assembly time or track replacement time. Track shoes are welded on both sides of the track links. Links are forged from deep hardening Boron Steels with certified hardenability based on Berco specification. Links are quenched and tempered for strong core hardness, superior strength and higher pin & bushing retention. Links rail surface is induction hardened (HRC>53) to the wear limit (HRC>45). Precision design and accurately machined for proper fit, higher reliability and longer life. Pins are dimensionally matched to the links to provide excellent track joint reliability. They are deep hardened for best resistance to wear and fatigue. Excellent wear resistance, strength and durability for longer life. Best possible cost/performance ratio. For excavator class ranging from 2 to 3,5 tons and 101,6 mm chain pitch. 3 possible configurations with track chain width (H) equal to 32, 38 or 43 mm. Rubber pads can be bolted on the track shoes (option). Track shoes have 2 bars. Track chains with welded and ruberizzed shoes (opzion).

F G H

HOLE FOR FASTENING THE RUBBER PAD

L DIMENSIONS

UNDERCARRIAGE CLASS 150

PART # MU1526 MU1531** VA1202A* VA1203A VA1191* VA1192

SHOE WIDTH 230

A 90

B 23

C 44 58

D 22

E 14

F 78 93.6 93.6 103 103

G 56 70 70 83 83 78 78 72 83 83

A H 26 32 32 43 43 38 38 32 43 43 53.5 101.6 300 200 300 69.5 31 32 22 300 VA1433* VA1420 VA3169** VA3166** VA3168** 99.5 99.5 93.6 103 103 * version with holes in the track shoes to bolt on the rubber pads. ** rubberized shoes.

TRACK CHAINS WITH BOLT-ON SHOES

Special track chains have been accurately designed for optimum pin & bushing retention and increased component life. Exclusive heat treatment give 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. All this results in excellent wear resistance, strength and durability for longer life. Track shoes, from heavy duty rolled steel profiles, are made of low alloyed Boron Steels with certified hardenability based on Berco specification. They are through hardened and stress relieved for high strength and resistance to bending and breakage. Surface hardness HRC 47 for reduced wear and longer life. Links are forged from deep hardening Boron Steels with certified hardenability based on Berco specification. Links rail surface is induction hardened (HRC>53) to the wear limit (HRC>45) while 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 design and accurate machined for proper fit, higher reliability and longer life. For excavator class ranging from 4 to 6 tons and 135 mm chain pitch. 3 possible configurations with track chain width (H) equal to 32, 42 or 85 mm. Rubber pads (as an option) can be bolted on the track shoes. Track shoes have 3 bars.

E H G F

UNDERCARRIAGE CLASS

PART # AK 167

DIMENSIONS SHOE WIDTH A B C 55.5 135 400 35.5 49.5 49.5 74.5 35 22.5 D E F 139 115 123 139 G 101 77 85 104 H 58 32 42 58

500

VA2051 KM2731 AK 184**

** rubberized shoes.

BMU

MINI UNDERCARRIAGE & UTILITIES

TRACK ROLLERS
Rollers feature single inner flange and have been designed and manufactured for long life. Specific design ensures interchangeability between steel and rubber track belts, either at machine assembly time or track replacement time. A specific version of roller, (with a taller flange) for rubber belts to be used in severe applications, is also available. Forged steel roller shell and specific heat treatment upgrade mechanical properties for increased wear life, superior structural support and resistance to deformation. Induction hardening and superior finishing of the shafts. Bimetallic bushings for high resistance to radial loads and longer life. Bercos exclusive seal groups help to ensure lifetime lubrication for extended life and to reduce your costs. Maintenance free, for longer life and perfect operation under any working condition. Precision design and carefully manufactured for perfect alignment, perfect fit of bushings and final assembly of the components. For excavator class ranging from 1 to 6 tons and and 90-135 mm chain pitch range.

A A D

Type 1

Type 2
G F C B Dimensions (mm) D 23 20 128 40 30 40 40 40 78 30 52 E 80 75 95 85 95 95 100 85 85 110 M14 M16 M14 M14 x 1,5 M16 20 18 20 M14 18 F M10 G 18 H 100 116 140 119 108 130 119 130 116 108 140 H Type 1 1 1 1 1 1 1 1 2 1 1 E

D C B

UNDERCARRIAGE CLASS 150

Part # MU1666 MU1667 MU1680 MU3232 MU3238 MU3220

A 131

B 140

C 80

161 158 173 161 190

170 167 181,8 170 202

122 128 128 136 118 122 158

300

MU3327 MU3195 MU3319 MU3286

500

MU5178

CARRIER ROLLERS
Carrier rollers feature inner flange and have been designed and manufactured for longer life. Specific design ensures interchangeability between steel and rubber track belts, either at machine assembly time or track replacement time. Specific heat treatment upgrade mechanical properties for increased wear life, superior structural support and resistance to deformation. Induction hardening and superior finishing of the shafts. Bimetallic bushings for high resistance to radial loads and longer life. Bercos exclusive seal groups help to ensure lifetime lubrication for extended life and to reduce your costs. Maintenance free, for longer life and perfect operation under any working condition. Precision design and carefully manufactured for perfect alignment, perfect fit of bushings and final assembly of the components. For excavator class ranging from 2 to 6 tons and and 101,6-135 mm chain pitch range.

B A D

UNDERCARRIAGE CLASS 300 500

PART # MU3184 MU5157

DIMENSIONS A 117 163 B 110 110 C 82 82 D 27 40 E 30 -

BMU

MINI UNDERCARRIAGE & UTILITIES

IDLER GROUPS
Specific design of functional dimensions ensure interchangeability between steel and rubber track belts, either at machine assembly time or track replacement time. A specific version of idler (with a thicker flange/tread) for rubber belts to be used in severe applications is also available. Berco idler groups have tensioning devices that improve the operative conditions of the machine for maximum flexibility. Berco idlers provide superior structural support and wear resitance. Special heat treatment ensure proper hardness level, providing long wear resistance. Bercos seal groups ensure lifetime lubrication eliminating idler maintenance and reducing operating costs. Idlers can be supplied with breckets or fully assembled, adjuster and tensioning device. Precision design and accurately machined for proper fit, higher reliability and longer life. For excavator class ranging from 1 to 6 tons and 90-135 mm chain pitch range.

I C E

G
A B

UNDERCARRIAGE CLASS 150

Part # MU1694* MU1695 MU3278 MU3332 MU3338 MU3339 MU3226

dimensions (mm) A 232 B 272 252 C 23 28 40 40 40 40 300 338 40 40 40 28 40 40 330 330 330 330 330 330 320 346 372 372 372 372 372 372 362 388 52 187 41.6 94 245 159 20 94 225 D 129 E 18 F 75 G 190 H 472 540 540 563 563 563 568 563 568 525 563 568 625 625 625 525 625 610 525 525 106 I 60 70 90 90 90 90 90 90 90 70 90 90 L 22 0 0 10 10 15 15 15 15 0 15 15 20 25 20 20 20 20 20 20

PRE LOAD MAX LOAD (daN) (daN) 1300 2520 2520 2520 3360 2520 3360 2476 2900 3360 2520 2520 3490 3490 3490 4645 4197 4185 3490 4645 2000 4200 4200 4200 4200 4200 4200 3028 3756 4200 3752 4200 4880 4415 4415 5983 6876 4880 4950 5983

STROKE (mm) 20 30 30 30 15 30 15 10 15 15 22 30 30 20 20 15 30 15 31.6 15

300

MU3227 MU3282A MU3280 MU3279 MU3341 MU3316 MU5239 MU5240 MU5241 MU5236* MU5237 MU5238 MU5245 MU5232*

500

* for rubber belt

SPROCKETS
Sprockets are designed to suit a wide variety of hub flanges enabling a full choice of gearbox types. Berco sprockets provide superior structural support and wear resitance. Forged or casted steel and special heat treatment ensure proper hardness level, providing long wear resistance and durability. Optimized design to reduce stress concentration areas. Hunting tooth design extends tooth wear life. Accurate machining of the mounting surfaces ensure best performance and perfect interchangeability. For excavator class ranging from 1 to 6 tons and 90-135 mm chain pitch range.
B

G F

A UNDERCARRIAGE CLASS Part # BC2270A MU1501A MU1537A MU1576A MU1577A MU1597A MU1599A MU1600A MU1606A MU1658A MU1659A KM1220A MU3001A MU3002A MU3019A MU3054A MU3069A MU3090A MU3100A MU3110A MU3111A MU3115A MU3148A MU3178A MU3179A MU3183A MU3190A MU3350 MU3288 MU5001A MU5153A MU5160A MU5052A N HOLES 9 9 9 9 9 8 8 8 9 9 8 9 9 9 9 9 8 9 12 9 9 9 11 8 9 8 9 12 10 9 12 16 12 DIMENSIONS mm B 277,2 277,2 305,3 305,3 277,2 305,3 277,2 277,2 277,2 277,2 305,3 376,9 376,9 376,6 376,6 376,6 376,6 376,5 376,6 376,6 376,6 376,6 312,9 376,6 376,6 376,6 376,6 344,69 376,6 415,0 415,0 415,0 500,4

M E

150

300

500

C 22,2 22,2 22,2 22,2 22,6 22,2 22,6 22,2 22,2 22,6 22,2 32,2 32,2 32,2 32,2 32,2 32,2 32,2 32,2 32,2 32,2 32,2 32,6 32,2 32,2 32,2 32,2 32 32 37 37 37 41

H 11 11 11 11 11 11 11 10,5 11 11 11 13,5 13,5 13,5 13,5 13,5 21 13,5 13,5 13,5 13,5 13,5 11 21 13,5 21 15 13,5 13 16 15 17 15

G 180 155 180 155 180 180 180 157 180 180 157 232 212 232 232 232 240 212 232 215 232 215 180 240 215 240 262 232 232 262 260

F 160 140 160 140 160 160 160 140 160 160 140 210 190 204 204 210 200 190 210 190 210 190 160 200 190 200 230 204 204 230 230 220 230

M 8,4 11 11 11 14,5 11 14,5 8 11 12 11 11 12,5 11 13 11 13 11 11 14 14 13 14,5 11 12 11 11 14,5 12

90

101,6

18

135

E 23 23 23 23 24 23 24 23 23 24 23 27 27 27 36 36 27 36 36 27 27 36 24 36 27 27 27 25 27 45 45 45 38

N of teeth 19 19 21 21 19 21 19 19 19 19 21 23 23 23 23 23 23 23 23 23 23 23 19 23 23 23 23 21 23 19 19 19 23

BMU

MINI UNDERCARRIAGE & UTILITIES

CTL TRACK ROLLERS
The profile of the track rollers has been designed to ensure excellent track roller/track belt matching: in order to support the rubber track belt during normal running and prevent dangerous kinks forming in the belt when the machine is working at an angle in harsh conditions. Two solutions (two flange rollers and three flange ones) have been developed with a greater axial length than track chain rollers, resulting in reduced specific pressure between roller shell and belt surface and thus guaranteeing a longer roller life.

CTL FRONT & REAR IDLERS

The front idlers (acting as track adjusters) and rear idlers are designed to ensure the minimum winding angle for the rubber track belt and the best pressure distribution, thus guaranteeing the longer life of the rubber components and greater machine stability. In particular, three are the available idler versions:

With laser welded steel forged roller shell, induction hardening, bimetallic bushing and heavy duty cast iron seal groups Berco can provide the best solution for every need.

The outer shell of the idlers is made of austempered ductile iron (ADI) or forged and induction hardened in case of single flange. Double flange idlers better eliminate vibrations generated by conventional single flange idlers and provide a smoother ride because the idlers roll into the flat outer surface of the track belt avoid bumping up and down following the metal embedded parts of the rubber belt. Single flange idlers, provide best de-tracking resistance, while triple flange idlers provide the best compromise between comfort and detracking resistance.

A B

A B

Part # ID2802 KM4034 VA2681 VA3282 ID2023C ID2076C VA2254A

A 208 208 180 155 170 170 170

B 215 215 195 161 215 215 195

D 200 200 200 140 350 350 350

E 212 364 Part # KM3891 A 44 B 215 D 350

A B

BERCO AFTERMARKETS COMPONENTS

OEM CNH JCB Machines New Holland C175/C185/C195 Case CT/440CT/445CT/450CT 180/190/1110 Track Roller CA 925 CA 925 Front Idler CA 935 LK 424 Rear Idler CA 928 LK 438

Berco developed also the track chain version for compact track loader applications. Specific undercarriage components have been developed and tested over the years in order to provide to its customers the best product for tougher heavy duty works. This solution is suitable for machines from 3 to 5 tons.

Undercarriage System for Skid Steer 5 rollers, steel version

A

D A B B

Part # VA2580A VA2577A LA 519

A 153 120

B 215 215 Track Group assembly

D 154 315

E 180 345

Customized designs of complete CTL systems as bolt on solutions including frame and complete undercarriage components are available upon specific request. Please contact Berco sales department directly.

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 -70C 250C) 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 product, Berco manufactures more than 180,000 track chains, 6,000,000 track shoes, 1,300,000 rollers and 320,000 idlers and sprockets per year. Track links are forged, quenched, tempered, machined and induction hardened on the rail surface. Bushings are turned and drilled in double spindle lathes, case hardened, ground and superfinished (lapped) for longer seal life. Track shoes are either hot rolled or forged for optimum internal grain flow and stronger core resistance, through hardened and stress relieved for perfect geometry and excellent resistance to bending. Complete track chains are then assembled in a fully automatic transfer line (Berco Design) where all important parameters (torque, lubrication, seals positioning, etc.) are monitored. Rollers are forged in two halves, welded in automated welding stations, through hardened, machined and finally assembled with shafts, hubs, collars and seal groups. Sprockets are forged for optimum internal grain flow and stronger core resistance, machined and induction hardened on the entire tooth profile. Idlers are fabricated by automated welding of hot 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.

AUTOMATED PROCESSES AUTOMATIC QUALITY

The entire production process is fully automated and computer controlled via Computer Manufacturing Technology systems. This guarantees a highly reliable process and constant quality of the products.

THE RIGHT PRODUCT AT THE RIGHT TIME

A vast variety of raw materials and flexible manufacturing give the competitive advantage of short lead times while matching your specific need. Thats what we also call Customer Satisfaction.

HEAT TREATED TO TREAT YOU EVEN BETTER

Quality materials and state-of-the-art manufacturing are not enough to guarantee the quality of the finished products. Thats why the heat treating processes are carried out making sure that all process parameters (temperature gradients, time, quenching temperature, etc.) are constantly monitored online. Hardening and tempering upgrade mechanical properties for superior wear resistance, stress relieving guarantees perfect geometry and excellent resistance for longer product life.

15

00907.WR424GB00D

ISO 9001 Cert. n. 0029/5

ISO 14001 Cert. n. 0009A/3

Published by Berco Communications Dept.

BERCO S.p.A.
Via 1 Maggio, 237 44034 Copparo (FE) Italy Phone +39 0532 864 111 Fax +39 0532 864 259 info@berco.com www.berco.com

Your Berco Dealer:

Published by Berco Communication Dept.