Heavy Duty Track ChainsThe Complete Choice

A Company ofThyssenKrupp

Technologies

BERCO S.p.A.

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BercoMoving Your Business Ahead

Leadership inUndercarriageFor about 90 years Bercosleadership and research hasresulted in the greatestundercarriage value. Quality is the critical linkthat assures the maximumproductivity of yourmachine. No one hasinvested more than Berco to assure dependable High QualityUndercarriage. Bercostarts with the highestquality steel, then controlshardened depth along withother performance features. As a result Bercosundercarriage is second tonone for extended wear lifeand value.

Getting the Most from your Undercarriage Since 1920 Berco hascontinued to innovate andimprove undercarriageperformance. High-qualitymaterials and carefulmanufacturing processesensure that Bercoundercarriage componentsare reliable, durable andwear at a predictable rate.Longer life and controllablewear mean that you get maximumundercarriage performanceat the lowest operatingcost. At Berco we call it Best UndercarriageValue

Berco Process ControlBerco builds value &durability into everyundercarriage component.Berco controls processescritical to durability andvalue, such as: design, rawmaterial, heat treating,manufacturing and becauseBerco has control overthese processes, our undercarriages wear ata predictable rate and canbe managed as a system.

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Heavy Duty Track ChainsThe Complete Choice

Berco Heavy Duty Track ChainsHeavy duty, sealed & lubricated track chains have been specificallydesigned for increased pin & bushing retention. Track linkincorporates greater pin-to-link and bushing-to-link contactareas while additional link wear material increasescomponent life. Heavy Duty chains are also availablein the version with EExxttrreemmee WWeeaarr RReessiissttaanncceeBBuusshhiinnggss for maximum life in high abrasionenvironment. Exclusive heat treatment givesBerco links consistent surface hardness, superiorhardened depth and strong core hardness. Bercopins & bushings are dimensionally matched to thelinks and manufactured to provide excellent trackjoint reliability, while the design ensures maximumsealability. All this results in excellent wear resistance,strength and durability for superior sealability andlonger life. Heavy duty track chains work best inmoderate to high impact conditions and they are ideal forrocky conditions, logging, reforestation, side sloping and for uneven terrain.Heavy duty track chains with Extreme Wear Resistance Bushings, work bestin high abrasion/low impact applications.

Your Best Undercarriage Value Greater pin-to-link and bushing-to-link contact areas for increased pin

retention Higher track link provide additional wear material Track links are forged from deep hardening low alloyed boron steels with

certified hardenability based on Bercos specification Links are quenched & tempered for tough and 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 The choice of the leading OEMs

The Complete Choice Heavy Duty Chains version with Extreme Wear

Resistance Bushings available as an option For track-type machines ranging in class from D4H-HD to D7H-HD Suitable for XR, XL, LGP and TSK undercarriages Ultra low temperature (-50C) version available The choice of the leading OEMs

Customer Satisfaction Considering that more than 50% of your maintenance costs will gointo maintaining the undercarriage, it is not surprising that Bercorepresents 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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Heavy Duty Track ChainsThe Complete Choice

Class D4HPitch 171,45 mm (6,75)

5/8 Hardware

D5N - D5M - D4H - LGP - XL

Link BERCO # OEM #

39 CR 5552/39 108-095341 CR 5552/41 108-095544 CR 5552/44 108-0954

39 CR 5563/3939 CR 5565/39

39 CR 5564/39 115-243839 CR 5566/39 N.A.

AC 226A 9G-3110CR 1250B 1M-1408CR 4357 3T-8601CR 5573 9G-8592

CR 4358/14 3T-0356CR 4358/16 3T-0358CR 4358/18 3T-0360CR 4358/20 8E-9812CR 4358/22 8E-9810CR 4358/24 8E-4972CR 4358/26 61-9573CR 4358/30 216-6286

CR 4826/18 6Y-5624CR 4826/20 8E-9816CR 4826/22 8E-9814CR 4826/24 1Q-4754CR 4826/30 236-1870

Class D5HPitch 190,5 mm (7,50)

3/4 Hardware

D6N - D6M - D5H LGPD6M XL - D5H XL - D5H STD

Link BERCO # OEM #

37 CR 5465A/37 106-163539 CR 5465A/39 106-163740 CR 54465A/40 110-297646 CR 5465A/46 106-163647 CR5465A/47 106-1634

37 CR 5508/3737 CR 5509A/37

37 CR 5466/37 115-243937 CR 5507/37 N.A.

CR 4441 6V-1792CR 1967 1S-1860CR 5443 106-1642CR 5444 107-0719

CR 5450/18 106-1603CR 5450/20 106-1604CR 5450/22 106-1607CR 5450/24 117-0615CR 5450/28 106-1602CR 5450/34 106-1605

CR 5451/18 106-1611CR 5451/20 106-1612CR 5451/22 106-1613CR 5451/24 117-0616CR 5451/28 106-1615CR 5451/34 106-1616

CR 5448/20 106-1608CR 5448/22 107-0713CR 5448/600 132-1334CR 5448/34 222-1796

CR 5449/20 106-1617CR 5449/22 107-0714CR 5449/600 132-1336CR 5449/34 222-1797

Class D6HPitch 203,2 mm (8,00)

3/4 Hardware

D6R - D6H LGPD6H XL - D6H XW - D6H XR

Link BERCO # OEM #

39 CR 5534B/39 6I-966840 CR 5534B/40 6I-967041 CR 5534B/41 6I-967145 CR 5534B/45 8E-9037

39 CR 5544A39 CR 5546B

39 CR 5545/39 115-244039 CR 5547/39 N.A.

CR 4441 6V-1792CR 1967 1S-1860CR 3326 9S-1838

CR 5320/20 6Y-6285CR 5320/22 6Y-6286CR 5320/24 6Y-6287CR 5320/26 133-2890CR 5320/30 6Y-8973CR 5320/36 196-7839

CR 5316/20 6Y-6292CR 5316/22 6Y-6294CR 5316/24 6Y-6296CR 5316/26 6Y-6298CR 5316/30 6Y-6300CR 5316/36 196-1236

CR 4443/18 6Y-6390CR 4443/20 6Y-6391CR 4443/22 6Y-6389CR 4443/24 1Q-4930CR 4443/30 138-5774CR 4443/36 169-5868

CR 3695/18 6Y-6392CR 3695/20 6Y-6394CR 3695/22 6Y-6412CR 3695/24 6Y-6397CR 3695/30 6Y-6404CR 3695/36 169-5867

Class D7HPitch 215,9 mm (8,50)

7/8 Hardware

D7R - D7H XR -D7H LGP

Link BERCO # OEM #

40 CR 5574/40 115-630141 CR 5574/41 115-630343 CR 5574/43 115-630246 CR 5574/46 123-8064

40 CR 5585/4040 CR 5587/40

40 CR 5586/40 128-560440 CR 5588/40 N.A.

CR 1000C 7H-3599CR 1969 2S-2140CR 4135 6V-1723CR 4789 9W-9058

CR 4526/22 7T-0737CR 4526/24 7T-3940CR 4526/26 7T-5968CR 4526/28 7T-2282CR 4526/30 115-7462CR 4526/36 6I-9912

CR 4054/20 117-0756CR 4054/22 7T-2750CR 4054/24 7T-5969CR 4054/26 1Q-4960CR 4054/36 247-0264

HEAVY DUTY TRACK CHAINSLubricated Chain without Shoes

BERCO CHAIN COMPONENTS Bushing and Seal Kit Pin & Bushing Kit

OEM CHAINS ONLY Bushing and Seal Kit Pin & Bushing Kit

TRACK SHOES HARDWARE Bolt Nut Short Master Link Bolt Long Master Link Bolt

TRACK SHOESStandard Shoe Single Grouser

Master Shoe Single Grouser

EXTREME SERVICE TRACK SHOESStandard Shoe Single Grouser

Master Shoe Single Grouser

Note: the table is not complete, for codes regarding chains with shoes (standard or extreme service) and chains with or without shoes (standard or extreme service).

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Adding Value to Our ProductsAdding value to Your Business

Making a Superior Product

Rapid prototyping

Stress analysis at extremetemperatures

Electron microscope withmicroanalysis

Photo-elasticity analisys

3D modeling of a link dieFEM analysis of pin & link press fit3D modeling of links joint for kinematic analysis

Reliability Test on components(ex. rollers) are carried out todetermine life and performancein a variety of field applications.

Artificial Intelligence andVision techniques are currentlybeing developed toautomatically inspect 100% ofcomponents. This reducesdefects (ex. after forging orheat treatment) attributable tomanufacturing to almost zero.

Huge efforts are also devotedto the development of New Materials andimprovement of the Heat Treating Processes, toguarantee longer product lifeand Superior Products.

Having supplied leading OEMsfor decades, BercosEngineers and productspecialists can help you designand manufacture the rightundercarriage, using high techsoftware, tools and expertise.Berco can also help you reducedevelopment and engineeringtime, tooling expenses andfacility costs. Berco AddsValue not only to our productsbut also to Your Business.

It all begins in the design stage,Berco Research &Development engineersemploy state of the artcomputer design. The use of3D modeling and finite elementanalysis (FEM) allow us todesign and evaluate acomponent before it is built.

Our Rapid Prototypingenables Bercos engineers tooptimize a design beforespending money in tooling.

Berco Metallurgy Laboratoryemploys advanced machinessuch as an electron microscopewith microanalysis, aspectrophotometer, tribometersfor wear tests, MTS presses forstatic and fatigue tests onmaterials and components.

Photo-elasticity and straingauge techniques arecommonly used for stress andfatigue analysis on individualand assembled components.

Stress analysis at extremetemperatures (-70C 250C)are also carried out.

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State of the Art ProductionState of the Art Components

Heat Treated to Treat You Even BetterQuality materials and state-of-art manufacturing are notenough to guarantee the qualityof the finished products. Thatswhy the heat treating processesare carried out making sure thatall process parameters(temperature gradients, time,quenching temperature, etc.)are constantly monitored online.Hardening and temperingupgrade mechanical propertiesfor superior wear resistance,stress relieving guaranteesperfect geometry and excellentresistance for longer productlife.

Bushings milling

Track chains fully automated assembly

QT Process

Track links forging

Automated Processes Automatic QualityThe entire production process isfully automated and computercontrolled via ComputerManufacturing Technologysystems. This guarantees ahighly reliable process andconstant quality of the products.

The Right Product at The Right TimeA vast variety of raw materialsand flexible manufacturing givethe competitive advantage ofshort lead times while matchingyour specific need. Thats what we also callCustomer Satisfaction.

Split master links creep feed grinding Induction hardening of track links

Track links forging

With a capacity of over 130,000 ton of finished product the Berco Track Chain Department manufacturesmore than 180,000 Track Chains per year. From the central raw material warehouse the steel bars aretransferred to one of the automatic cutting & forging stations. After quenching & tempering chain links aremilled on the shoe and rail surfaces. A conveyor then transfers the links to the two step inductionhardening and quenching station. Accurate induction frequency and artificial vision ensure optimumhardened depth and total quality of the links. Link boring and stress relieving completes the linkmanufacturing cycle. Bushings are turned and drilled in double spindle lathes, deep hardened aftercarburizing, grinded and superfinished (lapped) for longer seal life. These processes ensure high wearresistance and excellent core toughness. Pins are machined deep hardened and ground to ensure narrowdimensional tolerances and the best surface finish for longer life. Complete track chains are finallyassembled in automatic press (Bercos Design) where all importantant parameters (torque, lubrication,seals positioning, etc.) are monitored online. Painting completes the process while final inspection of thefinished products guarantees the Total Quality of all components.

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We Care

Leadership inEnvironmental Development

Not only do we care about ourcustomers supplying qualityproducts manufactured under ISO 9001 certified processes, but also we care about theEnvironment.

Since Jan 2000 Berco is ISO 14001 certified and hasadopted EnvironmentalProcedures throughout the entiremanufacturing process. We havean Environmental Strategy andwe continuously check on theprogress made toward the setObjectives.

Getting More out of Less.Reduction of energy consumption,improved use of materials andminimization of waste, allows for alower impact on the environment.We have given preference toenvironmentally friendlytransportation like trains and boatsand we have begun redesigningour packaging in order to userecyclable materials. We havechanged our painting processesand now use environmentallyfriendly water-based paint, with areduction in the amount ofpollutant emissions. We haveadopted a closed loop coolingsystem that reuses the water fromour heat treatment processesinstead of emitting it into theenvironment.

Customer Service

We have a large dealer networkcovering 70 countries in theworld. They have been inbusiness for decades, theyknow the business and theyknow it from their customerspoint of view. They understandcustomers needs and theyknow that their success is tied totheir customers successes.

We support our dealers with ourprofessional sales force. Wetrain them, we provide themwith the right marketing toolsand advanced technologicalsystems. We have developed acomputer based integratedsystem BOPIS (Berco OnlineProduct Information System)enabling a dealer technician touse a laptop computer from thefield to consult our databaseand easily find the right answer.

We back you, wherever youare. We work with our dealers toestablish a parts and servicepresence near you, in order toalways have the right product atthe right time in the right place.It is customer satisfaction thathas built our Berco TrackRecord.

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00802.WR429GB00C

BERCO S.p.A.Via 1 Maggio, 23744034 Copparo (Ferrara) ItalyPhone +39 0532 864 111 Fax +39 0532 864 259www.berco.cominfo@berco.com

Your Berco dealer:

The specifications and processes described in this brochure are subject to change without notice

Published by Berco Communication Dept.

ISO 9001 Cert. n. 0029/4

ISO 14001 Cert. n. 0009A/2

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