RobustusTM The n. 1 in Undercarriage - Berco S.p.A

Moving your Business AheadAll products shown in this document originate fromBerco exclusively.Any references to Caterpillar (the Caterpillar wordsigns) are mentioned to communicate that the aforemenionedproducts are only suitable for Caterpillarmachines with the corresponding model designation.YOUR BEST UNDERCARRIAGEVALUESince 1920 Berco has offered aninnovative, reliable and economicalsolution to any undercarriage need.Whether for the original equipmentmanufacturers (OEM) or the aftermarket,for a special machine or amini-excavator, for a bulldozer ora mining excavator, Berco can offeryou the right answer to your specificrequirement.Superior engineering, innovativetechnology, comprehensive knowhow and state-of-the-art manufactu-State-of-the-art 3D modeling, FiniteElement Analysis (FEM) and RapidPrototyping enables Berco to design,optimize and evaluate a componentbefore it is built.Artificial Intelligence techniquesare currently being developed to auringguarantee the total quality of theproducts and services offered to you.“Original Equipment Quality,Aftermarket Value”AN EXPERT PARTNER YOU CANRELY ONCustom made solutions and projectengineering support is available uponrequest.Our team of engineers can help youchoose or design the most effectiveand efficient solution to your specificundercarriage need.They can help you reduce developmentand engineering time, toolingexpenses and facility costs, while addingvalue to your business.“Berco, The choice of the leadingOEMs”Making a superior productADDING VALUE TO YOUR BUSINESStomatically inspect 100% of components.Reliability Test on componentsare carried out to determine lifeand performance in a variety of fieldapplications.Berco Metallurgy Laboratory employsadvanced machines such asan electron microscope with microanalysis,a spectrophotometer, tribometersfor wear tests, MTS pressesfor static and fatigue tests (also at extremetemperatures -70°C ÷ 250°C)on materials and components.Huge efforts are also devoted to thedevelopment of New Materials andimprovement of the Heat TreatingProcesses, to guarantee longer productlife and superior products.

Photo-elasticity and Strain Gaugetechniques are commonly used forstress and fatigue analysis on individualand assembled components.Berco adds value not only to theproducts but also to Your Business.State of the art productionAUTOMATED PROCESSESAUTOMATIC QUALITYThe entire production process is fullyautomated and computer controlledvia Computer ManufacturingTechnology systems. This guaranteesa highly reliable process and constantquality of the products.THE RIGHT PRODUCT AT THE RIGHTTIMEA vast variety of raw materials andflexible manufacturing give thecompetitive advantage of short leadtimes while matching your specificneed. That’s what we also call CustomerSatisfaction.HEAT TREATED TO TREAT YOU EVENBETTERQuality materials and state-of-theartmanufacturing are not enough toguarantee the quality of the finishedproducts. That’s why the heat treatingprocesses are carried out makingsure that all process parameters(temperature gradients, time, quenchingtemperature, etc.) are constantlymonitored online.Hardening and tempering upgrademechanical properties for superiorwear resistance, stress relievingguarantees perfect geometry andexcellent resistance for longer productlife.

50% OR MTHE MAINCOSTS, DULIFE OF ADOZER ORBELONUNDERCAMAINTENAREPARobustus TM systemAccording to common experience,50% or more of the maintenancecosts during the life of a crawler dozeror loader belongs to undercarriagemaintenance and repairs.In a machine fitted out with traditionalundercarriage the sprocket slides onthe external surface of the bushingduring normal operation, causingbushing and sprocket wear.THE WINNING STRATEGYIncreasing the life of undercarriagecomponents is the winning strategyto reduce ownership and operatingcosts.In the new system ROBUSTUS TM thebushing rotates when in contactwith the sprocket, reducing thebushing and sprocket friction andwear and thus enabling longer life.As a consequence, it is not necessaryto turn bushings and pins and replacesprocket segments during thewhole life of the undercarriage.A wider track link rail (“big footprint”track link) provides an extended runningsurface area, balancing the wearof all components and eliminatingscalloping wear in the contact betweenchain and roller and between chainand idler.The reinforced hardware improvesjoint stability.The resulting dampening of vibrationsand noise assures more comfortableride and maximum control of the machineduring the operations.Berco Positive Pin Retention andan improved seal design produce alasting seal capacity and assure longlife to the complete system.The new system is fully compatiblewith existing frames and standardcomponents: (D6H and D5H machines),older machines can be easilyupgraded to increase their productivityand the life of the undercarriage.In the same way ROBUSTUS TM isforward-compatible with the newgeneration undercarriages equippedwith parallel or twin links.The innovative rotating bushingtracks system can be easily installedon any machine at any time. With asimple operation and no extra workyou can extend the life of your undercarriage,improving reliability andreducing costs.Berco field tests proved that the newsystem increases the track life of 35percent, with a maximum of 6,000hours of operation without maintenance;and this means cutting operatingcosts up to 30 percent.

ORE OFTENANCERING THECRAWLERLOADER,GS TORRIAGENCE ANDIRSMain features & benefitsRotating bushingIncreased running surface area• Rotating bushing chain• Wear perfectly balanced throughall components• Positive pin retention (PPR)• New concept of seal design• Reinforced hardware to improvejoint stability• Completely interchangeablesystem, using standard sprocket• Rollers & idlers fitting existingframe• Increased machine resale value• Less friction, more powerBerco Pin Retention (BPR)Improved Seal DesignReinforcedBolt & Nutto improveJoint stability

ROBUSTUS TM CUTS CINCREASING THE LIFE OF UNDERWINNING STRATEGY TO REDUCE ORobustus TM VS StandardI - First Fit Cost (0 working hours)The initial cost for Robustus TM is higher than theone for a traditional undercarriage.II- Total cost,for 6000 working hoursThese are the necessary expenses for a traditionalundercarriage in 6000 working hours:no need of replacement for Robustus TM .6000 hours: Total replacement4500 hours: Pin & bushing turn +segment3000 hours: Total replacement1500 hours: Pin & bushing turn + segment0 hours: Inital cost

CARRIAGE COMPONENTS IS THEWNERSHIP AND OPERATING COSTSIII - 6000 working hours:a different prospective forthe end userSumming up all the necessary expenses forthe traditional undercarriage, the situationshown in the first graphic now is completelyreversed. The cost of Robustus TM has remainedexactly the same, while the traditional undercarriagecosts have more than doubled.IV - Cost/hour, considering theundercarriage maintenance:min* -30%PROVEN BENEFITSThe data refers to extensive facility tests andin-field tests.Berco field tests proved that the new RobustusTM system increases the track life of 35percent, with a maximum of 6,000 hours ofoperation without maintenance; and this meanscutting operating costs of min. 30 percent.The upgrade of older machines (even ifequipped with parallel or twin links) is easyand results in increase productivity and reliabilitywhile reducing costs.*(Benefit can be even bigger if considering also machinedowntimes and the cost of labour.)OSTS BY MIN. 30%

03012. WR434GB00AISO 9001 Cert. n. 0029/6ISO 14001 Cert. n. 0009A/4All manufacturers’s names, numbers, symbols and descriptions are used for reference purposes only. All parts listed are ofBerco original production. The specifications and processes described in this brochure are subject to change without noticePublished by Berco Communications Dept.YOUR BERCO DEALER: