Number 4 June 21st, 2002

Berco Forged Sprockets

for Excavators

Berco Marketing Department

for Berco Dealer Product Support Sales Personnel

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Forged Sprockets 004.06.02.I

Number 4 June 21st, 2002 Technical Specs Sprockets are hot forged for: Optimum internal grain flow

Features: high metallurgical and mechanical properties of hot forged parts absence of internal defects as compared to castings large sprockets forged for best possible cost/performance ratio

Visible flow lines (grain flow) created from hot forging processes

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Forged Sprockets 004.06.02.I

Number 4 June 21st, 2002

Stronger core resistance

Sprockets are induction hardened, with a single shot heat treatment (no interruption of the hardened profile), on the entire tooth profile for: best resistance to wear and fatigue

Visible heat treatment case depth of tooth profile

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Forged Sprockets 004.06.02.I

Number 4 June 21st, 2002

Three Goals In Mind for Improvement Over Traditional Cast Sprockets Best resistance to wear and fatigue High metallurgical and mechanical properties of hot forged parts Absence of internal defects as compared to castings

Berco Innovation in Large Forged Parts How We Produce Large Size Components: Screw forging press Maxi-press (32000 metric t force) Hot forging large-size components of undercarriages Description The Mller-Weingarten (Manufacturer) maxi-press is the heart of the new forging department for large-size undercarriage components (sprockets, track shoes, track links, rollers, etc.). As well as the press itself, there is also a circular heating furnace, preforming press and trimming press with 4 robot handling units. After forging, sprockets are placed in a normalizing furnace for optimum material properties. The screw press is anchored to a 10 m (32,8 ft) side cube of reinforced concrete known as the seismic mass, set underground on a system of springs and shock absorbers that dampen the high shock loads caused by the movement of the forging process. Technical data screw diameter 1200 mm (3,94 ft) max force 32000 t (metric) operating force 14400 t (metric) total height above ground level 15,8 m (51,84 ft) total weight of press 1900 t (metric) total motor power 1400 kW

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Forged Sprockets 004.06.02.I

Number 4 June 21st, 2002

For more information please refer to BOPIS

Sprocket Teeth # # 23 23 23 23 23 23 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 23 5 of 10
Forged Sprockets 004.06.02.I

Sprocket Specs Pitch P 170 170 170 170 170 170 171,45 171,45 171,45 171,45 171,45 171,45 171,45 171,45 171,45 171,45 171,45 171,45 171,45 171,45 171,45 171,45 171,45 171,45 171,45 171,45 Machine Type FH 150 FH 150.2 FH 150.3 FH 150 LC FH 150.2 LC FH 150.3 LC 311 311B 312 312B 312B L EX 100 EX 100-2 EX 100-3 EX 100-5 EX 120 EX 120-2 EX 120-3 EX 120-5 FH 130.3 FH 120.2 FH 120 120 (Steel Track) EC160 EX 135 JS130 Fiat Hitachi Fiat Hitachi Fiat Hitachi Fiat Hitachi Fiat Hitachi Fiat Hitachi Caterpillar Caterpillar Caterpillar Caterpillar Caterpillar Hitachi Hitachi Hitachi Hitachi Hitachi Hitachi Hitachi Hitachi Fiat Hitachi Fiat Hitachi Fiat Hitachi John Deere Volvo Fiat Hitachi JCB

Forged Sprocket P/N FT3057A FT3057A FT3057A FT3057A FT3057A FT3057A CR6358 CR6358 CR6358 CR6358 CR6358 FT3056A FT3056A FT3056A FT3056A FT3056A FT3056A FT3056A FT3056A FT3056A FT3056A FT3056A FT3056A FT3650A FT3650A LK 271B

Berco Marketing Department

for Berco Dealer Product Support Sales Personnel

Number 4 June 21st, 2002

Sprocket Specs Pitch P 176 176 176 176 176 176 176 176 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 Machine Type FH 200 FH 200.2 FH 200.3 FH 200 LC FH 200.2 LC FH 200.3 LC FH 200 E.2 FH 200 E.3 320B 320B L 320 N 320 L 320 322 322B 322B L 322B LN 322 N 322 L 322 LN 315 317 315 L 317 N EX 200-2 EX 220 EX 220-2 EX 220-3 EX 220-5 EX 220LC-5 FH 220 FH 220.2 FH 220.3 FH 240.3 FH 240.3 LC FH 240 EL.3 200 LC 230 LC 230L CR 230L CRD 790E LC EX 215 E EX 215 EX 235 Fiat Hitachi Fiat Hitachi Fiat Hitachi Fiat Hitachi Fiat Hitachi Fiat Hitachi Fiat Hitachi Fiat Hitachi Caterpillar Caterpillar Caterpillar Caterpillar Caterpillar Caterpillar Caterpillar Caterpillar Caterpillar Caterpillar Caterpillar Caterpillar Caterpillar Caterpillar Caterpillar Caterpillar Hitachi Hitachi Hitachi Hitachi Hitachi Hitachi Fiat Hitachi Fiat Hitachi Fiat Hitachi Fiat Hitachi Fiat Hitachi Fiat Hitachi John Deere John Deere John Deere John Deere John Deere Fiat Hitachi Fiat Hitachi Fiat Hitachi Forged Sprocket P/N FT3058A FT3058A FT3058A FT3058A FT3058A FT3058A FT3058A FT3058A CR5602A CR5602A CR5602A CR5602A CR5602A CR5602A CR5602A CR5602A CR5602A CR5602A CR5602A CR5602A CR5606A CR5606A CR5606A CR5606A FT3059A FT3059A FT3059A FT3059A FT3059A FT3059A FT3059A FT3059A FT3059A FT3059A FT3059A FT3059A FT3059A FT3059A FT3059A FT3059A FT3059A FT3648A FT3648A FT3648A Sprocket Teeth # # 23 23 23 23 23 23 23 23 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 6 of 10
Forged Sprockets 004.06.02.I

Berco Marketing Department

for Berco Dealer Product Support Sales Personnel

Number 4 June 21st, 2002

Sprocket Specs Pitch P 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 Machine Type EX 255 EX 255 EL EX 165 EX 165 LC 160 LC EX 215 LC EX 200-3 EX 200-5 EX 215 EX 230-5 EX 255 LC PC 200-3 PC 200LC-3 PC 220-3 PC 220LC-3 PC 240-3 PC 240LC-3 PF 55L-1 PC 210LC-5 PC 210-5 PC 210LC-6 PC 210-6 PC 220-6 PC 220LC-5 PC 220LC-6 PC 230-6 PC 230LC-6 PC 240-5 PC 240LC-5 PC 240-6 PC 240LC-6 PC 240NLC-5 PC 240NLC-6 PC 200-7 PC 200LC-7 PC 200NLC-7 PC 210-7 PC 210LC-7 PC 210NLC-7 PC 240-7 PC 240LC-7 PC 240NLC-7 R932 R924 Li Fiat Hitachi Fiat Hitachi Fiat Hitachi Fiat Hitachi John Deere Fiat Hitachi Hitachi Hitachi Hitachi Hitachi Fiat Hitachi Komatsu Komatsu Komatsu Komatsu Komatsu Komatsu Komatsu Komatsu Komatsu Komatsu Komatsu Komatsu Komatsu Komatsu Komatsu Komatsu Komatsu Komatsu Komatsu Komatsu Komatsu Komatsu Komatsu Komatsu Komatsu Komatsu Komatsu Komatsu Komatsu Komatsu Komatsu Liebherr Liebherr Forged Sprocket P/N FT3648A FT3648A FT3742A FT3742A HT 403 HT 403 HT 403 HT 403 HT 403 HT 403 HT403 KM1217A KM1217A KM1217A KM1217A KM1217A KM1217A KM1217A KM1501A KM1501A KM1501A KM1501A KM1501A KM1501A KM1501A KM1501A KM1501A KM1501A KM1501A KM1501A KM1501A KM1501A KM1501A KM1501A KM1501A KM1501A KM1501A KM1501A KM1501A KM1501A KM1501A KM1501A LH 761 LH 761 Sprocket Teeth # # 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 23 23 7 of 10
Forged Sprockets 004.06.02.I

Berco Marketing Department

for Berco Dealer Product Support Sales Personnel

Number 4 June 21st, 2002

Sprocket Specs Pitch P 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 190 203,2 203,2 203,2 203,2 203,2 203,2 203,2 203,2 203,2 203,2 203,2 203,2 203,2 203,2 203,2 203,2 Machine Type R934 R904 R914 R924 JS180 NLC JS200 N JS200 S JS210 LC JS220 LC JS220 LC XD JS220 LR JS220 N JS220 N XD JS220 S JS220 S XD JS240 JS240 LC JS240 NLC JS240 S JS260 LC JS260 LC XD JS260 NLC JS260 NLC XD JS260 S JS260 S XD JS160 LC JS160 NLC SK200 325 320 S 325B 325 L 325 N 325 LN 325B L 325B LN FH 300 FH 300.2 FH 300 LC FH 300.2 LC FH 330.3 FH 330.3 LC FH 330 EL.3 FH 330 BEH.3 Liebherr Liebherr Liebherr Liebherr JCB JCB JCB JCB JCB JCB JCB JCB JCB JCB JCB JCB JCB JCB JCB JCB JCB JCB JCB JCB JCB JCB JCB Kobelco Caterpillar Caterpillar Caterpillar Caterpillar Caterpillar Caterpillar Caterpillar Caterpillar Fiat Hitachi Fiat Hitachi Fiat Hitachi Fiat Hitachi Fiat Hitachi Fiat Hitachi Fiat Hitachi Fiat Hitachi Forged Sprocket P/N LH 761 LH1017A LH1017A LH1017A LK 105B LK 105B LK 105B LK 105B LK 105B LK 105B LK 105B LK 105B LK 105B LK 105B LK 105B LK 105B LK 105B LK 105B LK 105B LK 105B LK 105B LK 105B LK 105B LK 105B LK 105B LK 272A LK 272A SI 881 CR5604A CR5604A CR5604A CR5604A CR5604A CR5604A CR5604A CR5604A FT3060A FT3060A FT3060A FT3060A FT3060A FT3060A FT3060A FT3060A Sprocket Teeth # # 23 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 8 of 10
Forged Sprockets 004.06.02.I

Berco Marketing Department

for Berco Dealer Product Support Sales Personnel

Number 4 June 21st, 2002

Sprocket Specs Pitch P 203,2 203,2 203,2 203,2 203,2 203,2 203,2 203,2 203,2 203,2 203,2 203,2 203,2 203,2 215,9 215,9 215,9 215,9 215,9 215,9 215,9 215,9 215,9 215,9 216 216 216 216 216 216 228,6 228,6 228,6 228,6 228,6 228,6 Machine Type FH 270.3 EX 300 EX 300-2 EX 285 EX 285 LC EX 270 LC-5 EX 270-5 EX 300-3 JS300 JS330 LC JS330 LC XD JS330 NLC JS330 NLC XD 529 (D7) 330 330 L 330 LN 330B 330B L 330B LN EX 355 LC EX 355 EL EX 300-5 EX 330-5 PC 350LC-6 PC 300-6 PC 300LC-6 PC 340LC-6 PC 340NLC-6 PC 350-6 PC 400-6 PC 400LC-6 PC 450-6 PC 450LC-6 PC 400HD-6 PC 350HD-6 Fiat Hitachi Hitachi Hitachi Fiat Hitachi Fiat Hitachi Hitachi Hitachi Hitachi JCB JCB JCB JCB JCB Guria Caterpillar Caterpillar Caterpillar Caterpillar Caterpillar Caterpillar Fiat Hitachi Fiat Hitachi Hitachi Hitachi Komatsu Komatsu Komatsu Komatsu Komatsu Komatsu Komatsu Komatsu Komatsu Komatsu Komatsu Komatsu Forged Sprocket P/N FT3060A FT3060A FT3060A HT 410 HT 410 HT 410 HT 410 HT 410 LK 229A LK 229A LK 229A LK 229A LK 229A VA1042A CR5861A CR5861A CR5861A CR5861A CR5861A CR5861A HT 411 HT 411 HT 411 HT 411 KM2385A KM2385A KM2385A KM2385A KM2385A KM2385A KM2384A KM2384A KM2384A KM2384A KM2384A KM2384A Sprocket Teeth # # 21 21 21 21 21 21 21 21 23 23 23 23 23 23 23 23 23 23 23 23 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21

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Forged Sprockets 004.06.02.I

Number 4 June 21st, 2002 Wear patterns on Sprocket Root wear (bushing vertical wear) Due to sliding contact with bushing O.D. Normal (30) wear pattern with lubricated chains with no packing and sealed chains with no pitch extension RDS and / or FDS wear (Reverse & Forward Drive Side) Due to sliding contact with bushing O.D. Normal [(30 - 60)] wear pattern with lubricated chains with moderate packing and sealed chains with pitch extension If sealed chain, typical RDS most worn; in some applications, FDS most worn area Forward Drive Side (FDS) tip wear Due to interference with bushing O.D. (>60 and <90) caused by its mislocation during motion Occurs mostly in reverse, with severe packing on lubricated chains or in forward in sealed chains with pitch extension Sprocket side scratches towards the root No effects on sprocket (it may continue to be used) Reverse Drive Side (RDS) tip wear Due to interference with bushing O.D. (>60 and <90) caused by its mislocation during motion Occurs mostly with severe packing on lubricated chains (or sealed chains with no pitch extension) in forward motion (bottom of sprocket). Severe packing may lead to chain popping Also occurs at the bottom of sprocket in reverse in case of loose chains (both sealed with no pitch extension and lubricated); in this case it is also called back jamming If sprocket side scratches towards the root = packing; if towards the tip = too loose chain No effects on sprocket (it may continue to be used) Sprocket gouging and side wear Due to interference with links inner sides during motion If extended to less than 360, usually caused by sprocket / frame misalignment If extended uniformly over 360, sprocket lateral displacement, lack of guards guidance or snaky chains are normally the causes Generally, the worst effects are on track chains (links,bushings), not on sprockets, unless thickness reduction dramatically increases bushing to sprocket pressure Berco Marketing Department
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Forged Sprockets 004.06.02.I