Resolving Seized Track Links in Berco Undercarriages

[MikePhua]

Berco’s Legacy in Undercarriage Systems
Berco, founded in Italy in 1920, has long been a global leader in manufacturing undercarriage components for earthmoving equipment. Their track chains, rollers, idlers, and sprockets are widely used in dozers, excavators, and forestry machines across OEM and aftermarket sectors. Known for their hardened steel metallurgy and sealed-and-lubricated track (SALT) designs, Berco products are engineered for longevity in abrasive environments. However, even high-quality components can experience issues—especially when machines sit idle for extended periods.
Identifying Seized Track Links and Bridging Behavior
Seized track links typically manifest as stiff or immobile joints within the track chain, preventing smooth articulation around sprockets and idlers. In some cases, only one or two links are affected; in others, the majority of the chain may be compromised. This condition is often referred to as “bridging,” where the pin and bushing interface becomes locked due to corrosion, lack of lubrication, or excessive internal pressure.
Terminology:

• Track link: A segment of the track chain that houses the pin and bushing, allowing rotation and flexibility
  
• Bridging: A failure mode where multiple links seize, causing the track to behave as a rigid beam
  
• SALT (Sealed and Lubricated Track): A track system with internal grease or oil sealed by elastomer rings to reduce wear
  

In one example, a dozer equipped with relatively new Berco tracks exhibited two seized links despite minimal wear. The machine had been parked for weeks, and the links were free of debris—suggesting internal binding rather than external obstruction.
Common Causes of Link Seizure
Track link seizure can result from several factors:

• Extended machine inactivity leading to grease migration or hardening
  
• Manufacturing tolerances that leave insufficient clearance for wear particles
  
• Improper installation or lack of break-in operation
  
• Environmental exposure to moisture, salt, or temperature extremes
  

In one case involving an excavator, a batch of Berco rails was found to have overly tight clearances. Without space for wear debris to escape, the bushings began to bind, eventually locking the links. The machine was operable but suffered from jerky movement and accelerated wear.
Field Remedies and Practical Solutions
Technicians have developed several field-tested methods to address seized links:

• Apply penetrating oil (e.g., PB Blaster or diesel fuel) and allow time for absorption
  
• Park the machine in a shallow water hole overnight to encourage expansion and contraction
  
• Use wooden blocks and machine weight to force articulation at the seized joint
  
• Operate the machine gently to encourage movement and distribute lubricant
  
• If all else fails, cut the link and replace the pin and bushing assembly
  

In one repair, a seized link was freed by placing a timber under the joint and slowly driving the machine forward, forcing the link to rotate. While risky, this method restored movement without disassembly.
When Replacement Is the Only Option
If more than 50% of the track links are seized, replacement may be more economical than repair. Replacing pins and bushings individually is labor-intensive and may not restore full flexibility. In one case, a dozer with 80% seized links continued operating until the bushings began rotating in the rails—indicating total failure. The machine was still functional, but the undercarriage was nearing the end of its service life.
Replacement considerations:

• Source OEM or high-quality aftermarket rails with verified tolerances
  
• Confirm compatibility with existing sprockets and idlers
  
• Break in new tracks with gradual operation and regular inspection
  
• Monitor pilot holes and seal integrity during installation
  

Some operators have reported better long-term results by switching from Berco to CAT or ITM rails, citing improved wear characteristics and fewer binding issues.
Warranty and Dealer Support
Berco offers limited warranties on their undercarriage components, typically covering defects in materials or workmanship. However, labor costs and consequential damage are often excluded. In one case, a dealer honored the warranty for idler replacement but declined to cover installation costs or downtime. This underscores the importance of dealer relationships and clear documentation during purchase.
Recommendations:

• Retain purchase records and installation dates
  
• Document symptoms and attempted remedies
  
• Contact regional Berco representatives for technical support
  
• Consider third-party inspection if warranty claims are disputed
  

Conclusion
Seized track links in Berco undercarriages can disrupt machine performance and lead to costly repairs. Whether caused by tight manufacturing tolerances, environmental exposure, or prolonged inactivity, the issue demands a methodical approach. From penetrating oil treatments to full rail replacement, technicians must weigh time, cost, and long-term reliability. In the world of heavy equipment, a seized link isn’t just a nuisance—it’s a signal that the undercarriage is asking for attention. And when steel stops moving, the job stops too.