Publication # 350-05010-00 Publication Date: April 1994

Revised: January, 2010

INSTRUCTION
MANUAL
FOR

SPLIT ROLLER BEARINGS

P.O. Box 8447, Mankato, MN 56002-8447, (507) 625-4011 Fax (507) 345-2798 www.kato-eng.com
1
 Table of Contents

Introduction 3

General 4

Lubrication 5

Bearing Replacement and Disassembly 5

Initial Grease Fill Chart 8

Bearing Replacement, Assembly 9

Periodic Maintenance 12

Field Service of Split Roller Bearings 13

Anti Brinelling Device 14

Torque Chart 16

2
Introduction
Foreword
This manual contains instructions for installing, operating and maintaining split roller bearings in
Kato Engineering generators. This specific bearing maintenance must be performed by an individ-
ual fully trained to perform maintenance on this split roller bearing.

Lubrication information, electrical connection drawings, dimensional drawings and parts listings for
your model are contained in the manual package as supplementary information and are the specific
source of information for making connections and ordering replacement parts. Information about
optional components of your generator may also be contained as a supplement.

Please read this manual and all included manuals in its entirety before unpacking, installing,
and operating your generator. If your manual came on a CD, read all the files included on the
CD.

Safety instructions
In order to prevent injury or equipment damage, everyone involved in installation, operating and
maintenance of the generator described in this manual must be qualified and trained in the current
safety standards that govern his or her work.

While “common-sense” prevention of injury or equipment damage cannot be completely defined by any
manual (nor built into any piece of equipment), the following paragraphs define warnings, cautions, and notes
as they are used in this manual:

Warning: Warnings identify an installation, operating or maintenance procedure, practice, condition, or state-
ment that, if not strictly followed, could result in death or serious injury to personnel.

Caution: Cautions identify an installation, operating or maintenance procedure, practice, condition, or state-
ment that, if not strictly followed, could result in destruction of or damage to equipment or serious impairment
of system operation.

Note: Notes highlight an installation, operating or maintenance procedure, condition, or statement and are
essential or helpful but are not of known hazardous nature as indicated by warnings and cautions.

Ratings/description
Nameplates, which are located on the side of the generator, include serial and model number as
well as rating information and bearing and lubrication information.

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INSTRUCTION SUPPLEMENT
FOR KATO Generators Fitted With Split Roller Bearings
GENERAL

This instruction covers the installation and removal of split roller bearings in Kato Generators. Refer to your
generator manual for maintenance schedules.

Figure 1
Exploded View of Split Roller Bearing

The picture above shows an exploded view of a split roller bearing. Note the names of the
parts and be familiar with them. Use this page for reference as needed while performing the
maintenance on the bearing.

4
1. LUBRICATION
Replenishment - For periodic replenishment of lubri-
cation, refer to the Bearing Lubrication Plate mounted
on your unit. If your unit does not have a Lubrication
Plate, Contact Kato Engineering Parts Department
for a replacement. Very stiff greases which tend to
channel or very soft greases which may churn at high
speed should not be used. We use and recommend
Mobilith SHC 220.

NOTE: Do not mix synthetic and non-synthetic

greases. Mixing greases may result in rapid
failure of the grease by setting up hard or break-
down
Figure 2
2. BEARING REPLACEMENT, Loosen Bolts
DISASSEMBLY

NOTE: It may be necessary to remove the exciter/

PMG to do maintenance on your bearing, espe-
cially if the complete bearing has to be changed.
Also, for units without an anti brinelling bracket,
some disassembly may be required to remove
internal bearing parts. The pictures being used
in these procedures are for reference only. They
may not match your unit. If they do not match,
use them as a guide, adapting them for your
needs. Use good shop safety procedures.

A. To remove drive end bearing, proceed as follows:

1. Remove exciter and drive end covers.

2. Place wood or fiber protective strips Figure 3

between the generator field poles and the
bottom of the stator. These strips must be of
such thickness and strength as to minimize
downward movement of the rotor if it rests on
the stator.
3. Disconnect alternator field leads. Remove
the exciter armature and PMG retaining
bolts. Thread two 5/8 threaded stock
through the PMG rotor into the shaft as
shown in figure 3.
Remove PMG Rotor
CAUTION
TAKE SUITABLE PRECAUTIONS TO PREVENT
INJURY TO FINGERS CAUSED BY THE STATOR
FRAME BEING FORCIBLY ATTRACTED TO PER-
MANENT MAGNETS ON PILOT ROTOR.
4. Remove clips securing exciter field leads
to the exciter frame, generator frame and
generator endbell.

Remove the PMG rotor. The rotor should
be removed by grasping the inside magnets
and then pulling quickly and sharply straight
back, overcoming the magnetic pull off the
PMG rotor to the PMG armature. Take care
not to cock the PMG when pulling it off.
Place the PMG in a clean area, or seal it in
plastic to avoid contamination with metal
particles. See Figures 2 & 3.
5. Connect a hoist to the lifting eyes on the
exciter stator and remove the exciter stator
mounting bolts. Remove the exciter stator
from the endbell, being careful not to dam
age stator or rotor windings.
See figures 4 & 5.

5

Figure 4
Remove Bolts
6. Remove the exciter armature and rotating
rectifier as follows:
a. Disconnect alternator field leads from the
positive (+) and negative (-) terminals located
on the heat sinks of the rotating rectifier
assembly.
Figure 6
Remove Exciter Armature
7. Place a sling about the drive end of the
shaft and attach the sling to an overhead
crane or hoist. Put enough pressure on the
sling to hold the shaft level.
See figure 7.

Figure 7
Sling Placement

8. Remove the bolts holding the two halves

Figure 5
Remove Exciter Stator
b. Using a hoist and strap, remove exciter
armature and rotating rectifier. See figure 6.
of the flanged bearing cap together. Take
out the bolts holding the flanged bearing cap
to the endbell and remove the two halves.
Since the cartridge cannot move axially on
the drive end bearing, the flanged cap halves
must be tilted out of the recess in the end
bell. See figures 8, & 9.

Figure 8

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 Figure 9
9. Remove the joint screws from the housing;
remove the two halves of the housing. Leave
the outer race in the housing. See figure 10.
B. To remove the exciter end bearing, proceed as fol-
lows: Note: Remove exciter per previous steps.
Figure 10
Removing Housing
10. Pull the outer seal off the shaft. Clean it
and set it aside.
11. Remove the jointing clips from the roller
cage; remove the roller cage.
12. Carefully measure the position of the
inner race on the shaft so that the new inner
race can be placed in exactly the same
position. Measure from a specific surface on
the coupling or shaft step.
13. Remove the screws from the clamping
rings. Remove the clamping rings and the
inner race. See figure 11.
7
Figure 11
Removing Clamping Rings
14. If the sling is to be removed, make sure
that the wood or fiber strips are in position
between the generator field and stator.
1. Place a strap around the exciter end of the
shaft and lift enough to take the pressure off
the bearing.
2. Remove the bolts holding the flanged
bearing cap to the endbell; slide the bearing
assembly out so that the cap is clear of the
recess in the endbell
3. Remove the joint screws from the cap;
remove the two halves of the cap.
4. Remove the joint screws from the housing;
remove the two halves of the housing. Leave
the outer race in the housing.
5. Slide the seals out of the way. Do not
remove them unless they are to be replaced.
6. Remove the jointing clips from the roller
cage; remove the roller cage.
7. Measure and record the position of the
inner race on the shaft. Measurement should
be accurate within 0.015". Kato Engineering
can be contacted for the measurement re
corded during assembly.
8. Remove the screws from the clamping
rings. Remove the clamping rings and inner
race.
9. If the sling is to be removed, make sure
that the strips are in position between the
generator field and stator.
Note: Initial grease fills only. Do not use for periodic regreasing.

Table 1
Split bearing grease initial fill chart
(Shaft size measured at end of drive end)

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3. BEARING REPLACEMENT, ASSEMBLY
To assemble a bearing, proceed as follows:
Note: Clean the parts and shaft with solvent to
remove any oil.
1. Apply a light coat of O-ring lubricant to the o-rings
in the ID of the seal. See figure 12.
Figure 12
Lube ID of Inner Seal
2. Install the inner seal onto the shaft. Use a square
to get the correct position. See figure 13.
Figure 13
Install Inner Seal
3. Place the two halves of the inner race at the cor-
rect position on the shaft. A light tap with a rawhide or
rubber hammer may be required to spring the races
over the shaft. Hold together with plastic ties or a
hose clamp temporarily. Consult the measurements
taken during disassembly. The drive end race and
non drive end race must be placed exactly where the
original race had been. See figures 14 & 15.
9
Note: The inner race and the clamping rings are
matched sets and are not interchangeable. They
are stamped with identifying numbers. Make sure
the numbers match and are facing the same di-
rection. The clamping ring stamps will face away
from the inner race on both sides.
Figure 14
Match Numbers and Direction
Figure 15
Placing inner race
4. There should be a gap at the joints of the inner
race. Some gap in each joint helps insure good seat-
ing. The gaps should be even, It may be helpful to
place shim stock in the gaps to keep them even, and
remove them before final tightening. If the measured
gap is outside the range of 0.05" to 0.020, contact
Kato Engineering.
5. Verify the shoulders of the clamp collars face each
other. Fit the clamping rings with their joints rotated
between 30o and 90° from the joints in the inner race.
Partially tighten all four clamping screws equally.
Strike each clamping ring with a soft mallet about 90O
from the parting line to ensure the proper seating of
the clamping rings. Tighten bolts and strike with mal-
let again. Fully tighten bolts to torque value specified
on page 15. See figure 16.

Figure 16
Install Clamping Rings
6. Tap down each half of the inner race and clamping
rings all around the shaft, placing a fiber or hardwood
block between hammer and bearing parts. Retighten
screws. Repeat until the screws are fully tight. Make
sure that the rings are hard against the race shoul-
ders all around. The total gap is not critical provided
the shaft is within the required tolerance.
Make sure the placement of the inner race is the
same measurement as recorded earlier. Also, lubri-
cate the bores and the seal area of the outer seal
and install. See figure 17.
Figure 17
On drive end, Positioning must be exact
10
7.Inject sufficient grease to fill the grease passages
of the roller bearing cage. Refer to Table 1 for grease
amounts. See figure 18.
Figure 18
Grease the bearing rollers
8. Place the cage around the inner race, matching
the race halves. Insert the jointing clips.
Note: Some units will have Allen screws. See
page 16 for torque specification.
Verify the grease is evenly distributed between the
rollers and the cage, and the joint clips remain in
position by rotating the cage on the race five times.
See figures 19 and 20.
Figure 19
Insert joint clips or Allen screws
 Figure 21
Fill grease passages

Figure 20
Installing roller cage

9. Inject sufficient grease to fill the grease passages. Grease hole

Fill each half of the cartridge with grease. See Table
1 for grease amounts. See figure 21.

10. After the cartridge has grease in it, tap and slide
in the outer race. Repeat for the bottom half. See
figure 22.

11. Assemble the cartridge with races installed.

Tighten the four split screws to set the outer races in
position. Tighten and torque the twelve Allen head No grease hole
race locking screws to secure the outer races. Disas-
semble the cartridge.

Figure 22
Install outer race

11
12. Assemble the two halves of the cartridge around
the bearing cage and seals. (The outer race halves
should be in the housing halves). Tighten the four
joint screws, making sure the end faces are flush.
13. Tighten in an X pattern to torque spec, refer to
page 15 for torque spec.
Figure 23
Lubricate Spherical Seating
14. Rotate the cartridge five times to ensure proper
seating. Make sure the anti-rotation pin is on top.
15. Lubricate the spherical seating all the way around
with MolyKote or similar.
16. Allow the spherical seating to self-align while
tightening the flange bolts. Then loosen the flange
bolts on the top housing and at the split line. Note:
If working on both bearings, loosen flange and
split line bolts on both drive end and non drive
end. Rotate the shaft at least five revolutions to allow
the cartridge to align. Fully tighten the bolts to torque
spec, refer to page 15 for torque spec.
Caution: Tightening the flange halves without
ensuring the cartridge alignment will result in
premature bearing failure.
Note: the cap screws or bolts holding the bearing
assembly to the end bell on the exciter end each
have a lock washer and a hardened flat metal
washer. These screws must not be allowed to
bottom out in their holes.
Verify all the bolts are torqued to the proper levels
when assembling the generator, refer to page 15.
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Figure 24
Assemble bearing housing
4. RECOMMENDED MAINTENANCE
Replenishment - For periodic replenishment of lubri-
cation, refer to the Bearing Lubrication Plate mounted
on your unit. If your unit does not have a Lubrication
Plate, Contact Kato Engineering Parts Department
for a replacement.
Very stiff greases which tend to channel or very soft
greases which may churn at high speed should not
be used. We use and recommend Mobilith SHC 220.
NOTE: Do not mix synthetic and non-synthetic
greases. Mixing greases may result in rapid
failure of the grease by setting up hard or break-
down.
Caution:
Kato Engineering strongly advises rotating idle
units, especially those subject to vibration, at
least 1/2 turn each week to keep a film of grease
between the roller and the race. This will help
prevent bearing damage and brinelling.
Every 12,000 hours or 3 years of operation
Remove the upper flange cap and the upper outer
race and remove the old grease. Inspect the bearing,
re-pack with grease as indicated in table 1.
Re-torque the roller bearing cage if it is equiped with
Allen screws.
See the generator manual for complete maintenance
instructions.
5. FIELD SERVICE OF SPLIT ROLLER BEARINGS
This section is for bearing maintenance when a
full shop disassembly is not possible. Refer to
Chapter 3 for full procedures. Torque all bolts and
screws per page 15. Be sure to safely support
generator parts while working on them.
5. Prepare and lubricate the roller cage per previous
instructions.
6. Install the cage first, then roll in the cartridge. Add
Molykote to spherical seat only.
7. Roll the cartridge to verify ease of rotation.

Drive end bearing 8. Ensure the lower cartridge is seated squarely to

Disassemble
1. Set a jack to support the shaft, be sure to center
the jack on the shaft. Protect the shaft surface with
hardwood or brass, etc.
2. Check the torque of the lower bearing flange.
Insure bearing lower half is secure.
3. Remove the upper flange.
4. Remove the upper cartridge.
eliminate a cocked bearing. Place a straight edge
across the cartridge and flange to check for even
seating.
9. Slowly lower the shaft to allow the bearing to take
the rotor weight. Recheck that the lower cartridge is
still seated squarely.
10. Install the upper cartridge. Install, tighten and
torque the split line screws.
11. Install the upper cap. Leave loose if working on
the opposite end.

5. Place the dial indicator on the shaft so as to mea-
sure the upward force on the shaft.
6. With a jack or a Kato lifting device, raise the shaft
.020”, (insure the jack is sufficient to support the rotor
during work).
7. Roll out the lower cartridge to expose the bearing
cartridge roller. Inspect.
8. Remove the roller. Inspect in cage.
9. Inspect and disassemble the inner race. Remove
the screws and collar. Take care not to drop the in-
ner race.
Non drive end bearing
1. Loosen the PMG and remove.
2. Reinstall the PMG bolts to the shaft for saftey.
3. Move the exciter to the rear, no need to remove it
from the shaft.
4. Work within the constraints of the exciter frame,
making sure the shaft is supported during bearing
disassembly.
5. Tighten and torque the bearing bolts after comple-
tion of ODE and DE assembly.

10. Inspect the grease seals. Replace if necessary.

Bearing removal, inspection and maintenance is the
Use a hose clamp to squeeze and remove pins. same as the drive end.

Prep and assemble

1. Install the inner race and torque. (Measurements

from shaft center line or race line.)

2. Prepare the cartridge. Clean and lubricate. Re-

move, clean, and reinstall the outer race per instruc-
tions.

3. Clean the shaft, seals and rollers, inspect for dam-

age.

4. Reinstall and re-lubricate the rollers or replace with

new parts.
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 Optional Anti-Brinelling Device

Lifting Block

Figure 25
Optional anti-brinnelling device, note brass lifting block

Prior to start up, bolts MUST be loosened three or four turns. Verify clearance to
brass lifting block, see figure 25 and 26.

FAILURE TO DO SO MAY CAUSE DAMAGE TO THE EQUIPMENT

To block rotor for transportation, tighten both screws indicated above to 25 ft/lbs.
Total rise in shaft is about .005"-.010"

14
Optional Anti-Brinelling Device

Figure 26
Lifting Bolts

15
 Torque Specifications for Split Roller Bearings

5" shaft bearings

TORQUE SPECIFICATION
BOLT SIZE HEX WRENCH SIZE IN/LBS FT/LBS N/m
CLAMP COLLAR 1/4-28 X 1 S.H.C.S. 3/16 120.0 10.0 13.6
ROLLER CAGE* #10-32 X 3/8 LOW HEAD 3/32 29.3 2.4 3.3
CARTRIDGE PUSHER SCREWS #10-24 X 3/4 S.S. 3/32 40.0 3.3 4.5
CARTRIDGE ASSEMBLY BOLTS 1/4-20 X 1 S.H.C.S. 3/16 108.0 9.0 12.2
LOCATING PIN (BOLT) 3/8-16 X 1/2 S.H.C.S. 5/16 396.0 33.0 44.7
FLANGE ASSEMBLY BOLTS 5/8-11 X 2 1/2 S.H.C.S. 1/2 1,908.0 159.0 215.6
VIBRATION BRACKET 3/8-16 X 1 5/8 S.H.C.S. 5/16 396.0 33.0 44.7
FLANGE MOUNTING BOLTS 7/8 (GRADE 8) COARSE NA 5,448.0 454.0 615.6

5.5" shaft bearings

TORQUE SPECIFICATION
BOLT SIZE HEX WRENCH SIZE IN/LBS FT/LBS N/m
CLAMP COLLAR 5/16-24 X1 S.H.C.S. 1/4 240.0 20.0 27.1
ROLLER CAGE* 1/4-20 X 3/8 LOW HEAD 3/16 68.4 5.7 7.7
CARTRIDGE PUSHER SCREWS #10-24 X 3/4 S.S. 3/32 40.0 3.3 4.5
CARTRIDGE ASSEMBLY BOLTS 5/16-18 X 1 S.H.C.S. 1/4 216.0 18.0 24.4

16
LOCATING PIN (BOLT) 3/8-16 X 1/2 S.H.C.S. 5/16 396.0 33.0 44.7
FLANGE ASSEMBLY BOLTS 5/8-11 X 2 1/2 S.H.C.S. 1/2 1,908.0 159.0 215.6
VIBRATION BRACKET 3/8-16 X 1 5/8 S.H.C.S. 5/16 396.0 33.0 44.7
FLANGE MOUNTING BOLTS 7/8 (GRADE 8) COARSE NA 5,448.0 454.0 615.6

6" shaft bearings

TORQUE SPECIFICATIONS
BOLT SIZE HEX WRENCH SIZE IN/LBS FT/LBS N/m
CLAMP COLLAR 5/16-24 X 1 S.H.C.S. 1/4 240.0 20.0 27.1
ROLLER CAGE* 1/4-20 X 1/2 LOW HEAD 3/16 68.4 5.7 7.7
CARTRIDGE PUSHER SCREWS 1/4-20 X 1/2 S.S. 1/8 108.0 9.0 12.2
CARTRIDGE ASSEMBLY BOLTS 5/16-18 X 1 S.H.C.S. 1/4 216.0 18.0 24.4
LOCATING PIN (BOLT) 3/8-16 X 1/2 S.H.C.S. 5/16 396.0 33.0 44.7
FLANGE ASSEMBLY BOLTS 3/4-10 X 3 S.H.C.S. 5/8 3,384.0 282.0 382.4
FLANGE MOUNTING BOLTS 1 (GRADE 8) COARSE NA 8,184.0 682.0 924.8

NOTE: ALL VALUES REPRESENT DRY OR LIGHTLY OILED, IF THEY ARE HEAVILY OILED REDUCE TORQUE RATING BY 10%
*The NYLOK™ patch incorporated into the threads is a thread locking compound. According to the screw manufacturer, any screw with NYLOK
embedded into the threads can be re-used up to 5 times. In the event of inspection or change out, re – use the screws if spares are not available
We strongly recommend using new screws if available
 Field Installation Split Roller Bearing Checklist
BEFORE DISMANTLING
Technician's Name: ___________________ Technician's Company: _________________
Serial Number: _______________________ # Hours ran: _________________________
Date: _______________________________ Site Location: ________________________
Check cleanliness of insulation on Exciter End

Vibration recorded by site operation

Visual Estimation of Axial Movement of the rotor in

operation
ENGINE STOPPED, COUPLING GUARD REMOVED

Location of Magnetic center, relative to the seal face

WHEN BOTH BEARINGS ARE OPENED ( TOP CASING AND TOP CARTRIDGE REMOVED)

Dimension between center of roller and center of lower part Drive End :
of out race, for both bearings Non Drive End :

Slowly rotate the generator and visually check the rollers Roller Condition:
and cage condition, record Cage Condition:

Record grease amount in bearings and grease color

Type of seal present? ALUMINUM RACE BRONZE RACE

WHEN THE INNER RACE IS REMOVED FROM THE SHAFT

Measure the shaft diameter where the race was mounted.

Measure at 3:00 and 9:00 and 12:00 and 6:00 at (2)
locations under the race (Ex.: 4.999 - 3 digits)

Visual aspect of the shaft under the race

If Inner race removed / replaced Inner race NOT removed / replaced

Record the gap with a feeler gage between the
Inner race removed / replaced
two halves of the inner race tightened on the shaft
Gap Measurement: ____________________

All screws are torqued with a torqued wrench

WHEN THE BEARINGS ARE PARTIALLY REASSEMBLED, NOT HAVING THE UPPER PART OF THE CASING AND
CARTRIDGE ON YET

Rotate slowly by hand for 5 turns or with turbine slowly

REMAINING REASSEMBLY

The rotor can be rotated smoothly and quietly by hand

AFTER ALIGNMENT, BUT BEFORE THE GUARD IS INSTALLED

Location of Magnetic center, relative to the seal face

DURING OPERATION

Check cleanliness of insulation on Exciter End

Vibration recorded by site operation

ALL PARTS REMOVED AND REPLACED FROM BEARINGS MUST BE RETURNED TO KATO WITH IDENTIFICATION

S/N and Site Name: ____________________________________

DE or ODE: ___________________________________________
17
Number of hours on turbine: ______________________________
Date and Name of Service Tech: __________________________