Rotrex C-range Manual

Rev 10
Rotrex C-range
Superchargers
Setup and Maintenance

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Contents
02 Introduction
03 Key points
05 Lubrication system
06 The oil system components
07 Routing of the oil lines
07 Connect the components
09 Initial start-up
10 Oil level checking and maintenance
10 Testing
11 Oil and filter change procedure
12 Pulley change procedure
13 Warranty

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Introduction
Thank you for choosing Rotrex and congratulations on your new Rotrex supercharger!
Rotrex superchargers are based on a patented high-speed planetary traction drive.
Through innovative technology, advanced materials, and quality control, we strive to
make this product the best in the market. To get the most out of your Rotrex
supercharger and to avoid problems, carefully follow the instructions in your
supercharger kit documentation and this leaflet.
The guidelines in this leaflet are only for general issues, please contact your Rotrex
dealer or see rotrex.com for all specifications and requirements of the Rotrex
supercharger.
WARNING!
Before beginning any installation of the Rotrex supercharger, read and
familiarize yourself with all the accompanying literature.
Do not attempt to install this product before discussing the details with your Rotrex
dealer. Make sure you have the necessary technical knowledge and experience with
forced induction systems.
In case there are any questions prior to or during the installation of the unit or kit,
please contact your Rotrex dealer.
Disconnect the battery of the vehicle before starting any installation or maintenance
work.
DANGER –ROTATING PARTS!
Do not put hands or fingers near the running Rotrex supercharger.
Suction is extremely powerful and can cause loose clothes, hair, and
fingers to be sucked into the unit with risk of serious injury.
The surfaces of the supercharger, the connected air hoses and oil lines
is hot during and after the supercharger has been in operation.
Allow the supercharger and hoses to cool or wear gloves while working
on the supercharger
Use protective eyewear when working near the running Rotrex
supercharger. Keep tools, bodyparts, hair etc. clear of the pulley and
drive belt while the engine is running.

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Key Points
For best performance and durability please follow the key points stated below:
•Prior to initial start-up make sure to prime the supercharger oil system (see
page 9). Failure to do so may result in severe damage.
•The oil used must be special Rotrex traction fluid.
•The Rotrex supercharger can only be operated in one rotational direction.
Never turn the pulley in the incorrect direction by hand or otherwise. For your
unit, please find the correct rotational direction in the technical datasheet found
on rotrex.com
•Do not try to change the compressor setup. The outlet direction of the
compressor house is pre-set by your dealer to fit the kit setup. Changing this
setup must only be done by authorized personnel. Contact your Rotrex dealer
if you encounter problems with the setup.
•To avoid engine damage: make sure to run the appropriate fuel grade (octane).
If any sign of knocking is detected immediately discontinue running the engine
under boost conditions until the problem has been solved.
•It is important to place the Rotrex supercharger as the highest component in
the system (s/c and oil system, see page 5) and with the flat surface of the
supercharger facing downwards within +/- 15º to horizontal.
•Check the supercharger oil level after initial start-up. Always follow the correct
procedure for oil level check (see page 10)
•To secure optimal oil conditions: Do not modify or change the oil circuit
supplied with your kit.
•Always respect the oil and filter change interval and procedure (see page 11)
•Always follow the correct pulley ring changing procedure (see page 12).
•Always take care not to over tighten the supercharger bracket and banjo bolts
as this will strip the threads. Follow the torque specified in your kit installation
instructions or download the datasheet available at rotrex.com

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NOTE!
Always place, store, transport and operate the
Rotrex supercharger within +/- 15º to horizontal
flat surface facing down. This will prevent oil
spills and prevent the oil pump from failing.
Failure to do so may lead to oil spills and oil
pump starvation, resulting in catastrophic
failure.
Max
mounting
angle ±15º
!

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Lubrication system
The Rotrex superchargers incorporate an independent dry sump lubrication system.
Please follow these instructions closely during installation. If your supercharger was
bought as part of a kit, please refer to the kit documentation.
IMPORTANT!
The Rotrex supercharger has been developed and extensively tested with special
Rotrex traction fluid.
To maintain the ultimate level of performance and durability it is very important that
the unit is exclusively run with special Rotrex traction fluid supplied by a Rotrex
dealer
The lubrication circuit provided with the kit is an integrated and essential part of the
supercharger system.
To ensure performance and durability: Carefully follow the instructions provided with
your kit on how to install the lubrication circuit in the vehicle.
•Make sure there is no debris in the oil system before beginning the installation.
•Engine vibration and movement must be considered when placing the
components and while routing the oil lines.
•The oil lines and the oil system components (filter, canister and cooler) must
be placed below or level with the Rotrex supercharger shaft.
•Place the oil cooler where external clogging (debris, stones, sand etc.) can be
prevented.
•Place the oil canister where sufficient space allows for easy and safe oil level
checking (see page 10)

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The oil system components
The following components are supplied with the Rotrex supercharger. Only use original
Rotrex oil hoses for the oil system as the traction fluid is corrosive to some materials
1. Oil canister fitted with dipstick in the blue cap
2. Inline oil filter
3. 2 x oil canister brackets
4. 8 x hose clamps
5. 4 x banjo and banjo bolts
6. 8 x copper washers
7. Approx. 2,5m oil hose
8. 1L SX150 traction fluid
9. Optional oil cooler and fittings
Rotrex supercharger
Oil cooler
Oil filter Oil canister
1.
2.
3.
4.
6. 5.
7.
8.
9.

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Routing of the oil lines
IMPORTANT!
When routing the oil supply and return lines: Care must be taken to prevent cracks
and cuts.
An undiscovered oil leak will cause catastrophic failure to the supercharger and
can damage engine.
Please note the below bullets to correctly install the oil system:
•Make sure there is sufficient clearance from moving parts such as the
ventilator fan, belts, and pulleys etc.
•Oil lines must be routed at a safe distance from the exhaust system and other
hot parts.
•To prevent restricted oil flow only use large radius bends when routing the oil
hoses and avoid any sharp bends and kinks.
•Prime the oil system correctly prior to initial start-up (see page 9)
Connect the components
IMPORTANT!
Tightening torque of the banjo bolts: 21Nm (15lbft)
Tightening torque of the oil cooler fittings: 21Nm (15lbft)
2. Mount the oil cooler in
front of other coolers in
a location with good air
flow. Place the oil
cooler below or level
with the supercharger
shaft. The threads for
the fittings must be
facing upwards to
prevent air pockets
1. Place the oil canister with the
cap below or level with the
supercharger shaft. Use the
bracket supplied in the oil set.
Make sure the canister is
placed upright. Leave the
plastic plugs in place to
prevent debris from entering
the system

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Clockwise direction counterclockwise direction
The finished oil system is shown above with oil flow direction as indicated by the arrows.
Oil flows from the oil canister through the filter into the compressor oil inlet. The
compressor oil outlet routes through the cooler before entering the oil canister at the
top.
To prevent oil leaks it is of utmost importance that the oil cooler, oil filter and the oil
canister with its cap are placed below or level with the supercharger shaft.
4. With the supercharger
properly in place fit one
end of the hose to the
oil inlet using the banjo
fitting and banjo bolt.
Make sure to use a
copper washer on each
side of the banjo fitting
to prevent leaks
6. Now press the filter studs
into the hose ends as
shown and secure with
hose clamps. Observe
the flow direction of the
filter! Following the same
method, continue fitting
the remaining parts of the
oil system
3. With a pair of pliers,
compress a hose
clamp and slide it
over one end of the
hose. Press a banjo
fitting into the hose
end and secure it
with the hose clamp
5. Find a suitable place
for the oil filter
somewhere along the
oil inlet hose. Place
the oil filter below or
level with the s/c
shaft. Cut the hose
using a sharp knife or
hose scissors. Slide
a hose clamp over
each end of the hose

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Initial Start-up
To ensure proper traction fluid circulation and adequate lubrication, it is important to
prime the oil system before the engine is started for the first time after the supercharger
installation.
The priming process is done most easily with all oil components in place and installed.
1. Carefully fill the oil canister with traction fluid without exceeding the maximum
mark on the dipstick. The oil level is measured with the thread of the dipstick
cap fully engaged.
2. The banjo bolt at the oil line attached to the supercharger inlet marked IN
should be loosened a couple of turns allowing air to escape the system.
3. Carefully apply pressurized air to the oil filler hole at the
top of the canister. Do not pressurize the system to more
than one bar or 15psi. Use a rag or a sponge as a seal
between the air gun and the canister.
4. When oil appears at the oil inlet, tighten the banjo bolt and the system is
primed.
5. Carefully top up the oil canister to the maximum mark on the dipstick.
6. Turn on the engine and rev it to 2-3000 rpm and make sure the oil starts
flowing by visual inspection, looking into the oil canister. Do not rev the engine
more than specified as this can cause damage to the supercharger. Carefully
top up the oil canister to the max marking on the dipstick.
7. Let the engine idle for 5 minutes while checking the oil system for leaks
8. Check the oil level using the correct procedure (see page 9)
9. A run-in period of 100 km (65 miles) is highly recommended. During this run-in
period, drive the vehicle carefully and avoid unnecessary revving and heavy
acceleration
IMPORTANT!
Under no circumstances can the canister run dry; this will cause immediate
catastrophic failure.

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Oil level checking and maintenance
MAINTAIN YOUR SYSTEM!
The oil and filter change interval of the Rotrex supercharger is 80.000 km / 50.000
miles or two years, whichever comes first.
Always keep the oil level between minimum and maximum.
Overfilling the Rotrex supercharger may cause oil leaks, and too little oil may cause
severe damage to the unit.
Oil level checking procedure
Check the oil level using the correct oil level checking procedure as described below.
•Set the engine speed between 2 and 3000 rpm.
•Remove the dipstick and wipe it clean.
•Check the oil level while the engine is kept running at 2 –3000 rpm.
•The correct oil level is between the min and max marking of the dipstick
measured with the thread of the cap fully engaged.
IMPORTANT!
The procedure above is the correct and only way to check the oil level (checking the oil
level with the system turned off does not give a correct reading).
Testing
Upon completion of the installation, the vehicle must be tested thoroughly. Testing
should identify any leaks, noise, vibration, improper alignment of belt, overheating or
other faults in the installation. It should also ensure the engine is running properly with
the correct air/fuel ratio and ignition timing. Incorrect installation or use of the
supercharger can cause severe damage to the product and/or the engine.

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10. Top up the canister
(see page 8 point 5-
8) and check the oil
level
7. Remove the canister cap
5. Clean all the oil hose
connections on the oil
canister to prevent any
debris or dirt from
entering the oil circuit
4. Remove the hose
clamp pliers
6. Remove the top
banjo bolt and
sealing washers on
the canister.
Remove the hose
and let the old oil
flow into a temporary
open oil reservoir
(min. capacity 1 liter)
8. Start up the engine and let it idle while
continually adding new Rotrex traction oil to
the canister and letting the old traction fluid
drain into the temporary oil reservoir.
Always observe the canister to make sure it
never empties. Continue to pour in Rotrex
traction oil until approximately 800ml has
been flushed through the system and then
stop the engine
9. Remount the canister’s oil
inlet hose and remember
to replace the copper
washers with new ones
Oil and filter change procedure
Please see below procedure for correct oil and filter replacement:
2. Slide away the two
hose clamps on the
oil filter and remove
the oil filter
3. Mount the new oil filter.
Make sure to mount the
filter in the correct
direction according to the
arrows on the filter
indicating the correct oil
flow direction. Slide the
two oil hose clamps back
to the correct position
1. To avoid traction oil
spilling into the engine
compartment, use a hose
clamp pliers to clamp the
oil hose as close to the oil
filter as possible on the oil
canister side (filter inlet)

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Pulley change procedure
IMPORTANT!
Always use the original pulley bolts, supplied with your Rotrex supercharger
If the Rotrex supercharger is removed to perform the procedure, make sure to prime
the oil system after reinstallation (see page 9 point 2)
Do not remove the pulley adapter (hub with centre bolt behind the pulley ring) from
the Rotrex Supercharger, as this will void warranty of the unit
To change the pulley, carefully follow the below procedure:
•Disconnect the battery.
•Remove the belt from the pulley.
•Without rotating the pulley, carefully loosen the 6 x M6 Torx30 bolts
from the pulley.
•Remove the pulley from the Rotrex supercharger
•Install the new pulley on the pulley adapter using the original bolts
supplied with the Rotrex supercharger.
•Without turning the S/C shaft, cross tighten the 6 bolts to a tightening
torque of 10Nm.
•Install the pulley belt, make sure the dynamic tensioner is adjusted to the
new size. Consult with your Rotrex dealer to make sure your belt is the
correct length.

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Warranty
For warranty issues and other questions please contact your Rotrex dealer.
Parts found to be defective due to misuse will not be honoured for warranty or other
associated liabilities. The guidelines in this leaflet are only for general issues, please
contact your Rotrex dealer or see rotrex.com for all specifications and requirements of
the Rotrex supercharger system.
If the Rotrex supercharger has been disassembled, has had the pulley adapter
removed, the pulley incorrectly replaced or has been altered in any other way the
warranty will be void.
Rotrex is not responsible for any special, incidental, or consequential damages or costs
incurred due to the failure of this product

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