Balex ABL2500 Owner'S Manual Download Page 2 | Manualshive

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CONTENTS

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QF-T06-Rev 3 2017-02-28

INTRODUCTION ....................................................................................................................................... 3

GENERAL SAFETY PRECAUTIONS ............................................................................................................. 4

INSTALLATION ......................................................................................................................................... 6

Pre-Installation ........................................................................................................................................ 6

Installation Stages ................................................................................................................................... 7

OPERATION ........................................................................................................................................... 13

Pre-Launch Checks ................................................................................................................................ 13

Launching .............................................................................................................................................. 13

Retrieving .............................................................................................................................................. 13

Battery Charging ................................................................................................................................... 13

MAINTENANCE ...................................................................................................................................... 14

Drive Unit Maintenance ........................................................................................................................ 14

Power Unit Maintenance ...................................................................................................................... 14

Hydraulic Hose Maintenance ................................................................................................................ 14

Boat Hull Maintenance ......................................................................................................................... 14

Trailer Maintenance .............................................................................................................................. 14

Owner Inspections ................................................................................................................................ 14

TECHNICAL DATA .................................................................................................................................. 15

APPENDIX .............................................................................................................................................. 16

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Summary of Contents for ABL2500

Page 1: ...Owner s manual ABL2500 Please read the owner s manual carefully and make sure you understand the instructions before using the unit ...

Page 2: ...ation 6 Installation Stages 7 OPERATION 13 Pre Launch Checks 13 Launching 13 Retrieving 13 Battery Charging 13 MAINTENANCE 14 Drive Unit Maintenance 14 Power Unit Maintenance 14 Hydraulic Hose Maintenance 14 Boat Hull Maintenance 14 Trailer Maintenance 14 Owner Inspections 14 TECHNICAL DATA 15 APPENDIX 16 ...

Page 3: ...boat especially when conditions at the boat ramp get difficult during retrieval Your purchase gives you access to professional help with repairs and service whenever this may be necessary It is our wish that you will be satisfied with your ABL2500 for a long time Think of this Owner s manual as a valuable document By following its content Installation Operation Maintenance etc the life span and th...

Page 4: ... with the battery case and charge the battery in a well ventilated place Turn off the main switch before removing fitting the battery cables or checking fuses Electrical The electrical system stores energy that can be released in large amounts This is why you should always be conscious to not short the battery terminals Example Metal watch straps metal tool handles etc High Pressure The hydraulic ...

Page 5: ...ief valve will activate if the boats bow is driven up against the winch post vee block Battery Fuse A fuse and fuse holder come standard with the Power Unit Battery It is connected to the Positive Terminal on the Battery 12V Input Plug Fuse A Fuse is incorporated into the 12V input circuit Isolator Switch The Power Unit has a main isolator switch and all power is removed from the ABL2500 when the ...

Page 6: ...Unit Battery Assembly x1 10 Mounting Bracket and Strap Battery x1 11 Battery x1 12 Remote Controls x2 13 Hydraulic Hose Kit5 Kit x1 14 Schumacher Charging Kit Optional 15 Solar Panel Charging Kit Optional 16 CTEK Adaptor lead Optional 17 POWERTECH Adaptor lead Optional 18 Vehicle Power Supply System6 Optional Notes 1 The Drive Unit Brackets are available in different heights to suit the trailer bo...

Page 7: ...ppendix 3 Drop In Beam Trailer Stage 1 Boat Removal I Position the trailer and boat on a flat surface with the motor raised and ensure there is at least 3m behind the motor II Position a tyre behind the transom rear of the boat Disconnect the safety chain latch and unwind the winch rope 0 5m while simultaneously pushing the boat backwards off the trailer III Slowly let out more winch rope while si...

Page 8: ...uld match that recommended in the Accreditation Pack Please refer to the Accreditation Pack to determine this distance Figure 4 Fitting the mounting brackets V Tighten the Drive Unit Brackets 3 to the trailer VI Position the Drive Unit Starboard 1 to the Drive Unit Bracket 3 installed in the previous step Fit two M12 Grade 8 8 bolts through the Drive Unit Starboard 1 and Drive Unit Bracket 3 only ...

Page 9: ...st and not the winch post Please refer to the Accreditation Pack to determine the height underneath the Mounting Brackets III Sit the Power Unit Pump Assembly 7 onto the Mounting Bracket 8 and using the bolts provided fix them together Hint Check there is no interference with the winch handle or jockey wheel IV Sit the Power Unit Battery Assembly 9 on the Mounting Bracket 10 and using the two nylo...

Page 10: ...the hoses where they connect into the Power Unit Pump 7 then cut the hoses to length using a sharp knife Hint If the cut is square the fittings are much easier to fix into the hoses VI Using the straight fittings in the Hydraulic Hose Kit 13 screw these fittings into the end of the long hoses cut in the previous step and attach to the Power Unit Pump 7 If the fittings supplied are crimp style this...

Page 11: ...ve Unit Brackets 3 to the Drive Units 1 2 are fully tightened to 88Nm using the torque wrench IX Ensure the bolts holding the Rear Rollers 4 to the cross beam are fully tightened Caution The Drive Units 1 2 will lift 25mm and their belts will start turning with the next steps X Push the isolator key into the Power Unit Pump 7 and turn the system on Hint The lights should flash and the battery leve...

Page 12: ... on the trailer and the Drive Units 1 2 use the Retrieve button on the Remote Pendant 12 and simultaneously wind the boat fully onto the boat trailer VI With the boat fully loaded make sure the winch rope is clipped on and locked up VII Now get under the boat trailer and joggle the Drive Units 1 2 and try to roll the Rear Rollers 4 If the Drive Units 1 2 don t joggle and the Rear Rollers 4 do not ...

Page 13: ...depth to a point on your trailer which you can see when reversing III With your trailer at the correct depth guide the boat towards the Drive Units 1 2 with the bow rope and just before your boat gets to the Drive Units 1 2 press Retrieve on the remote Hint This helps by using the boats momentum to start the loading Optional Drive the boat up to the Drive Units 1 2 and just before your boat gets t...

Page 14: ...e type and rating VI Check the oil for any contamination and replace if necessary VII Check enclosures for any accumulated water and use a sponge to remove VIII Replace Remote Control batteries IX Test 12V Marine Hybrid Battery to ensure optimum performance Hydraulic Hose Maintenance I Check that all hoses are secured II Check all hoses for damage or abrasion at all rub points Replace any hoses or...

Page 15: ...commended 65 80 100 CCA Minimum Recommended 550 600 700 Balex Marine Validated Batteries Exide Marine Stowaway Dual Purpose MSDP24 MSDP27 Century Marine Pro M24MF 680 M27MF 720 Hella Endurant Boatmaster Marine MMF24 680 MMF27 780 Barden UK PowerMax 85 Sealed Remote Control Type Two Button Frequency 433MHz Battery Lithium CR2016 x 2 Code Length 26 bit Digital Code Hydraulics Oil Biodegradable Fuchs...

Page 16: ...APPENDIX 1 CUTAWAY TRAILER ASSEMBLY DRAWINGS QF T06 Rev 3 2017 02 28 ...

Page 17: ...ION SIZE BALEX MARINE 1 3 SHEET WEIGHT PS B 1 30 A3 ABL2500 GA 001 SHEET SCALE CHECKED BY N A D SC APPROVED BY 9 12 2016 ABL2500 PS Address Balex Marine Limited PO Box 14367 Tauranga 3143 New Zealand Phone 64 21 466 536 Website paul balexmarine com REV DESCRIPTION NAME DATE A ISSUED FOR PRODUCTION SC 12 09 2016 B UPDATED FOR CUSTOMER DOCUMENTATION EE 15 12 2016 NOTES ILLUSTRATIONS ARE INDICATIVE O...

Page 18: ...copyright disclosed without express prior consent of the copyright holder DO NOT SCALE ALL DIMENSIONS IN mm whole of this drawing may be reproduced used or 6 E Copyright Balex Marine and or their respective clients No part or NZS AS 1100 101 1992 DRIVE UNIT CUTAWAY TRAILER DESCRIPTION SIZE 207774 33 g 1 3 SHEET 1 30 BALEX MARINE A PS WEIGHT ABL2500 GA 101 SHEET SCALE CHECKED BY SC APPROVED BY PS C...

Page 19: ...lexmarine com ISOMETRIC VIEW ISOMETRIC VIEW ISOMETRIC VIEW RIGHT VIEW RECOMMENDED ASSEMBLY POSITION WINCH POST MOUNTED TOP ALTERNATE ASSEMBLY POSITION WINCH POST MOUNTED BOTTOM ALTERNATE ASSEMBLY POSITION WINCH POST MOUNTED TOP BOTTOM RIGHT VIEW RIGHT VIEW LEFT VIEW LEFT VIEW LEFT VIEW REV DESCRIPTION NAME DATE A ISSUED FOR DOCUMENTATION SC 13 09 2016 B ISSUED FOR CUSTOMER MANUALS EE 15 12 2016 NO...

Page 20: ...Marine Limited PO Box 14367 Tauranga 3143 New Zealand Phone 64 21 466 536 Website paul balexmarine com REV DESCRIPTION NAME DATE A ISSUED FOR DOCUMENTATION SC 13 09 2016 B ISSUED FOR CUSTOMER MANUALS EE 15 12 2016 ALTERNATE ASSEMBLY POSITION DRAWBAR BRACKET MOUNTED RIGHT VIEW LEFT VIEW LEFT VIEW RIGHT VIEW ISOMETRIC VIEW ISOMETRIC VIEW ALTERNATE ASSEMBLY POSITION DRAWBAR POST MOUNTED STRAIGHT NOTE...

Page 21: ...TTERY TERMINALS REMOVE THE FUSE ON THE POSITIVE CABLE CONFIRM THE POLARITY THEN ATTACH THE NEGATIVE CABLE THEN THE THE POSITIVE 3 PS CHECKED BY ABL2500 GA 201 1 10 PS APPROVED BY BALEX MARINE DWG No DRAWN BY SHEET DESCRIPTION PROJECT DRAWN MOUNTING ARRANGEMENT 5 3 2 4 B DRAWING PREPARED TO C All drawings are confidential and copyright ALL DIMENSIONS IN mm DO NOT SCALE disclosed without express pri...

Page 22: ... HOSE TO LENGTH CLEANLY AND 5 SQUARE ALL HYDRAULIC HOSE FITTINGS ARE TO BE SCREWED IN WITH FULL ROTATION TO 6 ENSURE ROBUST SEAL BETWEEN HOSE AND FITTING FIVE HOSES IN TOTAL IN ASSEMBLY TWO LONG HOSES FROM POWER UNIT TO DRIVE 7 UNITS TWO 660MM HOSES CONNECTED ONTO EACH DRIVE UNIT SINGLE HOSE LINKING THE TWO DRIVE UNITS ELEVATION VIEW SCALE 1 20 PLAN VIEW SCALE 1 20 NOTES WHERE LONG HOSE IS PUSHED ...

Page 23: ...APPENDIX 2 FIXED BEAM TRAILER ASSEMBLY DRAWINGS QF T06 Rev 3 2017 02 28 ...

Page 24: ...WEIGHT PS B 1 30 A3 ABL2500 GA 001 SHEET SCALE CHECKED BY N A D SC APPROVED BY 9 12 2016 ABL2500 PS Address Balex Marine Limited PO Box 14367 Tauranga 3143 New Zealand Phone 64 21 466 536 Website paul balexmarine com REV DESCRIPTION NAME DATE A ISSUED FOR PRODUCTION SC 12 09 2016 B UPDATED FOR CUSTOMER DOCUMENTATION EE 15 12 2016 POWER UNIT ARRANGEMENT ABL GA 201 NOTES ILLUSTRATIONS ARE INDICATIVE...

Page 25: ...ET UP OF BOAT ON TRAILER THE BOAT SHALL BE TRANSMITTING LOAD EQUALLY BETWEEN THE DRIVE UNITS AND THE 2 ROLLERS THE INSTALLER SHALL CONFIRM THIS BY ENSURING THAT IT IS NOT POSSIBLE TO JOGGLE THE DRIVE UNITS WHILE ROTATING THE REAR ROLLERS DRIVE UNIT BRACKETS REAR ROLLERS FOR ILLUSTRATIVE PURPOSES ACCREDITATION PACK DETAILS THE CORRECT BRACKETS ROLLERS TO USE 3 ISOMETRIC VIEW CLIENT DWG No DRAWN BY ...

Page 26: ...lexmarine com ISOMETRIC VIEW ISOMETRIC VIEW ISOMETRIC VIEW RIGHT VIEW RECOMMENDED ASSEMBLY POSITION WINCH POST MOUNTED TOP ALTERNATE ASSEMBLY POSITION WINCH POST MOUNTED BOTTOM ALTERNATE ASSEMBLY POSITION WINCH POST MOUNTED TOP BOTTOM RIGHT VIEW RIGHT VIEW LEFT VIEW LEFT VIEW LEFT VIEW REV DESCRIPTION NAME DATE A ISSUED FOR DOCUMENTATION SC 13 09 2016 B ISSUED FOR CUSTOMER MANUALS EE 15 12 2016 NO...

Page 27: ...Marine Limited PO Box 14367 Tauranga 3143 New Zealand Phone 64 21 466 536 Website paul balexmarine com REV DESCRIPTION NAME DATE A ISSUED FOR DOCUMENTATION SC 13 09 2016 B ISSUED FOR CUSTOMER MANUALS EE 15 12 2016 ALTERNATE ASSEMBLY POSITION DRAWBAR BRACKET MOUNTED RIGHT VIEW LEFT VIEW LEFT VIEW RIGHT VIEW ISOMETRIC VIEW ISOMETRIC VIEW ALTERNATE ASSEMBLY POSITION DRAWBAR POST MOUNTED STRAIGHT NOTE...

Page 28: ...TTERY TERMINALS REMOVE THE FUSE ON THE POSITIVE CABLE CONFIRM THE POLARITY THEN ATTACH THE NEGATIVE CABLE THEN THE THE POSITIVE 3 PS CHECKED BY ABL2500 GA 201 1 10 PS APPROVED BY BALEX MARINE DWG No DRAWN BY SHEET DESCRIPTION PROJECT DRAWN MOUNTING ARRANGEMENT 5 3 2 4 B DRAWING PREPARED TO C All drawings are confidential and copyright ALL DIMENSIONS IN mm DO NOT SCALE disclosed without express pri...

Page 29: ... HOSE TO LENGTH CLEANLY AND 5 SQUARE ALL HYDRAULIC HOSE FITTINGS ARE TO BE SCREWED IN WITH FULL ROTATION TO 6 ENSURE ROBUST SEAL BETWEEN HOSE AND FITTING FIVE HOSES IN TOTAL IN ASSEMBLY TWO LONG HOSES FROM POWER UNIT TO DRIVE 7 UNITS TWO 660MM HOSES CONNECTED ONTO EACH DRIVE UNIT SINGLE HOSE LINKING THE TWO DRIVE UNITS ELEVATION VIEW SCALE 1 20 PLAN VIEW SCALE 1 20 NOTES WHERE LONG HOSE IS PUSHED ...

Page 30: ...APPENDIX 3 DROP IN BEAM INSTALLATION ASSEMBLY DRAWINGS QF T06 Rev 3 2017 02 28 ...

Page 31: ...01 SHEET SCALE CHECKED BY N A D SC APPROVED BY 9 12 2016 ABL2500 PS Address Balex Marine Limited PO Box 14367 Tauranga 3143 New Zealand Phone 64 21 466 536 Website paul balexmarine com REV DESCRIPTION NAME DATE A ISSUED FOR PRODUCTION SC 12 09 2016 B ISSUED FOR CUSTOMER DOCUMENTATION EE 15 12 2016 NOTES ILLUSTRATIONS ARE INDICATIVE ONLY THE INSTALLATION OF THE BALEX ABL 2500 1 DEPENDS ON YOUR SPEC...

Page 32: ...R CROSS BEAM DETAIL A DRIVE UNIT BRACKET SCALE 1 5 DRIVE UNIT BRACKET BOLTED DRIVE UNIT REMOVED FROM VIEW FOR CLARITY B CLIENT DWG No DRAWN BY SHEET DESCRIPTION PROJECT DRAWN GENERAL ARRANGEMENT 5 3 2 4 B C 1 F A 6 E DRAWING PREPARED TO Copyright All drawings are confidential and copyright DO NOT SCALE ALL DIMENSIONS IN mm holder disclosed without express prior consent of the copyright whole of th...

Page 33: ...lexmarine com ISOMETRIC VIEW ISOMETRIC VIEW ISOMETRIC VIEW RIGHT VIEW RECOMMENDED ASSEMBLY POSITION WINCH POST MOUNTED TOP ALTERNATE ASSEMBLY POSITION WINCH POST MOUNTED BOTTOM ALTERNATE ASSEMBLY POSITION WINCH POST MOUNTED TOP BOTTOM RIGHT VIEW RIGHT VIEW LEFT VIEW LEFT VIEW LEFT VIEW REV DESCRIPTION NAME DATE A ISSUED FOR DOCUMENTATION SC 13 09 2016 B ISSUED FOR CUSTOMER MANUALS EE 15 12 2016 NO...

Page 34: ...Marine Limited PO Box 14367 Tauranga 3143 New Zealand Phone 64 21 466 536 Website paul balexmarine com REV DESCRIPTION NAME DATE A ISSUED FOR DOCUMENTATION SC 13 09 2016 B ISSUED FOR CUSTOMER MANUALS EE 15 12 2016 ALTERNATE ASSEMBLY POSITION DRAWBAR BRACKET MOUNTED RIGHT VIEW LEFT VIEW LEFT VIEW RIGHT VIEW ISOMETRIC VIEW ISOMETRIC VIEW ALTERNATE ASSEMBLY POSITION DRAWBAR POST MOUNTED STRAIGHT NOTE...

Page 35: ...TTERY TERMINALS REMOVE THE FUSE ON THE POSITIVE CABLE CONFIRM THE POLARITY THEN ATTACH THE NEGATIVE CABLE THEN THE THE POSITIVE 3 PS CHECKED BY ABL2500 GA 201 1 10 PS APPROVED BY BALEX MARINE DWG No DRAWN BY SHEET DESCRIPTION PROJECT DRAWN MOUNTING ARRANGEMENT 5 3 2 4 B DRAWING PREPARED TO C All drawings are confidential and copyright ALL DIMENSIONS IN mm DO NOT SCALE disclosed without express pri...

Page 36: ... HOSE TO LENGTH CLEANLY AND 5 SQUARE ALL HYDRAULIC HOSE FITTINGS ARE TO BE SCREWED IN WITH FULL ROTATION TO 6 ENSURE ROBUST SEAL BETWEEN HOSE AND FITTING FIVE HOSES IN TOTAL IN ASSEMBLY TWO LONG HOSES FROM POWER UNIT TO DRIVE 7 UNITS TWO 660MM HOSES CONNECTED ONTO EACH DRIVE UNIT SINGLE HOSE LINKING THE TWO DRIVE UNITS ELEVATION VIEW SCALE 1 20 PLAN VIEW SCALE 1 20 NOTES WHERE LONG HOSE IS PUSHED ...

Page 37: ...APPENDIX 4 WARRANTY FORM QF T06 Rev 3 2017 02 28 ...

Page 38: ...t because of repair examination demonstration or rental return 7 The warranty ownership is transferable provided the end user has a copy of the original purchaser s invoice 8 Determination of the suitability of the product and the materials for the use contemplated by the buyer is the sole responsibility of the buyer and BALEX shall have no responsibility in connection with such suitability 9 BALE...

Page 39: ...ress 1 Address 2 Address 2 Postal ZIP Postal ZIP City City Country Country Phone Phone Email Email Serial Numbers Installation Power Unit Boat Brand Drive Unit 1 Boat Model Drive Unit 2 Trailer Brand Date of Purchase Trailer Model Installation New Retro fit Please email the completed Warranty Registration Form to service balexmarine com or submit the form on www balexmarine com warranty Balex Mari...

Page 40: ...APPENDIX 5 PROGRAMMING THE REMOTE CONTROL QF T06 Rev 3 2017 02 28 ...

Page 41: ... once on the control panel the left blue LED will remain on Press the LAUNCH button on the remote control the left LED will go out then both LEDs will be flashing slowlyagain 4 Press the RETRIEVE button once the right blue LED will remain on Press the RETRIEVE button on the remote control the right LED will go out then both LEDs will be flashing slowly again 5 Repeat steps 3 and 4 again for the ne...

Page 42: ...APPENDIX 6 INSTALLING THE VEHICLE POWER SUPPLY SYSTEM QF T06 Rev 3 2017 02 28 ...

Page 43: ...n plug mounting bracket not included 3 Positive Negative Cable Run the Positive Cable to the battery avoiding sharp edges and hot exhaust components secure firmly Do not attach this lead to other smaller leads or hoses Find a suitable 12mm bolt close to the tow ball and bolt the short Negative Cable to the bolt Ensure it is grounded properly 4 Circuit Breaker Mount 200A Circuit Breaker close to Ba...

Page 44: ...APPENDIX 7 LOSS OF TRACTION QF T06 Rev 3 2017 02 28 ...

Page 45: ...Typically the boat bow will stop short by 1m 3 0 Solution Where loss of traction has occurred 2 solutions are available 1 ABL assisted manual retrieve Attach the winch hook to the bow apply the ratchet manually winch the boat while simultaneously pressing the ABL remote control and the boat will be retrieved with little to no effort Apply the safety chain before driving up the ramp 2 Relocate vehi...

Page 46: ...APPENDIX 8 DRIVE BELT REPLACEMENT QF T06 Rev 3 2017 02 28 ...

Page 47: ...100114 The following tools are required to perform this task Allan key set Torque wrench Lock tite Thread lock It is recommended that the Drive Units are NOT removed from the Trailer during Drive Belt replacement 1 Identify three screws holding bump guard in position Non motor side 2 Remove screws and bump guard Non motor side 3 Identify two screws holding bump guard in position Motor side ...

Page 48: ...017 03 01 docx 2 4 Remove screws and second bump guard Motor side 5 Loosen the Belt tensioner screws by approximately 5mm each but do NOT remove fully 6 Loosen four screws but do not remove 7 Remove the four corresponding screws from the other side ...

Page 49: ...he drive unit frame 9 Remove the chassis from the unit and remove drive belt 10 Install the new drive belt into position and lower the drive unit over the chassis Be careful that chassis pulleys and axles maintain their correct position 11 Install four screws starting with the two outside screws Only screw 50 of their full depth ...

Page 50: ...hten all screws on previous side 13 Using a torque gauge tighten the eight screws through the chassis frame Tighten to 12Nm 14 Apply Loctite thread lock to screws then attach bump guard to unit Do NOT over tighten screws as this may crack plastic bump guards 15 Apply Loctite thread lock to screws and attach second bump guard ...

Page 51: ...2017 03 01 QF T15 BML Drive Belt Replacement 2017 03 01 docx 5 16 Re tighten the Belt tensioner screws until fully tight 17 Check that Nip guard plate is set 3 to 5mm off face of belt ...

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