Balex ABL2500 Owner's Manual

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Owner's manual

ABL2500®

Please read the owner's manual carefully and make sure you understand the instructions before using the unit.

Table of Contents

Summary of Contents for Balex 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: Table Of Contents
CONTENTS 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 ........................
Page 3: Introduction
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 the second-hand value of the ABL2500®...
Page 4: General Safety Precautions
 Please read this manual carefully. energy that can be released in  Check that the ABL2500® is correctly large amounts. This is why you installed. See instructions under the should always be conscious to not short the battery terminals.
Page 5 Isolator Switch:  The Power Unit has a main isolator switch and all power is removed from the ABL2500® when the switch is turned off. Momentary Buttons:  The Power Unit and the Remote Controls have momentary buttons so...
Page 6: Installation
Power Unit – Battery Assembly (x1) Mounting Bracket and Strap – Accreditation Pack Battery (x1) Prior to the installation of the ABL2500® system Battery (x1) the installer shall ensure they have the Remote Controls (x2) Accreditation Pack that supports the trailer and...
Page 7: Installation Stages
4. Hydraulic Hose Installation 5. Testing 6. Boat Loading and Final Adjustment Further it should be noted that there are typically three styles of trailer the ABL2500® system can fit Figure 3 – Drop-In Beam Trailer Type. following installation steps compatible with any trailer type.
Page 8 Identify the adjuster bolt (M10 x 35), VIII. You are now ready to start fitting the apply Grease and thread it into the hole ABL2500® to the trailer. underneath the Drive Unit (1) belt about 10mm. Stage 2 - Drive Unit Installation VIII.
Page 9 Install the Battery (11) into the Power determine this configuration. Unit – Battery Assembly (9).  Optional. If desired, the ABL2500® can be installed without the Battery Attach the Mounting Bracket (8) to the (11) and instead can be powered...
Page 10 INSTALLATION  Stage 4 - Hydraulic Hose Installation If the fittings supplied, are Before commencing this stage of installation, crimp style this step requires a check the types of fittings supplied in the different approach. The installer needs to get crimped Hydraulic Hose Kit (13): Crimp or Screw fittings.
Page 11  Please refer to the Use the Launch button on the Power Unit Accreditation Pack to – Pump (7) and operate the ABL2500® for determine if there are any 20 seconds ensuring the Drive Unit belts other specific modifications to are rotating in the correct direction.
Page 12: Operation
Drive Units (1,2) and the planing strakes of the boat. If there is, contact Balex® Marine to discuss support. Once the full boat load is on the trailer...
Page 13: Pre-Launch Checks
Optional. Connect your Solar Power grip the hull of the boat. Charging Kit (15) into the plug fitting Hint: The ABL2500® only has one speed on the side of the Power Unit – and the first time you use it this may Pump (7) to charge the battery.
Page 14: Maintenance
MAINTENANCE A full inspection of the ABL2500® should be Test 12V Marine Hybrid Battery to ensure completed annually by your Marine Dealer. optimum performance. Drive Unit Maintenance Hydraulic Hose Maintenance Ensure the bolts holding the Drive Unit Check that all hoses are secured.
Page 15: Technical Data
TECHNICAL DATA – ABL2500® Maximum Boat Weight 2500kg or 5500lb Fuse Specifications Battery Fuse 300 Amp Type: ANL Charging Port Fuse 20 Amp Type: Standard Blade Vehicle Kit Circuit Breaker 200 Amp (Continuous) Re-settable Battery Specifications Type Dual Purpose Marine (Start and Deep Cycle)
Page 16: Appendix
APPENDIX 1 – CUTAWAY TRAILER ASSEMBLY DRAWINGS QF-T06-Rev 3 2017-02-28...
Page 17 POWER UNIT ARRANGEMENT - ABL-GA-201 DRIVE UNIT ARRANGMENT - ABL-GA-101 NOTES: ILLUSTRATIONS ARE INDICATIVE ONLY. THE INSTALLATION OF THE BALEX ABL 2500 DEPENDS ON YOUR SPECIFIC BOAT AND TRAILER CONFIGURATION. DRIVE UNIT ARRANGEMENT CAN BE FOUND ON DRAWING ABL-GA-101. POWER UNIT ARRANGEMENT CAN BE FOUND ON DRAWING ABL-GA-201.
Page 18 Copyright: All drawings are confidential and copyright BALEX MARINE ABL2500 ABL2500-GA-101 Balex Marine and/or their respective clients. No part or whole of this drawing may be reproduced, used or disclosed without express prior consent of the copyright DRAWN DRAWN BY...
Page 19 Copyright: All drawings are confidential and copyright BALEX MARINE ABL2500 ABL2500-GA-201 Balex Marine and/or their respective clients. No part or whole of this drawing may be reproduced, used or disclosed without express prior consent of the copyright DRAWN DRAWN BY...
Page 20 Copyright: All drawings are confidential and copyright BALEX MARINE ABL2500 ABL2500-GA-201 Balex Marine and/or their respective clients. No part or whole of this drawing may be reproduced, used or disclosed without express prior consent of the copyright DRAWN DRAWN BY...
Page 21 Copyright: All drawings are confidential and copyright BALEX MARINE ABL2500 ABL2500-GA-201 Balex Marine and/or their respective clients. No part or whole of this drawing may be reproduced, used or disclosed without express prior consent of the copyright DRAWN DRAWN BY...
Page 22 Copyright: All drawings are confidential and copyright BALEX MARINE ABL2500 ABL2500-GA-401 Balex Marine and/or their respective clients. No part or whole of this drawing may be reproduced, used or disclosed without express prior consent of the copyright DRAWN DRAWN BY...
Page 23 APPENDIX 2 – FIXED BEAM TRAILER ASSEMBLY DRAWINGS QF-T06-Rev 3 2017-02-28...
Page 24: Drive Unit Arrangment - Abl-Ga
POWER UNIT ARRANGEMENT - ABL-GA-201 DRIVE UNIT ARRANGMENT - ABL-GA-101 NOTES: ILLUSTRATIONS ARE INDICATIVE ONLY. THE INSTALLATION OF THE BALEX ABL 2500 DEPENDS ON YOUR SPECIFIC BOAT AND TRAILER CONFIGURATION. DRIVE UNIT ARRANGEMENT CAN BE FOUND ON DRAWING ABL-GA-101. POWER UNIT ARRANGEMENT CAN BE FOUND ON DRAWING ABL-GA-201.
Page 25 Copyright: All drawings are confidential and copyright BALEX MARINE ABL2500 ABL2500-GA-101 Balex Marine and/or their respective clients. No part or whole of this drawing may be reproduced, used or disclosed without express prior consent of the copyright DRAWN DRAWN BY...
Page 26 Copyright: All drawings are confidential and copyright BALEX MARINE ABL2500 ABL2500-GA-201 Balex Marine and/or their respective clients. No part or whole of this drawing may be reproduced, used or disclosed without express prior consent of the copyright DRAWN DRAWN BY...
Page 27 Copyright: All drawings are confidential and copyright BALEX MARINE ABL2500 ABL2500-GA-201 Balex Marine and/or their respective clients. No part or whole of this drawing may be reproduced, used or disclosed without express prior consent of the copyright DRAWN DRAWN BY...
Page 28 Copyright: All drawings are confidential and copyright BALEX MARINE ABL2500 ABL2500-GA-201 Balex Marine and/or their respective clients. No part or whole of this drawing may be reproduced, used or disclosed without express prior consent of the copyright DRAWN DRAWN BY...
Page 29 Copyright: All drawings are confidential and copyright BALEX MARINE ABL2500 ABL2500-GA-401 Balex Marine and/or their respective clients. No part or whole of this drawing may be reproduced, used or disclosed without express prior consent of the copyright DRAWN DRAWN BY...
Page 30 APPENDIX 3 – DROP-IN BEAM INSTALLATION ASSEMBLY DRAWINGS QF-T06-Rev 3 2017-02-28...
Page 31: Power Unit Arrangement - Abl-Ga
POWER UNIT ARRANGEMENT - ABL-GA-201 DRIVE UNIT ARRANGMENT - ABL-GA-101 NOTES: ILLUSTRATIONS ARE INDICATIVE ONLY. THE INSTALLATION OF THE BALEX ABL 2500 DEPENDS ON YOUR SPECIFIC BOAT AND TRAILER CONFIGURATION. DRIVE UNIT ARRANGEMENT CAN BE FOUND ON DRAWING ABL-GA-101. POWER UNIT ARRANGEMENT CAN BE FOUND ON DRAWING ABL-GA-201.
Page 32 Copyright: All drawings are confidential and copyright BALEX MARINE ABL2500 ABL2500-GA-101 Balex Marine and/or their respective clients. No part or whole of this drawing may be reproduced, used or disclosed without express prior consent of the copyright DRAWN DRAWN BY...
Page 33 Copyright: All drawings are confidential and copyright BALEX MARINE ABL2500 ABL2500-GA-201 Balex Marine and/or their respective clients. No part or whole of this drawing may be reproduced, used or disclosed without express prior consent of the copyright DRAWN DRAWN BY...
Page 34 Copyright: All drawings are confidential and copyright BALEX MARINE ABL2500 ABL2500-GA-201 Balex Marine and/or their respective clients. No part or whole of this drawing may be reproduced, used or disclosed without express prior consent of the copyright DRAWN DRAWN BY...
Page 35 Copyright: All drawings are confidential and copyright BALEX MARINE ABL2500 ABL2500-GA-201 Balex Marine and/or their respective clients. No part or whole of this drawing may be reproduced, used or disclosed without express prior consent of the copyright DRAWN DRAWN BY...
Page 36 Copyright: All drawings are confidential and copyright BALEX MARINE ABL2500 ABL2500-GA-401 Balex Marine and/or their respective clients. No part or whole of this drawing may be reproduced, used or disclosed without express prior consent of the copyright DRAWN DRAWN BY...
Page 37 APPENDIX 4 – WARRANTY FORM QF-T06-Rev 3 2017-02-28...
Page 38 3. All repairs will be completed at a Balex nominated service center and all freight costs will be met by the purchaser. 4. All defective parts claimed are to be kept for further inspection. Failure to return those parts upon request will automatically void the warranty claim.
Page 39 Trailer Model □ □ Installation: Retro-fit Please email the completed Warranty Registration Form to service@balexmarine.com or submit the form on www.balexmarine.com/warranty Balex Marine Limited Unit 2/60 Aviation Ave Mount Maunganui Tauranga 3116 PO Box 14367 Tauranga 3143 New Zealand www.balexmarine.com...
Page 40 APPENDIX 5 – PROGRAMMING THE REMOTE CONTROL QF-T06-Rev 3 2017-02-28...
Page 41 Remote Control Setup Apply power through the ABL Power Key. The battery LEDs will cycle through then settle on the measured battery voltage. Press and hold the BATTERY LEVEL switch on for 5 seconds, both blue LEDs will flash slowly. Press the LAUNCH button once on the control panel, the left, blue LED will remain on.
Page 42 APPENDIX 6 – INSTALLING THE VEHICLE POWER SUPPLY SYSTEM QF-T06-Rev 3 2017-02-28...
Page 43 BALEX® ABL2500 VEHICLE CABLE 200A KIT 70mm² (PN: 300112) Must be fitted by an authorized auto electrician or approved motor vehicle dealer 1. Vehicle Cable 200A KIT includes: 1 x 175 Amp Anderson Type Plug 1 x Positive Cable (Red) 7.0m x 70mm²...
Page 44 APPENDIX 7 – LOSS OF TRACTION QF-T06-Rev 3 2017-02-28...
Page 45 Loss of Traction The ABL2500 is designed for fibreglass & alloy boats up to 2,500 kg (5,500 Lbs), up to 7.2m (24’-0”) length, and to operate on boat ramps up to 9° degrees (1:6.3 gradient or 16 % slope). If the ABL2500 has been installed or used on boats exceeding any of these parameters, then this could result in loss of traction from time to time.
Page 46 APPENDIX 8 – DRIVE BELT REPLACEMENT QF-T06-Rev 3 2017-02-28...
Page 47 Drive Belt Replacement Procedure The following procedure highlights the steps required to replace a worn or damaged drive belt - 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.
Page 48 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. 2017-03-01 QF-T15 - BML - Drive Belt Replacement - 2017-03-01.docx...
Page 49 8. Remove the remaining four screws. The chassis will drop out of the 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.
Page 50 12. Fully install four screws on other side, and then fully tighten 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.
Page 51 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. 2017-03-01 QF-T15 - BML - Drive Belt Replacement - 2017-03-01.docx...