Balex ABL2500 User manual

Owner’s manual
ABL2500®
Please read the owner’s manual carefully and make sure you understand the instructions before using the unit.

CONTENTS
2 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

INTRODUCTION
3 QF-T06-Rev 3 2017-02-28
Dear customer,
Congratulations on your choice to buy the Balex® Marine - Automatic Boat Loader (ABL2500®).
Your ABL2500® will make launching and retrieving very easy and much safer. In fact, you should be
able to launch and retrieve your boat in 30 seconds!
You will still need to monitor your boat as it is launched and retrieved from and to your trailer as some
alignment still depends on the trailer set-up. However, you should never need to climb down the
trailer to clip or unclip the boat on the winch rope and in most cases, you should never need to get
your feet wet.
You will also appreciate the speed at which you can gain control of your 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 the second-hand value of the ABL2500® can be extended. If you ever lend or sell the
ABL2500®, make sure that the borrower or buyer gets the Owner’s manual, so they will know how to
operate and maintain it.
Balex Marine has a policy of continuous product development and therefore reserves the right to
modify the design and appearance of products without prior notice.
Thank you for using our Balex Marine product.
For customer assistance, contact us at our website:
www.balexmarine.com

GENERAL SAFETY PRECAUTIONS
4 QF-T06-Rev 3 2017-02-28
Before using your ABL2500®
Please read this manual carefully.
Check that the ABL2500® is correctly
installed. See instructions under the
heading Installation.
The ABL2500® is designed to make
boating safer however it is also a
powerful machine and therefore there
are a few more things you should be
familiar with.
Replaceable Fuses:
For continued protection
against the risk of fire only
replace fuses with the same
type and rating.
Pinch Points:
The ABL2500® Drive Unit belt
has a surface texture designed
to give traction, this also makes
it difficult to eliminate a pinch
point injury.
You must keep all items clear of
the belts when operating.
Examples: Hands, Clothes, Hair,
Ropes etc.
Battery Acid:
The Battery is full of sulphuric
acid that will burn skin and
most other items.
If you see liquid in the bottom
of the battery box do not
assume it is water. If burnt with
acid, flush continuously with
lukewarm water for 30
minutes. Seek medical advice!
Explosion:
The Battery may give off, and
contains gases that could
explode.
Do not tamper 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 system is under
pressure when operating. Keep
clear of hoses and connections
when operating.
Do not operate the power unit
with the cover removed.
Inspect the hoses and fittings
periodically for damage or oil
loss, do not operate the system
if a hose or fitting is damaged,
replace damaged parts.
Caution:
The boat can move
unexpectedly, depending on
how many remotes are
programed and who is using
them.
The ABL2500® can also be
activated from the control
panel.
When storing your remotes
make sure that items cannot
move and push the buttons.
Apart from the ABL2500®
moving unexpectedly, this will
also flatten the batteries in the
remote.
Crush Hazard:
The ABL2500® Drive Units can
generate forces exceeding
500kg.
Maintain a safe distance of
1.5m from the trailer and or
the boat during launch or
retrieval.
Make sure all bystanders and
children are kept at a safe
distance from the trailer.

GENERAL SAFETY PRECAUTIONS
5 QF-T06-Rev 3 2017-02-28
Caution:
Never drive up the ramp
without securing the boat. With
large acceleration forces, and
or vibration, the boat could
slide backward causing
damage.
ABL2500® Safety Features
Hydraulic Relief Valve:
A relief valve is incorporated into the
Power Unit –Pump.
The relief valve limits the pressure in
the system to prevent internal system
damage and motor overloading.
The relief 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 switch is
turned off.
Momentary Buttons:
The Power Unit and the Remote
Controls have momentary buttons so
that the system will only run when
your finger is on the button, the
moment your finger is removed the
system will stop.

INSTALLATION
6 QF-T06-Rev 3 2017-02-28
Pre-Installation
Accreditation Pack
Prior to the installation of the ABL2500® system
the installer shall ensure they have the
Accreditation Pack that supports the trailer and
boat combination they are putting the ABL2500®
onto. The Accreditation Pack is paramount to
ensuring a successful installation of your
ABL2500®.
If no Accreditation Pack is available it may still be
possible to install the ABL2500® system, however
a trailer and boat survey form may need to be
completed beforehand. Contact Balex® Marine to
discuss support in this situation.
Part and Tools
The installer shall check that they have all the
parts and tools necessary for the installation. This
is detailed in the Accreditation Pack.
Tools
1
Spanner Set (12-30mm)
2
Deep Drive Socket Set (12-30mm)
3
Torque Wrench (10Nm-100Nm)
4
Allen Key Set (2mm –10mm)
5
Side Cutters
6
Small Paintbrush
7
Insulation Tape
8
Knife
9
2Ltr ABL2500® Oil1
10
Corrosion X® HD
11
Tyres x 3
12
Wooden Blocks x 4 (200mm High)
13
Tape Measure
Notes
1. See the section headed Technical Data for a list of
recommended oils.
Parts
1
Drive Unit –Starboard (x1)
2
Drive Unit –Port (x1)
3
Drive Unit Brackets1(x2)
4
Rear Roller Kit2(Optional)
5
Power Unit Drawbar Mounting
Bracket3 (Optional)
6
Power Unit Mounting Post4
(Optional)
7
Power Unit –Pump Assembly (x1)
8
Mounting Bracket and Strap –Pump
(x1)
9
Power Unit –Battery Assembly (x1)
10
Mounting Bracket and Strap –
Battery (x1)
11
Battery (x1)
12
Remote Controls (x2)
13
Hydraulic Hose Kit5Kit (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/boat combination and widths to fit to the
different cross- beam sizes. The Accreditation Pack details
which brackets shall be used.
2. The Rear Roller Kit, including brackets and bolts, are available
in different widths and configurations to suit the trailer/boat
combination. The Accreditation Pack details which Rear Roller
Kit to use.
3. A Power Unit Drawbar Mounting Bracket may be necessary if
mounting the Power unit to the drawbar. The Accreditation
Pack details if this bracket should be used.
4. An additional Power Unit Mounting Post may be necessary if
there is no room to mount the Power Unit to the trailers winch
post. The Accreditation Pack details if this additional mounting
post should be used.
5. The Hydraulic Hose Kits include five hoses and associated
fittings and cable ties. The Accreditation Pack details what
length these will be shortened to where appropriate.
6. When the towing vehicle is fitted with a Power Supply System
the Battery Assembly is not required.
Installation Time
We recommend that installation is completed in
the above stated order, and four hours should be
allowed for the installation and preferably two
people are available.

INSTALLATION
7 QF-T06-Rev 3 2017-02-28
Installation Stages
Installation of the ABL2500® includes six stages:
1. Boat Removal
2. Drive Unit Installation
3. Power Unit Installation
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
to:
Figure 1 –Cutaway Trailer Type.
Figure 2 –Fixed Beam Trailer Type.
Figure 3 –Drop-In Beam Trailer Type.
The following six installation steps are
compatible with any trailer type. However
additional trailer specific information can be
found in the assembly drawings found in
Appendix 1 (Cutaway Trailer), Appendix 2 (Fixed
Beam Trailer) and Appendix 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
simultaneously pushing the boat
backwards onto the tyre. Hint: You may
need to re-position the tyre during this
step.
IV. Drive the trailer forward then position
two tyres under each side of the boat
about 1-2m from the transom of the
boat. Hint: During this step you want the
boat to stay in position while the trailer is
driven forward.
V. Drive the trailer further forward so the
weight of the boat is on the rear rollers
only then position wooden blocks
centrally under the boat and forward of

INSTALLATION
8 QF-T06-Rev 3 2017-02-28
the tyres. Hint: The higher the blocks the
higher the boat which will allow it to load
easier back onto the trailer later.
VI. Drive the trailer forward slowly so the
weight is sitting only marginally on the
rear rollers then put some wooden
blocks under the side chines to restrict
any sideways movement of the boat.
VII. Remove the winch rope and drive
forward so the trailer is fully clear of the
boat.
VIII. You are now ready to start fitting the
ABL2500® to the trailer.
Stage 2 - Drive Unit Installation
I. Make sure all the items are on the boat
trailer before you start, i.e. spare wheels,
rollers, jockey wheel, winch handle etc.
II. Identify the rear cross member which the
drive units will be fitted to and mark the
centre point. Hint: Measure this point
from the outside main chassis in towards
the centre of the cross member using a
tape measure.
III. Now take the Drive Unit Brackets (3),
apply Grease on the underside of these
brackets and position onto the cross
member, do not bolt down just yet. Hint:
The angle of the brackets should be
facing inward.
IV. Measure the centre to centre distance
using the centre of the holes on top of
the brackets. The centre to centre
distance should 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 finger
tight. Hint: The bolt head shall be on the
outward side bracket, while the washer
on the threaded end of the bolt.
VII. Identify the adjuster bolt (M10 x 35),
apply Grease and thread it into the hole
underneath the Drive Unit (1) belt about
10mm.
VIII. The M12 bolts can now be tightened
between the Drive Unit Bracket (3) and
the Drive Unit (1).
IX. Repeat for the second Drive Unit –Port
(2).
X. Check the Accreditation Pack and
determine if the Rear Rollers and
Brackets need to be removed and
replaced. Fit the Rear Roller Kit (4) if
applicable. Only finger tight at this point.

Please refer to the
Accreditation Pack to
determine if the Rear Rollers
are to be replaced.
XI. The centre to centre distance between
the roller brackets should match that
recommended in the Accreditation Pack.
Hint: Measure the distance by ensuring
the rollers are horizontal and from the
centre point of each roller.

Please refer to the
Accreditation Pack to
determine this distance.
XII. Review the Accreditation Pack for any
additional modifications.

INSTALLATION
9 QF-T06-Rev 3 2017-02-28

Please refer to the
Accreditation Pack to
determine if there are any
other specific modifications to
your boat and trailer
combination.
XIII. You are now ready to move to the front
of the trailer to install the Power Unit.
Stage 3 - Power Unit Installation
I. Check the Accreditation Pack to
determine the configuration of the
Power Unit Assembly (7,9).

Please refer to the
Accreditation Pack to
determine this configuration.
II. Attach the Mounting Bracket (8) to the
starboard side of the winch post and the
Mounting Bracket (10) to the Port side of
the winch post. The height underneath
these brackets to the drawbar of the
trailer should match the height identified
in the Accreditation Pack. Hint: Ensure
the Mounting Brackets (8,10) are
horizontal to the drawbar.
Optional. If the Accreditation Pack
identifies an additional Drawbar
Mounting Bracket (5), this should be
fixed to the drawbar of the trailer.
The Mounting Brackets (8,10) would
be fixed to this new bracket and not
the winch post.
Optional. If the Accreditation Pack
identifies an additional Mounting
Post (6), this should be fixed to the
drawbar of the trailer. The Mounting
Brackets (8,10) would be fixed to
this new post 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 nyloc bolts provided, fix them
together. Hint: Check there is no
interference with the winch handle or
jockey wheel.
V. Install the Battery (11) into the Power
Unit –Battery Assembly (9).
Optional. If desired, the ABL2500®
can be installed without the Battery
(11) and instead can be powered
using the Vehicle Power Supply
System (18). See Appendix 6 for
details on installing this system.
VI. Identify the power cables (positive and
negative) inside the Power Unit –Pump
(7) and the marked polarity.
VII. Fit the power cables to the Battery (11)
accordingly, and tighten the associated
nuts.
VIII. Using the cable ties provided, tidy up the
power cables inside the Power Unit –
Pump Assembly (7) to restrict movement
of the cables.
XIV. Where the power cables exit the Power
Unit –Pump Assembly (7), tie down into
the holes using a cable tie.
XV. Review the Accreditation Pack for any
additional modifications.

Please refer to the
Accreditation Pack to
determine if there are any
other specific modifications to
your boat and trailer
combination.

INSTALLATION
10 QF-T06-Rev 3 2017-02-28
Stage 4 - Hydraulic Hose Installation
Before commencing this stage of installation,
check the types of fittings supplied in the
Hydraulic Hose Kit (13): Crimp or Screw fittings. If
they are Screw fittings continue to follow the
steps below. If they are Crimp fittings the installer
will need to crimp the fittings onto the hose. This
is relevant below at Step VI and Step IX.
I. Open the Hydraulic Hose Kit (13), find the
two long hoses which will have fittings on
one end only.
II. Fit the two long hoses to the Drive Units
(1,2). In the positions shown below. Hint:
They should be fitted to the connections
closest to the middle of the trailer.
Figure 5 –Long Hose Connection Points.
III. Using insulation tape, cover up the
openings on the other ends of the hoses
and run the two hoses from the Drive
Units (1,2) to the Power Unit –Pump (7)
via the openings in the chassis on each
side of the trailer.
Optional. The hoses can be run down the
length of the chassis on each side of the
trailer and cable tied in position.
IV. Make sure that the hoses do not touch
the Drive Units (1,2) in any of their
normal positions by testing the extremes
of the Drive Units (1,2) motors
movement.
V. Determine the exact length of 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 step requires a
different approach. The
installer needs to get crimped
to “13.7mm+/-0.125”.
VII. In the Hydraulic Hose Kit (13), are two
660mm hoses. Attach the first 660mm
long hose on Drive Unit (1) and the
second hose on Drive Unit (2). Hint: The
90Deg fitting attaches to the Drive Unit
Motor.
Figure 6 - Drive Hose Layout
VIII. In the Hydraulic Hose Kit (13), take the
final hose with straight fitting on one
end. Check the Accreditation Pack for the
length of the final link hose that connect
the two Drive Units (1,2) together.
IX. Cut the final length of hose to the correct
length and screw in the final fitting,
before attaching to the Drive Units (1,2).
If the fittings supplied, are
crimp style this step requires a
different approach. The
installer needs to get crimped
to “13.7mm+/-0.125”.
X. Make sure that the hoses do not touch
the Drive Units (1,2) in any of their
normal positions by testing the extremes
of the Drive Units (1,2) motors
movement. Hint: Use a big radius to allow
the hoses to be well clear of the Drive
Unit belts and Rear Rollers.

INSTALLATION
11 QF-T06-Rev 3 2017-02-28
Figure 7 - Drive Hose Layout
XI. Tidy and secure all the hoses with the
cable ties provided in the Hydraulic Hose
Kit (13) and cut the cable ties short.
XVI. Review the Accreditation Pack for any
additional modifications.

Please refer to the
Accreditation Pack to
determine if there are any
other specific modifications to
your boat and trailer
combination.
Stage 5 - Testing
I. Ensure the hydraulic hose fittings on the
Drive Units (1,2) are fully tightened.
II. Remove the lid from the Power Unit –
Pump Assembly (7) and ensure the hose
fittings are fully tightened.
III. Fill the oil tank in the Power Unit –Pump
(7) to level indicated.
IV. Ensure the bolts holding the Power Unit
–Pump Assembly (7) to the Mounting
Bracket (8) are fully tightened to 19Nm
using the torque wrench.
V. Remove the lid from the Power Unit –
Battery Assembly (9) and ensure the
power cables are fully tightened to the
Battery (11).
VI. Fit the lids onto the Power Unit –Pump
(7) and the Power Unit –Battery (9), then
using the Mounting Bracket Straps fasten
accordingly (8,10).
VII. Ensure the bolts holding the Drive Unit
Brackets (3) to the trailer cross beam are
fully tightened to 35Nm using the torque
wrench.
VIII. Ensure the bolts holding the Drive 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
level indicator will stay on. A green light
on the right side of the panel indicates
the battery is fully charged.
XI. Use the Launch button on the Power Unit
–Pump (7) and operate the ABL2500® for
20 seconds ensuring the Drive Unit belts
are rotating in the correct direction. Hint:
The system is self-bleeding and will take
4-5 seconds to fill the hoses.
XII. Use the Retrieve button on the Power
Unit –Pump (7) and operate the
ABL2500® for 20 seconds ensuring the
Drive Unit belts are rotating in the
correct direction.
XIII. Now test the Remote Controls (12) are
working (one at a time) by pointing the
remote at the Power Unit –Pump (7) and
pressing the Retrieve and Launch buttons
for 5 seconds each and confirm the Drive
Unit belts are rotating. Hint: If the
remotes are not working see Appendix 5
to program the remotes, then repeat this
step.
XIV. Re-check all the hose fittings to ensure
there are no oil leaks either at the Drive
Units (1,2) or the Power Unit –Pump (7).
XV. Open up the Power Unit –Pump (7) and
fill the oil tank to the level indicated.

INSTALLATION
12 QF-T06-Rev 3 2017-02-28
Hint: It will have reduced because of the
oil filling up the system.
XVI. You are now ready to load the boat on to
the trailer.
Stage 6 - Boat Loading and Final Adjustment
I. With the trailer attached to your vehicle,
reverse the trailer within 0.5m of the
boat sitting on the tyres and wooden
blocks as per Stage 1.
II. Unwind the winch rope and attach to the
boat, reverse the trailer further under
the boat, while keeping the tension in the
rope.
III. Remove the wooden blocks from under
the boat, and further wind the rope to
pull the boat onto the trailer.
IV. Continue to wind the rope to pull the
boat up onto the Drive Units (1,2). During
this step and the following ensure there
is no contact between the Drive Units
(1,2) and the planing strakes of the boat.
If there is, contact Balex® Marine to
discuss support.
V. Once the full boat load is 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 roll that is great, you are done and
can fill in the warranty card (Appendix 4)
and move on to the section headed
Operation.
VIII. If there is movement, the Drive Units
(1,2) heights can be adjusted by
loosening off the two M12 bolts on the
Drive Unit Brackets (3) and then rotate
the M10 adjustor bolt to move the Drive
Units (1,2) up or down as needed.
IX. Once the height is set, tighten the two
M12 bolts again, confirm the Drive Units
(1,2) do not joggle freely and the Rear
Rollers (4) do not roll.
X. If the Drive Units (1,2) don’t joggle and
the Rear Rollers (4) do not roll that is
great you are done and can fill in the
warranty card (Appendix 4) and move
onto section headed Operation.

OPERATION
13 QF-T06-Rev 3 2017-02-28
Pre-Launch Checks
I. Before you reverse down the ramp,
remove the safety chain but leave the
winch rope clipped to the boat.
II. The winch rope can be slackened off but
should be left clipped to the boat for
safety.
III. Fit the isolator key into the Power Unit –
Pump Assembly (7), and turn the
ABL2500® on.
IV. Fit your bow rope and we are ready to go.
Launching
Caution:
If the driver is getting out of the
vehicle make sure the
handbrake is on.

I. Reverse the trailer down the ramp and
stop when the Drive Units (1,2) are just
submerged. Hint: Convert the trailer
depth to a point on your trailer which you
can see when reversing. See Appendix 7
for more information around this.
II. Unclip the winch rope and holding onto
your bow rope push the Launch button
on the remote for 2 seconds, then
retrieve back to the winch post.
Hint: This will allow the Drive Units (1,2)
to lift up above the Rear Rollers to better
grip the hull of the boat.
Hint: The ABL2500® only has one speed
and the first time you use it this may
seem a bit fast, but rest assured the
ABL2500® will not go faster.
III. Now hold the Launch button on the
remote fully launch the boat.
IV. Turn the ABL2500® off and lock the
isolator key in your vehicle.
Retrieving
I. Fit the isolator key into the Power Unit –
Pump (7), and turn the ABL2500® on.
II. Reverse the trailer down the ramp and
stop when the Drive Units (1,2) are just
submerged. Hint: Convert the trailer
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 to the trailer press
Retrieve on the remote.
IV. Keep pressing the Retrieve button until
the boat is fully engaged with the trailer’s
vee-block. Hint: If the boat is losing
traction, refer to Appendix 7, for
guidance on minimising any loss of
traction.
V. Clip the winch rope onto the boat and
wind up to take up any final slack.
VI. Remove the isolator key to turn the
ABL2500® off.
VII. Drive the trailer away from the boat
ramp and tie down the boat to the trailer
so it doesn’t bounce around when on the
open road.
Battery Charging
I. Connect your SCHUMACHER® Charging
Kit (14) into a mains power supply.
II. Plug cable from SCHUMACHER®
Charging Kit (14) into the plug fitting on
the side of the Power Unit –Pump (7) to
charge the battery.
Optional. Connect your Solar Power
Charging Kit (15) into the plug fitting
on the side of the Power Unit –
Pump (7) to charge the battery.
Optional. If you already own a
CTEK® Charging Kit, connect into a
mains power supply and using the
CTEK® Adaptor Lead (16) connect to
the Power Unit –Pump (7) plug
fitting to charge the battery.
Optional. If you already own a
POWERTECH® Charging Kit, connect
into a mains power supply and
using the POWERTECH ® Adaptor
Lead (17) connect to the Power Unit
–Pump (7) plug fitting to charge the
battery.

MAINTENANCE
14 QF-T06-Rev 3 2017-02-28
A full inspection of the ABL2500® should be
completed annually by your Marine Dealer.
Drive Unit Maintenance
I. Ensure the bolts holding the Drive Unit
Brackets (3) to the trailer cross beam are
fully tightened to 35Nm using the torque
wrench.
II. Ensure the bolts holding the Drive Unit
Brackets (3) to the Drive Units (1,2) are
fully tightened to 88Nm using the torque
wrench.
III. Ensure the hydraulic hose fittings on the
Drive Units (1,2) are fully tightened and
there are no oil leaks.
IV. Check Drive Units (1,2) belts for UV
degradation, damage, wear and tear.
Replace belts every two years or if there
are signs of damage. See Appendix 8 for
procedure to replace drive belts.
V. Check the Drive Units (1,2) guards for
damage, wear and tear. Replace guards if
they have been damaged.
VI. Thoroughly clean the drive belt with a
moderate soap and rinse off.
Power Unit Maintenance
I. Ensure the bolts holding the Power Unit
–Pump Assembly (7) to the Mounting
Bracket (3) are fully tightened to 19Nm
using the torque wrench.
II. Remove the lid from the Power Unit –
Pump Assembly (7) and ensure the hose
fittings are fully tightened and there are
no oil leaks.
III. Fill the oil tank in the Power Unit –Pump
(7) to level indicated.
IV. Remove the lid from the Power Unit –
Battery Assembly (9) and ensure the
power cables are fully tightened to the
Battery (11).
V. Check all electrical cables, fuses and
terminals are secure and free from
corrosion or damage. If replacing fuses
only do so with same 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
fittings that have been damaged.
III. Remove and inspect all hoses that have
been installed inside trailer chassis and
are hidden from view.
Boat Hull Maintenance
I. Clean Boat Hull to remove any oil or
contaminants that may adversely impact
on traction. Waxes and soaps are
generally hard to remove but Methylated
spirits will remove most contaminants
along with some solid rubbing with a
cotton cloth. For aluminium hulls you can
use a Scotch-Brite® Green type pad if
necessary.
II. Check any penetrations and replace if
damaged.
III. Check aluminium hulls for sharp edges
and remove if found.
Trailer Maintenance
I. Check for grease leakage from any
bearings and joints. Hint: Any grease that
contacts the hull or drive belts could
affect traction and ABL2500®
performance.
Owner Inspections
I. Check the Drive Unit (1,2) belts for
damage or wear and tear. See Appendix
8 for procedure to replace drive belts.
II. Check all hose connections for oil leaks
on a regular basis.
III. Check inside Power Unit Assemblies (7,9)
for any accumulated water and use a
sponge to remove.
IV. Monitor the remote-control batteries
and replace if there are any signs of
deterioration.
V. Ensure the boat hull surface remains
clean and free from oils or contaminants
that may adversely impact on traction
and ABL2500® performance.

TECHNICAL DATA –ABL2500®
15 QF-T06-Rev 3 2017-02-28
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)
Voltage
12v dc
Size
BCI 24 or 27
Amp Hours (20 Hour Rating)
Minimum
Recommended
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 Plantohyd S 32
Total Biohydran TMP 32
Conoco Synterra Hydraulic fluid 32
Oil Quantity
2 Litres
Pressure
20 MPa (nominal working pressure)
Pressure Relief Valve
22 MPa (factory pre-set)

APPENDIX 1 –CUTAWAY TRAILER ASSEMBLY DRAWINGS
QF-T06-Rev 3 2017-02-28

DRIVE UNIT ARRANGMENT - ABL-GA-101
POWER UNIT ARRANGEMENT - ABL-GA-201
CLIENT DWG No.
DRAWN BY
SHEET DESCRIPTION
PROJECT
DRAWN
GENERAL ARRANGEMENT
5
3
2
4
B C
1
FA
6
E
DRAWING PREPARED TO
Copyright: All dr wings re confidenti l nd copyright
DO NOT SCALE
ALL DIMENSIONS IN m m
holder.
disclosed without express pri or consent of the copyrig ht
whole of this dr wing m y be reprodu ced, used or
B lex M rine nd /or their respective client s. No p rt or
NZS/AS 1100.101:1992
TRAILER - CUTAWAY
DESCRIPTION
SIZE
BALEX MARINE
1 / 3
SHEETWEIGHT
PS
B
1:30 A3
ABL2500-GA-001
SHEET SCALECHECKED BY
N/A
D
SC
APPROVED BY
9/12/2016
ABL2500
PS
Address: B lex M rine Limited
PO Box 14367, T ur ng 3143
New Ze l n d
Phone: [phone]
Website: p ul@b lexm rine.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 ONLY. THE INSTALLATION OF THE BALEX ABL 2500 1.
DEPENDS ON YOUR SPECIFIC BOAT AND TRAILER CONFIGURATION.
2. DRIVE UNIT ARRANGEMENT CAN BE FOUND ON DRAWING ABL-GA-101.
3. POWER UNIT ARRANGEMENT CAN BE FOUND ON DRAWING ABL-GA-201.
4. HYDRAULIC ROUTING ARRANGMENT CAN BE FOUND ON DRAWING ABL-GA-401.

REV DESCRIPTION NAME DATE
A ISSUED FOR CUSTOMER DOCUMENTATION EE 19/12/2016
PLAN VIEW
SCALE 1:20
ELEVATION VIEW
SCALE 1:20
NOTES:
BOLT AVAILABLE FOR FINE ADJUSTMENT, SEE DETAIL B. THE BOLT SHOULD BE CLEANED UP OF EXCESS ALVANISIN AND LUBRICATIN BEFORE 1.
FITTIN . THE M12 BOLTS NEED TO BE LOOSE TO ALLOW ADJUSTMENT.
WHEN COMPLETIN FINAL SET UP OF BOAT ON TRAILER. THE BOAT SHALL BE TRANSMITTIN LOAD EQUALLY BETWEEN THE DRIVE UNITS AND THE 2.
ROLLERS. THE INSTALLER SHALL CONFIRM THIS BY ENSURIN THAT IT IS NOT POSSIBLE TO JO LE THE DRIVE UNITS WHILE ROTATIN THE REAR
ROLLERS.
DRIVE UNIT BRACKETS/REAR ROLLERS FOR ILLUSTRATIVE PURPOSES. ACCREDITATION PACK DETAILS THE CORRECT BRACKETS/ROLLERS TO USE.3.
ISOMETRIC VIEW
16/09/2016
ABL2500
A3
D
DW No.
DRAWN BY
SHEET DESCRIPTION
PROJECT
DRAWN
GENERAL ARRANGEMENT
5
3
2
4
B C
1
F
DRAWIN PREPARED TO
A
All drawings are confiden tial and copyright
disclosed without express pri or consent of the copyrig ht
holder.
DO NOT SCALE
ALL DIMENSIONS IN m m
whole of this drawing may be reproduced, used or
6
E
Copyright:
Balex Marine and/or the ir 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
WEI HT
ABL2500- A-101
SHEET SCALECHECKED BY
SC
APPROVED BY
PS
CLIENT
Address: Balex Marine Limited
PO Box 14367, Tauranga 3143
New Zealand
Phone: [phone]
Website: paul@balexm arine.com
DRIVE UNITS REMOVED FROM VIEW
FOR CLARITY
REAR ROLLERS REMOVED FROM VIEW
FOR CLARITY
DRIVE UNITS
CENTRE TO CENTRE
REAR ROLLERS
CENTRE TO CENTRE
DETAIL C - REAR ROLLER BRACKET
SCALE 1:5
REAR ROLLERS, BRACKETS FITTED
TO CROSS BEAM. SPECIFIC TO
TRAILER/BOAT COMBINATION.
DETAIL B - ADJUSTOR BOLT
SCALE 1:2
FINE TUNE THE HEI HT OF THE DRIVE UNIT.
TRAILER CROSS-BEAM
ADJUSTMENT BOLT M10. USED TO
DRIVE UNIT REMOVED FROM
VIEW FOR CLARITY
SCALE 1:5
TO TRAILER CROSS-BEAM.
DETAIL A - DRIVE UNIT BRACKET
DRIVE UNIT BRACKET BOLTED
DRIVE UNIT REMOVED FROM
VIEW FOR CLARITY
B
A
C

CLIENT DWG No.
DRAWN BY
SHEET DESCRIPTION
PROJECT
DRAWN
GENERAL ARRANGEMENT
5
3
2
4
B C
1
FA
6
E
DRAWING PREPARED TO
Copyright: All drawings a re onfidential and opyright
DO NOT SCALE
ALL DIMENSIONS IN m m
holder.
dis losed without express prior onsen t of the o pyright
whole of this drawing may be reprodu e d, used or
Balex Marine and/or the ir respe tive lients. No part or
NZS/AS 1100.101:1992
POWER UNIT CONFIGURATIONS
DESCRIPTION
SIZE
D
1 / 3
SHEET
BALEX MARINE
A3
B
SC
APPROVED BY
ABL2500-GA-201
SHEET SCALECHECKED BY
15/09/2016 PSPS 1:15
WEIGHT
ABL2500
207774.33 g
Address: Balex Marine Limited
PO Box 14367, Tauranga 3143
New Zealand
Phone: [phone]
Website: paul@balexm arine. om
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
NOTES:
THE RECOMMENDED CONFIGURATION OF THE POWER UNIT ON THE TRAILER IS IDENTIFIED IN THE ACCREDITATION PACK FOR THE PARTICULAR BOAT/TRAILER COMBINATION.BEFORE1.
FINALISING THE POSITION OF THE POWER UNIT, THERE NEEDS TO BE ADEQAUTE CLEARANCE TO THE JOCKEY WHEEL AND TURNING CIRCLE OF THE WINCH HANDLE.2.
WHEN BOLTING DOWN THE POWER CABLES TO THE BATTERY TERMINALS, REMOVE THE FUSE ON THE POSITIVE CABLE. CONFIRM THE POLARITY THEN ATTACH THE NEGATIVE CABLE THEN THE THE POSITIVE. 3.

Mount Installation refer
to drawing XXXXXX
Mount Installation refer
to drawing XXXXXX
1:10PS
ABL2500BALEX MARINE
WG No.
RAWN BY
SHEET ESCRIPTION
PROJECT
RAWN
MOUNTING ARRANGEMENT
5
3
2
4
B C
1
F
RAWING PREPARE TO
A
All drawings are confiden tial and copyright
disclosed without express pri or consent of the copyrig ht
holder.
O NOT SCALE
ALL IMENSIONS IN mm
whole of this drawing may be reproduced, used or
6
E
Copyright:
Balex Marine and/or the ir respective clients. No part or
NZS/AS 1100.101:1992
POWER UNIT CONFIGURATIONS
ESCRIPTION
CLIENT
A3 2 / 3
SIZE SHEET
207774.33 g
WEIGHT B
SC
ABL2500-GA-201
SHEET SCALE
D
CHECKE BY APPROVE BY
15/09/2016 PS
Address: Balex Marine Limited
PO Box 14367, Tauranga 3143
New Zealand
Phone: [phone]
Website: paul@balexm arine.com
REV ESCRIPTION NAME ATE
A ISSUE FOR OCUMENTATION SC 13/09/2016
B ISSUE FOR CUSTOMER MANUALS EE 15/12/2016
ALTERNATE ASSEMBLY POSITION - RAWBAR BRACKET MOUNTE
RIGHT VIEW
LEFT VIEW
LEFT VIEW
RIGHT VIEW
ISOMETRIC VIEW
ISOMETRIC VIEW
ALTERNATE ASSEMBLY POSITION - RAWBAR POST MOUNTE (STRAIGHT)
NOTES:
THE RECOMMEN E CONFIGURATION OF THE POWER UNIT ON THE TRAILER IS I ENTIFIE IN THE ACCRE ITATION PACK FOR THE PARTICULAR BOAT/TRAILER COMBINATION.BEFORE1.
FINALISING THE POSITION OF THE POWER UNIT, THERE NEE S TO BE A EQAUTE CLEARANCE TO THE JOCKEY WHEEL AN TURNING CIRCLE OF THE WINCH HAN LE.2.
WHEN BOLTING OWN THE POWER CABLES TO THE BATTERY TERMINALS, REMOVE THE FUSE ON THE POSITIVE CABLE. CONFIRM THE POLARITY THEN ATTACH THE NEGATIVE CABLE THEN THE THE POSITIVE. 3.