Castex BR-2250 Product manual

Burnisher
607357
Rev. 01 (07-99)
Model No.:
608192 – BR-2250
607358 – BR-2500
BR-2250/2500
Operator and Parts Manual
A TENNANT COMPANY
1–800-522–7839
616-786–2330
FAX: [phone]
CUSTOMER SERVICE: 1–800-964–9644
CASTEX INCORPORATED
12875 RANSOM STREET
HOLLAND MI 49424 U.S.A.

OPERATION
2BR-2250/BR-2500 (07–99)
This manual is furnished with each new model. It
provides necessary operation and maintenance
instructions.
Read this manual completely and understand the
machine before operating or servicing it.
A complete illustrated parts list is also included in this
manual, use this list to order parts. Before ordering
parts or supplies, be sure to have your machine model
number and serial number handy. Parts and supplies
may be ordered by phone or mail from any authorized
parts and service center, distributor or from any of the
manufacturer’s subsidiaries.
This machine will provide excellent service. However,
the best results will be obtained at minimum costs if:
The machine is operated with reasonable care.
The machine is maintained regularly - per the
machine care instructions provided.
The machine is maintained with manufacturer
supplied or equivalent parts.
MACHINE DATA
Pleasefill out at time of installation for future reference.
Model No.-
Install. Date -
Serial No.-
Copyright 1999 Tennant Company Printed in U.S.A
Castex is a registered United States trademark of Tennant Company
TABLE OF CONTENTS
SAFETY PRECAUTIONS 3. . . . . . . . . . . . . . . . . . . . . . .
MACHINE COMPONENTS 4. . . . . . . . . . . . . . . . . . . . . .
MACHINE SETUP 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MACHINE OPERATION 5. . . . . . . . . . . . . . . . . . . . . . . . .
PRE OPERATION CHECKS 5. . . . . . . . . . . . . . . . . .
BURNISHING WITH THE NON–DRIVE MODEL 5.
BURNISHING WITH THE
SELF–PROPELLED DRIVE MODEL 6. . . . . . . . . . .
ADJUSTING PAD PRESSURE 6. . . . . . . . . . . . . . . .
BATTERY LEVEL METER 7. . . . . . . . . . . . . . . . . . . .
HOUR METER 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CARBON BRUSH INDICATOR LAMP 8. . . . . . . . . .
MACHINE MAINTENANCE 8. . . . . . . . . . . . . . . . . . . . . .
DAILY MAINTENANCE: 8. . . . . . . . . . . . . . . . . . . . . .
WEEKLY MAINTENANCE: 8. . . . . . . . . . . . . . . . . . .
MONTHLY MAINTENANCE: 9. . . . . . . . . . . . . . . . . .
EVERY 250 HOURS OF USE: 9. . . . . . . . . . . . . . . .
CHARGING THE BATTERIES 9. . . . . . . . . . . . . . . . . . .
STORING MACHINE 10. . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS 10. . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLE SHOOTING 11. . . . . . . . . . . . . . . . . . . . . . . .
PARTS LIST 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRAME GROUP 12. . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE GROUP 14. . . . . . . . . . . . . . . . . . . . . . . . . . .
COVER GROUP 16. . . . . . . . . . . . . . . . . . . . . . . . . .
COMPONENT PANEL GROUP 17. . . . . . . . . . . . .
INSTRUMENT PANEL GROUP 8. . . . . . . . . . . . . . .
SPEED CONTROL GROUP 20. . . . . . . . . . . . . . . .
PAD SHROUD LINKAGE GROUP 22. . . . . . . . . . .
PAD DRIVER GROUP 24. . . . . . . . . . . . . . . . . . . . .
PAD MOTOR BREAKDOWN 26. . . . . . . . . . . . . . . .
DRIVE MOTOR BREAKDOWN 27. . . . . . . . . . . . .
BATTERY GROUP 28. . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL DIAGRAMS 30. . . . . . . . . . . . . . . . . . . .

OPERATION
BR-2250/BR-2500 (04–99) 3
SAFETY PRECAUTIONS
This machine is suited to burnish smooth floor
surfaces in an indoor environment and is not
constructed for any other use. The pick up of any
liquid or dangerous type of dust is unsuitable and
therefore usage of this type is not allowed.
The following safety alert symbols are used throughout
this manual as indicated in their descriptions.
WARNING: To warn of hazards or unsafe
practices which could result in severe personal
injury or death.
CAUTION: To warn of hazards or unsafe
practices which could result in minor personal
injury.
FOR SAFETY: To identify actions which must be
followed for safe operation of equipment.
The following information signals potentially dangerous
conditions to the operator or equipment:
FOR SAFETY
1. Do not operate machine:
– Unless trained and authorized.
– Unless operation manual is read and
understood.
– In flammable or explosive areas unless
designed for use in those areas.
2. Before starting machine:
– Make sure all safety devices are in place
and operate properly.
3. When using machine:
– Go slow on inclines and slippery surfaces.
– Use care when reversing machine.
– Always follow safety and traffic rules.
– Report machine damage or faulty
operation immediately.
4. Before leaving or servicing machine:
– Stop on level surface.
– Turn off machine.
5. When servicing machine:
– Avoid moving parts. Do not wear loose
jackets, shirts, or sleeves.
– Block machine tires before jacking
machine up.
– Use hoist or jack of adequate capacity to
lift machine.
– Disconnect battery connections before
working on machine.
– Wear protective gloves when handling
batteries or battery cables.
– Avoid contact with battery acid.
– Use manufacturer supplied or approved
replacement parts.
WARNING: Batteries emit hydrogen gas.
Explosion or fire can result. Keep sparks and
open flame away. Keep battery compartment open
when charging.
WARNING: Flammable materials or reactive
metals can cause explosion or fire. Do not pick
up.
WARNING: Moving parts. Turn off power
before working on machine.
CAUTION: Pad head must be in full up (pad
load) position before making pad pressure
adjustment.

OPERATION
4BR-2250/BR-2500 (04–99)
MACHINE COMPONENTS
1. Control Console
2. Dust Control Hose
3. Dust Bag Access Door
4. Dust Control Skirt
5. Battery Cover
6. Frame
7. Wall Rollers
8. Pad Driver
9. Main Wheels
10. Circuit Breakers
11. Pad Pressure Meter
12. Key ON Light
13. Travel Speed Selection Switch
14. Key Switch
15. Fuse Holder
16. Control Grips
17. Battery Level Meter
18. Carbon Brush Indicator Lamp
1
2
3
4
5
6
7
8
9
11
17
13
14
15
16
12
18
10
FIG. 1.
MACHINE SETUP
Carefully check carton for signs of damage. Report
damages at once to the carrier.
Unpack the machine and check machine for
completeness according to the packing list.
Battery installation must be accomplished after
removing the machine from the pallet. Carefully follow
the battery installation diagram on page 28 in your
parts manual.
Complete the machine:
1. Select a burnishing pad that is designed to
operate over 2000 RPM. The pad should be a
maximum of 25.4 mm (1 inch) thick,
483 mm (19 inch) in diameter with a standard 89
mm (3.5 inch) center hole.
FOR SAFETY: Before leaving or servicing
machine, stop on level surface and turn off
machine.
2. Tap the right front side of the pad shroud with your
toe. The head will rise to the pad mounting
position (Figure 2) .
FIG. 2.
3. Remove the plastic centerlock from the pad driver
by turning it clockwise. Position the pad
accurately centered on the pad driver, and screw
the centerlock in place counter-
clockwise until it is tight (Figure 3).

OPERATION
BR-2250/BR-2500 (04–99) 5
Close Open
FIG. 3.
NOTE: This machine is equipped with a pad
centerlock with a left hand thread.
ATTENTION: Care must be exercised to be sure
centerlock does not cross–thread or floor damage
could occur. Do not overtighten.
ATTENTION: Do not operate machine without a
pad and the pad centerlock in place.
MACHINE OPERATION
PRE OPERATION CHECKS
1. Check battery meter charge level to ensure
batteries are fully charged. See CHARGING THE
BATTERIES.
2. Sweep or dust mop the floor to remove debris.
Then damp mop or scrub the floor to assure that
dirt is not burnished into the finish.
3. Check that a pad is installed.
4. Check that a dust bag is installed.
5. Make sure floor to be burnished is dry.
BURNISHING WITH THE NON–DRIVE MODEL
ATTENTION: Loose objects on floor can become
dangerous projectiles if struck by the high speed
pad. Remove them before operating the machine.
1. Turn the key switch to the ”ON” position
(Figure 4) . The key ON light on the panel will light
green.
FIG. 4.
2. With the control grips released, step down on the
rear of the pad shroud until the head locks in the
down position (Figure 5).
FIG. 5.
3. Remove foot from the pad shroud.
4. Twist the control grips forward (Figure 6) . The pad
motor will start and suction will draw the moving
pad to the floor. Immediately push or pull the
machine in the desired direction.
FIG. 6.
ATTENTION: Keep the machine moving at all
times to prevent damage to the floor finish.

OPERATION
6BR-2250/BR-2500 (04–99)
5. To stop, release the control grips. The pad will
automatically lift from the floor until the grips are
activated again.
BURNISHING WITH THE SELF–PROPELLED
DRIVE MODEL
ATTENTION: Loose objects on floor can become
dangerous projectiles if struck by the high speed
pad. Remove them before operating the machine.
1. Turn the key switch to the ”ON” position (Figure
4 ). The key ON light on the panel will light green.
2. With the control grips released, step down on the
rear of the pad shroud until the head locks in the
down position (Refer to Figure 5).
3. Remove foot from the pad shroud.
4. Select a speed with the travel speed selection
switch (Figure 7) :
UP position provides both slow and fast forward
speeds.
DOWN position provides slow forward speed only.
Use this position for maneuvering in tight areas.
FIG. 7.
5. Twist control grips forward until the pad motor
starts (Figure 6) . The machine will transport
forward and suction will draw the moving pad to
the floor.
6. To reverse, twist the control grips backward. The
pad motor will start and the machine will transport
backwards.
7. To stop, release the control grips.
ATTENTION: Keep the machine moving at all
times to prevent damage to the floor finish.
8. To increase travel speed (mode switch in ”UP”
position), twist the control grips all the way forward
to select the second (high) travel speed.
9. To stop, release the control grips and hold back on
the machine until it stops moving. The reverse
direction may be used as a stopping brake if
desired.
NOTE: The drive circuit is equipped with a circuit
breaker located on the lower left rear frame. If the
driver system is overloaded during use the breaker will
trip. Allow it to cool for a few moments and reset the
breaker by pushing on the black button ( Figure 8).
FIG. 8.
ADJUSTING PAD PRESSURE
CAUTION: The pad head must be in the full
up (pad load) position before making the pad
pressure adjustment. DO NOT ADJUST in the
down position as the head could release and
pinch arm or fingers in the mechanism.
1. Your machine has a pad pressure meter located
on top of the control console. This meter has one
green bar and 2 red bars (Figure 9) :
GREEN BAR: The operating zone within which the
needle must read.
RED BAR TO THE RIGHT: Indicates too much
pressure or pad resistance.
RED BAR TO THE LEFT: Indicates too low pressure
or that the battery charge is low.

OPERATION
BR-2250/BR-2500 (04–99) 7
PAD PRESSURE
BATTERY
CHARGE
OPERATING
ZONE
DO NOT
OPERATE
IN RED
FIG. 9.
2. Operate the machine on the actual floor with the
finish and pad you will be using. Notice the needle
position on the meter. For most jobs the needle
should be in the center of the green bar.
3. If the needle is not in the center of the green bar,
raise the pad head into the full up position and
locate the pad pressure knob under the rear frame
(Figure 10).
FIG. 10.
4. If the needle indicates too much pressure turn the
knob counterclockwise and repeat testing until the
needle is in the center.
5. If the needle indicates too little pressure turn the
knob clockwise and repeat testing until the needle
is in the center.
NOTE: Increasing pad pressure will improve shine but
it will also reduce battery run time.
ATTENTION: Do not adjust the pressure so the
needle runs in the right red bar. This will cause
the circuit breaker to trip.
6. If high performance is needed and run time is not
a consideration, adjust the pressure so the needle
runs in the higher (right side) of the green bar.
7. If long run time is needed, adjust the pressure so
the needle runs in the lower (left side) of the green
bar.
Once initial pad pressure has been set:
8. If during use the needle moves into the right red
bar, it will cause the circuit breaker to trip. Allow
the pad motor to cool down and then press the
pad motor circuit breaker red reset button.
9. If the needle moves again into the right red bar
and the circuit breaker trips, the pad may have
become dirty and filled with finish. Turn the pad
over to a clean side or replace the pad. Then
reset the circuit breaker. To remove/change pads
see INSTALLATION .
NOTE: The operator should watch the pad meter
during operation and change the pad before the circuit
breaker trips.
10. If the needle drops into the left red bar, this
indicates the battery charge is low and recharging
is required. See CHARGING BATTERIES in the
Maintenance section.
BATTERY LEVEL METER
1. Your machine has a battery level meter located on
top of the control console. This meter has one
green bar and 2 red bars (Figure 11) :
GREEN BAR: The operating zone within which the
needle must read.
RED BAR TO THE RIGHT: Indicates the batteries are
overcharged or that the batteries are connected
wrong. If the needle runs in this area, turn the
machine power off immediately and call your
service technician.
RED BAR TO THE LEFT: Indicates the batteries need
to be recharged. See CHARGING BATTERIES
section.
BATTERY LEVEL
DO NOT
OPERATE
IN RED
OPERATING
ZONE
FIG. 11.

OPERATION
8BR-2250/BR-2500 (04–99)
HOUR METER
1. Your machine has an hour meter located inside
the battery compartment next to the machine
connector (Figure 12).
FIG. 12.
2. To gain access to this meter remove the battery
cover.
3. This meter keeps a running total of the hours of
operation of your machine.
4. Use this meter to determine when your machine
should to be maintained.
CARBON BRUSH INDICATOR LAMP
1. Your machine has an amber carbon brush
indicator lamp which will light when the carbon
brushes in the pad drive motor need to be
replaced ( Figure 13) . See EVERY 250 HOURS
OF USE section.
FIG. 13.
MACHINE MAINTENANCE
To keep machine in good working condition, simply
follow daily, weekly and monthly maintenance
procedures.
FOR SAFETY: When leaving or servicing machine,
stop on level surface and turn off machine.
FOR SAFETY: When servicing machine,
disconnect battery connections before working on
machine.
ATTENTION: Contact an Authorized Service
Center for machine repairs. Machine repairs
performed by other than an authorized person will
void your warranty.
DAILY MAINTENANCE:
1. Remove burnishing pad. Clean and replace or
install a new pad (Refer to Figure 3).
2. Dust bag maintenance:
Open the dust bag access door to gain access to
the dust bag.
Paper Bag: Grasp the bag to check the contents.
Remove and discard the bag if it is full. Install a
new bag on the fitting and close the dust bag
access door.
Cloth Bag (Option): Remove the bag. Unzip,
invert and shake the contents from the bag. Close
the zipper and reinstall on the fitting. Close the
dust bag access door.
NOTE: If the bag is extremely soiled, launder the bag
before reuse.
3. Wipe the entire machine with a damp cloth.
4. Charge the batteries. See CHARGING
BATTERIES.
WEEKLY MAINTENANCE:
1. Inspect the dust control skirt for wear and proper
adjustment. The skirt should be adjusted so it just
touches the floor in the run position.
To adjust: Loosen the band and push the skirt
down. Tighten the band.
2. Check the specific gravity in each battery cell with
a hydrometer. All cells should show a reading of
at least 1.260 (Figure 14).

OPERATION
BR-2250/BR-2500 (04–99) 9
FIG. 14.
MONTHLY MAINTENANCE:
1. Check battery cables for tightness or corrosion.
Clean and lubricate if necessary.
2. Grease main wheel bearings and swivel and wheel
on the caster (Figure 15).
FIG. 15.
3. For self–propelled DRIVE Model:
Check the lubrication and tension of the drive
chain. If maintenance is necessary, ask
assistance from your Authorized Service Center.
4. Grease the brass acorn nut on the head stop
bracket.
EVERY 250 HOURS OF USE
It is recommended that these maintenance procedures
be performed by technicians from your authorized
service center.
1. Inspect carbon brushes in the pad motor. Replace
if worn to 10 mm or less.
2. Inspect the carbon motor brushes in the traction
motor. Replace if worn to 10 mm or less.
CHARGING THE BATTERIES
WARNING: Batteries emit hydrogen gas.
Explosion or fire can result. Keep sparks and
open flame away. Keep battery compartment open
when charging.
FOR SAFETY: When servicing machine, avoid
contact with battery acid.
1. Slide the battery cover from the machine.
2. Remove all battery caps and check the water level
in each battery cell.
3. If needed add enough distilled water to cover
plates or to a maximum of 6 mm below the fill
neck ring (Figure 16).
FIG. 16.
4. For machines with 305 amp batteries, to gain
access to the 2 top rear battery cells, remove the
2 acorn nuts holding the console to the frame
(Figure 17) . Tip the console back on the hinge to
access these cells.
FIG. 17.

OPERATION
10 BR-2250/BR-2500 (04–99)
5. Disconnect the battery connector from the
machine connector and plug the charger
connector into the battery connector
(Figure 18).
FIG. 18.
NOTE: Do not plug the charger connector into the
machine connector or damage to the machine may
occur.
6. Plug the charger cord into a wall outlet. The
charger will automatically start and charge the
batteries.
After charging:
7. Make sure that the charger has turned off by
making sure the needle on the charger is at ”0”.
8. Unplug the charger connector from the battery
connector. Plug the battery connector into the
machine connector.
9. Check all battery cells for low water level. Add
distilled water to just below the fill ring if needed.
10. Replace the battery caps.
11. Wipe off the top of the batteries with a clean cloth.
12. Slide the battery cover into place.
STORING MACHINE
The machine must be stored in a dry area in a
horizontal upright position.
SPECIFICATIONS
ITEM MEASURE
Length 1350 mm
Width 550 mm
Height 1020 mm
Weight: NONDRIVE MOD
EL
104 kg (excluding batteries)
Weight: DRIVE MODEL 118 kg (excluding batteries)
Speed: NONDRIVE MODEL Push
Speed: DRIVE MODEL 5 k/hr
Pad Diameter/Burnishing
Path
483 mm
Pad Motor 2,24 kW (3hp)
Pad Speed 2,500 rpm
Battery Life: NONDRIVE
MODEL
2,53,5 hours
Battery Life: DRIVE MODEL 23 hours
Decibel Level 75 dBA

OPERATION
BR-2250/BR-2500 (04–99) 11
TROUBLE SHOOTING
PROBLEM CAUSE SOLUTION
Machine does not operate. Key switch is OFF. Turn key switch ON.
Battery connector is not plugged into Plug connector into machine.
machine connector.
Batteries discharged. Charge batteries.
Ignition fuse blown. Replace fuse.
Loose or corroded battery cables. Clean and lubricate.
Electrical malfunction. Contact Authorized Service Center.
Machine does not self-propel Drive circuit breaker tripped. Reset breaker.
(Drive model ONLY). Drive chain broken. Replace.
Electrical malfunction. Contact Authorized Service Center.
Wheel bearing frozen. Contact Authorized Service Center.
Pad motor does not operate. Head not lowered and locked in Lower head into ready position.
ready (down) position.
Pad circuit breaker tripped. Reset breaker.
Electrical malfunction. Contact Authorized Service Center.
Pad drive motor circuit breaker Dirty pad. Replace.
trips continuously. Improper pad for application. Change to correct pad.
Improper pressure adjustment. Reduce pressure.
Defective circuit breaker. Contact Authorized Service Center.
Worn motor brushes. Contact Authorized Service Center.
Pad driver vibrates during use. Pad off center. Reposition pad.
Pad out of round or damaged. Replace with new pad.
Pad driver damaged or out of balance. Contact Authorized Service Center.
Batteries deliver below-normal Batteries not fully charged. Charge batteries.
run time. Electrolyte level is low. Fill to proper level and charge.
Cables are loose or corroded. Clean and lubricate.
Pad pressure is too heavy. Reduce pressure.
Improper pad causing too much amp Change to proper pad.
draw.
Charger is defective. Contact Authorized Service Center.
Battery is defective. Contact Authorized Service Center.
Dust control ineffective. Filter bag is full or dirty. Empty, clean or replace.
Skirt not adjusted properly Adjust skirt per instructions.
or damaged.
Pad is worn excessively. Replace pad.
Dust control hose plugged with debris. Clean out hose.
Transport drive circuit breaker Operator attempting inclines. Machine not designed for inclines.
trips during use. Machine travel obstructed. Remove obstruction.
Operator using directional control as Do not use directional control as brake.
brake.
Drive circuit breaker defective. Contact Authorized Service Center.
Drive Motor brushes worn. Contact Authorized Service Center.

PARTS LIST
12 BR-2250/BR-2500 (04–99)
FRAME GROUP
1
2
3
4
5
6
7
8
910
11
12
13
14
15
16
17 (Non-Drive)
19
20
21 22
23
24
18 (Drive)
25 25
27 25
29
31
30 28
33
32
31
30
29
33
32
26
27
25
25
28
26 27
36
34
34
44
40
41
43
42
SLOW SPEED
RETROFIT KIT
#600481
26
38
37
39

PARTS LIST
BR-2250/BR-2500 (04–99) 13
FRAME GROUP
Ref. Part No. Description Qty.
1 621 286 000 Screw, pan hd. 2
2 200 160 017 Nut 2
3 200 001 483 Screw 2
4 069 767 001 Frame weldt. 1
5 069 762 009 Grommet 1
6 602 040 000 Decal, Caution 1
7 069 767 102 Bracket, wall roller 1
8 069 767 178 Bracket, frame supp. 1
9 630450 Wheel, rubber 2
10 578427 Standoff, terminal 1
11 069 767 036 Hinge, shroud 1
12 140015 Washer lock 2
13 200 640 017 Nut, hex 2
14 069 760 030 Caster 1
15 190905 Circ. break., 70 amp 1
16 186 002 085 Screw, pan hd. 2
17 130781 Circ. break., 80 amp (non-drive model) 1
18 069 767 136 Circ. break., 7 amp (drive model) 1
19 200 351 020 Washer, lock 4
20 200 031 541 Screw, hex hd. 4
21 069 787 174 Bracket, frame supp. 1
22 069 767 121 Edging 1
23 575380 Nut, hex 2
24 069 762 005 Washer, lock 2
25 069 767 077 Screw, carriage 14
26 602 202 000 Decal, Hot Caution 1
27 140546 Nut, Lock 12
28 200 607 491 Screw, hex hd. 2
29 069 762 115 Screw hex hd. 2
30 140016 Washer, lock 2
31 200 651 019 Washer, Flat 2
32 200 160 017 Nut, hex lock 2
33 200 303 019 Washer, Flat 2
34 200 031 433 Screw hex hd. 7
35 578 728 Washer, lock 2
36 140012 Washer 7
37 140916 Clamp 1
38 140196 Screw 1
39 140552 Nut, Lock 1
40 069 764 063 Resistor, slow speed 1
41 069 767 164 Screw, carriage 2
42 140016 Washer, lock 2
43 059 650 595 Nut, hex 2
44 621 052 000 Plate, battery 1

PARTS LIST
14 BR-2250/BR-2500 (04–99)
DRIVE GROUP
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
2
1
2
2
2
10
10
4
4
2
5
3
3
5
4
7
7
7
9
9
9
8
4
41
8
Non-Drive
Model
8
24
29
24
8
24
25
26
26
28
27
26
Drive
Model

PARTS LIST
BR-2250/BR-2500 (04–99) 15
DRIVE GROUP
Ref. Part No. Description Qty.
∇1 069 767 082 Wheel 1
2 602 171 000 Washer thrust 4
3 069 767 004 Spanner, bushing 2
4 602 014 000 Grease retainer 2
5 602 013 000 Bearing, wheel 2
6 069 767 003 Wheel 1
7 069 767 002 Bracket, wheel mnt. 2
8 069 760 082 Washer, flat 2
9 069 764 157 Nut, hex lock 2
10 621 237 000 Screw, hex hd. 2
11 069 767 008 Sprocket 1
12 602 011 000 Screw, set 2
13 069 767 011 Chain 1
14 621 238 000 Screw, hex hd. 1
15 069 767 007 Sprocket 1
16 069 767 005 Spacer, wheel 1
17 140501 Nut, hex 4
18 140016 Washer, lock 4
19 069 767 010 Motor, drive 1
20 602 130 000 Motor brush (set/2) 1
21 069 767 006 Spacer, sprock. mnt. 4
22 069 767 161 Support, wheel mnt. 1
23 579 212 Screw, hex hd. 4
621 311 000 Service kit, whl shims 1
24 140546 Nut,Lock 4
25 621 311 000 Shim, wheel 1
26 579 210 Washer, flat 5
27 578 728 Washer, lock 9
28 200 031 438 Screw, hex hd. 2
29 14880.5 Washer 4

PARTS LIST
16 BR-2250/BR-2500 (07–99)
COVER GROUP
1
2
3
6
47
8
10
11
12
13
14
15
17
16
18
19
18
22
21
5
20
9
23 24
Ref. Part No. Description Qty.
1 607355 Hood, front, Blue 1
2 603083 Decal, Castex 1
3 069 767 135 Decal, maint. 1
4 069 767 074 Decal, wire (non-drive model) 1
069 767 119 Decal, wire (drive model) 1
5 069 780 017 Decal, Caution Charge 1
6 607353 Shroud, rear, Blue 1
7 130164 Plug, button 3
8 069 764 060 Screw, truss hd 2
9 069 767 179 Door, vac compart. 1
10 14880.5 Washer, plain 2
11 621 325 000 Retainer, e ring 2
12 069 767 096 Stiffener, r. shroud 2
13 602 074 000 Nut, wing, shroud 2
14 14880.5 Washer, plain 2
15 039 707 079 Bag, Vacuum (10pcs) 1
16 069 767 187 Hose, dust control 1
17 069 767 189 Cuff, dust control 1
18 602 139 000 Washer, flat, nylon 2
19 578439 Knob 1
20 579028 Nut, Hex 1
21 200058432 Screw 4
22 602068000 Screw, Carriage 2
23 200031441 Screw 1
24 607570 Decal, BR-2500 2
608194 Decal, BR-2250 2

PARTS LIST
BR-2250/BR-2500 (04–99) 17
COMPONENT PANEL GROUP
2
11
14
13
12
15
3
4 Pad Motor
5
6 Speed Resistor
20
19
18
8 Forward
7
9
17
16
8 Reverse
1
Dynamic Brake
10
19
20
15
Ref. Part No. Description Qty.
1 069 760 440 Contactor, SPDT, 100A 1
2 621 297 000 Meter, Hour (Option) 1
3 069 767 033 Panel, Electrical 1
4 621 381 000 Contactor, 200A, Pad Motor 1
5 019 686 055 Spacer, Nylon 2
6 069 764 063 Resistor, Speed (drive model) 1
7 069 767 121 Edging, 8” L 11
8 069 760 440 Contactor, SPDT, 100A 2
9 630446 Washer, Nylon 2
10 602 203 000 Heat shield 1
11 602 202 000 Decal, Caution HOT 1
12 200 031 433 Screw, M06x10 2
13 578728 Washer, Lock, Spg. 2
14 579210 Washer 2
15 069 767 164 Screw, Carriage, .25–20x.5” 10
16 200 031 438 Screw, M06 x 20 2
17 579 210 Washer, Flat, 6.4 ID 2
18 200 303 019 Washer, Flat, M08 10
19 140016 Washer, Lock, SPG. 10
20 059 650 595 Nut, Hex, 1/4–20 10

PARTS LIST
18 BR-2250/BR-2500 (04–99)
INSTRUMENT PANEL GROUP
1 (Non-Drive)
2 (Drive)
34
5
6 (Non-Drive)
7 (Drive)
8
9
10
11
12
13
14
15
16
17 18
19
20
21
22
3
14
20
2423
26
28
27
25
29
30
31
32
33
34 35

PARTS LIST
BR-2250/BR-2500 (04–99) 19
INSTRUMENT PANEL GROUP
Ref. Part No. Description Qty.
1 602235 Gauge,amp (non-drive model) 1
2 602235 Gauge, amp (drive model) 1
3 626114 Pilot light 1
4 602 050 000 Wire assy 2
5 610026 Meter, Battery 1
6 600345 Decal, console (non-drive model) 1
7 600346 Decal, console (drive model) 1
8 069 767 055 Bracket, switch 1
9 069 764 009 Switch, snap 1
10 630186 Collar, shaft 1
11 069 764 069 Spring 1
12 069 767 026 Plate 1
13 069 764 005 Collar, swtch.actuator 1
14 069 760 582 Washer, nylon 8
15 N/A Tab, key switch 2
16 200823 Grip, handle bar 2
17 612471 Switch, key lock 1
18 069 762 236 Key 1
621 437 000 Bracket, key Switch 1
19 069 764 062 Bar, Handle 1
20 578418 Fuse holder 1
21 069 760 639 Fuse 1
22 602 140 000 Washer, retention 1
23 140506 Nut 1
24 140015 Washer 1
25 069 764 002 Screw 2
26 069 764 053 Washer, flat 2
27 140023 Washer, lock 2
28 200 102 014 Nut, Hex 2
29 069 764 190 Screw 2
30 200 351 012 Washer 2
31 069 762 005 Washer, lock 1
32 575380 Nut 1
33 069 762 306 Washer, lock 1
34 069 764 060 Screw 3
35 130164 Plug, dome 3

PARTS LIST
20 BR-2250/BR-2500 (04–99)
SPEED CONTROL GROUP (DRIVE MODEL)
18
17
42
5
1
12
2
4
6
7
13
16
43
25 26
12
24
11
19
20
21
24
23
22
24
14
30 29 928 27
8
3
31
32
33
34
10
40
41
35
38
37
39
15
5
1
6
10
36