Excel Two Bag Catcher User manual

112601_1211
•••••
P.O. Box 7000
•••
Hesston, Kansas
•
67062-2097
Excel Two Bag Catcher
42"/46"/48"/54" Decks
Operator’s Manual

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112601_1211 c-1
Table of Contents
General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Assembly Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Maintenance & Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Illustrated Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

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112601_1211 1-1
GENERAL INFORMATION
To the new owner
The purpose of this manual is to assist owners and operators
in maintaining and operating the Excel Two Bag Catcher.
Please read it carefully; information and instructions
furnished can help you achieve years of dependable
performance.
Using this manual
General operation, adjustment and maintenance guidance is
outlined for both the experienced and novice Excel user.
Operating conditions vary considerably and cannot all be
addressed individually. Through experience, however,
operators should find no difficulty in developing good
operating skills suitable to most conditions.
Directions used in this manual, for example RIGHT or
LEFT, refer to directions when seated on mower facing
forward, unless otherwise stated.
Photographs and illustrations used were current at the time
of printing, but subsequent production changes may cause
your machine to vary slightly in detail. Excel Industries, Inc.
reserves the right to redesign and change the machine as
deemed necessary, without notification. If a change has been
made to your machine which is not reflected in this owner’s
manual, or the parts manual, see your Excel dealer for current
information and parts.
Warranty registration
The Delivery and Warranty Registration form must be
completed and signed to validate your warranty protection.
As the new equipment owner, you are expected to see that the
card is completed and forwarded to Excel Industries, Inc. at
time of delivery.
Be sure to register the mower plus each attachment that
displays a model and serial identification number plate with
Excel Industries, Inc.
IMPORTANT: Any unauthorized modification, altera-
tion, or use of non-approved attachments voids the warranty
and releases Excel Industries, Inc. from any liability arising
from subsequent use of this equipment.
Parts and service
Use original Excel replacement parts only. These parts are
available through your local Excel dealer. To obtain prompt,
efficient service, always provide the following information
when ordering parts:
1. Correct part description and number, as given in the
parts manual supplied with your owner’s packet.
2. Correct model number.
All warranty repair and service must be handled through an
authorized Excel dealer. Arrangements should be made
through your local service center.

1-2 112601_1211

112601_1211 2-1
SAFETY PRECAUTIONS
This safety alert symbol is used to call attention to a message
intended to provide a reasonable degree of PERSONAL
SAFETY for operators and other persons during the normal
operation and servicing of this equipment.
DANGER – denotes immediate hazards which WILL result
in severe personal injury or death.
WARNING – denotes a hazard or unsafe practice which
COULD result in severe personal injury or death.
This manual uses two other words to highlight information.
IMPORTANT calls attention to special mechanical information
and NOTE: emphasizes general information worthy of special
attention.
All operators should read this manual and be instructed about
safe operating and maintenance procedures. This is the owner’s
responsibility.
Improper use or maintenance by the operator or owner
can result in injury. To reduce the potential for injury,
comply with these safety instructions and always pay
attention to the safety alert symbol, which means
DANGER or WARNING - “personal safety instructions."
Failure to comply with the instructions may result in
personal injury or death.
Incorrect usage of this machine may result in severe
injury. Personnel operating and maintaining it should be
trained in the proper use and should read the manuals
completely and thoroughly before attempting to set-up,
operate, adjust, or service this machine.
It is the owner’s responsibility to make certain that the
operators and mechanics read and understand this manual. It is
also the owner’s responsibility to make certain that the
operators and mechanics are qualified and physically able
individuals, properly trained in the operation of this equipment.
All operators and mechanics must become familiar with the safe
operation of the equipment, operator controls and safety signs.
Never let children or untrained people operate or service the
equipment. Local regulations may restrict the age of the
operator.
The owner/user can prevent and is responsible for accidents or
injuries occurring to themselves, other people or property.
The owner should also ensure that the operator/mechanic
know that they are responsible for their own safety as well as the
safety of other persons within the vicinity. Remember, the
operator is responsible for accidents or hazards occurring to
other people or their property.
Evaluate the terrain to determine what accessories and
attachments are needed to properly and safely perform
the job. Only use accessories and attachments approved
by the manufacturer.
Always stop on level ground, disengage deck clutch,
place steering control lever in the park brake position,
stop engine and remove ignition key before leaving oper-
ator’s seat for any reason including emptying the catcher
bags or unclogging the chute.
Always be aware of any obstructions, especially small
children, when backing or unloading the bags.
Always keep safety shields and covers in place, except
for servicing.
Never work on mower deck when the engine is running.
Never operate machine with bagger lid in the raised posi-
tion except for unloading.
Never attempt high speed maneuvering in crowded or
congested areas.
Always operate with complete catcher system, mulching
system or side discharge chute in place and in the lowest
position.
Always keep clear of the mower blades and attachments
during their operation.
Turn off blades when not mowing.
Stop the engine before removing the grass catcher or
unclogging the discharge chute. Never clear the discharge
chute with the engine running. Turn off the engine and be
sure the blades have stopped before cleaning. Use a stick
to clear a plugged discharge area. Never use your hand!
Clean flammable material from machine. Prevent
fires by keeping engine compartment, exhaust area,
battery, fuel line, fuel tank and operator’s station
clean of accumulated trash, grass clippings , and
other debris. Always clean up spilled fuel and oil.
Grass collection system components are subject to wear,
damage and deterioration, which could expose moving
parts or allow objects to be thrown. Frequently check
components and replace with manufacturer’s recom-
mended parts when necessary.
Never direct discharged material toward anyone. Avoid
discharging material against a wall or obstruction. Mate-
rial may ricochet back towards the operator. Always dis-
engage the blades and wait for them to stop before
crossing gravel drives, walks or roads.
WARNING: Thrown objects! Part Number 601624
• Never operate the mower
deck with side deflector
damaged, altered, removed
or in raised position,
except when the entire
grass catcher attachment
or mulching system is
being used.

2-2 112601_1211

112601_1211 3-1
ASSEMBLY INSTRUCTION
These instructions apply to the assembly of the Excel Two
Bag Catcher to an Excel 42", 46", 48" and 54" mower.
It is intended that these units be installed by trained Excel
service personnel. If additional assistance is required, contact
the Excel Customer Service Department.
Directions given in these instructions, for example left and
right, refer to direction while seated on the mower.
Before proceeding, read thru the following instructions to
familiarize yourself, while at the same time identify and
inventory kit parts supplied.
Unpack and inspect all parts. Notify carrier of any shipping
damages immediately.
Parts list – 42" & 46"
NOTE: It will be necessary to replace the right hand
mower blades when using this catcher. The catcher does
not include these blades. Therefore, you must order the
mower blades separately. Order one of part number 793935
when attaching the catcher to a 42" deck. Order one of part
number 602414Ywhen attaching the catcher to a 46" deck.
Parts list – 48"
Parts list – 54"
Part No. Description Qty
N/A CATCHER BAG ASSEMBLY 2
112679 PLATE, HITCH MOUNT 1
705954 CS .500-13 X 1.25 HX G Z 1
036244 CS .375-16 X 1.00 HX G5 6
112677 FRAME BRACE, LH 1
767954 FW .406 x .812 x .060 20
112678 FRAME BRACE, RH 1
054502 NT .375-16 8
080655 CS .376-16 X 1.50 HX G5 2
767962 FW .531 X 1.063 X .09 6
112707 SHIELD 1
008193 NT .500-13 UNT LK 3
111544 WEIGHT PLATE 6
111462 DEFLECTOR 1
077859 CS .500-13 X 3.25 HX G5 2
112449 CHUTE PLATE 1
112655 CATCHER SUPPORT 1
602666 6.00" X 31.0" FLEX TUBE 1
602577 CATCHER CHUTE 1
N/A 2 BAG CATCHER 1
034272 NT .312-18 2
086660 NT .375-16 NY 2
025395 CB .375-16 X 1.00 2
036236 CS .312-18 X 1.00 2
768523 FW .343 X .687 X .051 4
112680 FRAME BRACE, LH ROPS 1
112681 FRAME BRACE, RH ROPS 1
077859 CS .500-13X3.250 HX G5 4
023317 NT .500-13 UNT LK G8 ZN 4
773275 BUSHING SPACER 2
000398 CLAMP 1
016410 CS .375-16 X 2.00 G5 ZN 1
016899 NT .375-16 HXFLK ZN 1
Part No. Description Qty
N/A CATCHER BAG ASSEMBLY 2
112679 PLATE, HITCH MOUNT 1
705954 CS .500-13 X 1.25 HX G Z 1
036244 CS .375-16 X 1.00 HX G5 6
112677 FRAME BRACE, LH 1
767954 FW .406 x .812 x .060 20
112678 FRAME BRACE, RH 1
054502 NT .375-16 8
080655 CS .376-16 X 1.50 HX G5 2
767962 FW .531 X 1.063 X .09 6
112707 SHIELD 1
008193 NT .500-13 UNT LK 3
111544 WEIGHT PLATE 6
111462 DEFLECTOR 1
077859 CS .500-13 X 3.25 HX G5 2
112655 CATCHER SUPPORT 1
602677 6.00" X 31.0" FLEX TUBE 1
N/A 2 BAG CATCHER 1
034272 NT .312-18 3
086660 NT .375-16 NY 2
025395 CB .375-16 X 1.00 2
036236 CS .312-18 X 1.00 3
768523 FW .343 X .687 X .051 6
602594 CATCHER CHUTE 1
112454 CATCHER BAFFLE 1
112461 CATCHER CHUTE BRACE 1
795757 MOWER BLADE (16.50") 2
112680 FRAME BRACE, LH ROPS 1
112681 FRAME BRACE, RH ROPS 1
077859 CS .500-13X3.250 HX G5 4
023317 NT .500-13 UNT LK G8 ZN 4
113616 48" DECK TEMPLATE 1
773275 BUSHING SPACER 2
000398 CLAMP 1
016410 CS .375-16 X 2.00 G5 ZN 1
016899 NT .375-16 HXFLK ZN 1
Part No. Description Qty
N/A CATCHER BAG ASSEMBLY 2
112679 PLATE, HITCH MOUNT 1
705954 CS .500-13 X 1.25 HX G Z 1
036244 CS .375-16 X 1.00 HX G5 6
112677 FRAME BRACE, LH 1
767954 FW .406 x .812 x .060 20

3-2 112601_1211
Assembly
NOTE: Refer to illustrated parts listings when assembling
the unit.
WARNING: Allow engine and muffler to cool
before assembling the unit to the mower.
WARNING: Never work under the machine or
attachment unless it is safely supported with jack
stands. Make certain machine is secure when it is
raised and placed on the jack stands. The jack stands
should not allow the machine to move when the
engine is running and the drive wheels are rotating.
Use only certified jack stands. Use only appropriate
jack stands, with a minimum weight rating of 2000
pounds to block the unit up. Use in pairs only. Fol-
low the instructions supplied with the vehicle
stands.
1. Park the mower on a flat surface. Always place the
deck clutch switch in the disengaged position, place
the steering control levers in the park brake position
and shut off the ignition switch and remove the key
from the switch. Disconnect the negative battery cable.
Block up mower on jack stands to access blades.
2. Remove the discharge chute and discharge chute plate.
NOTE: Retain these parts as they will be re-installed
when the Catcher is removed.
3. For 48" mowers with serial numbers prior to
11010000, the discharge opening will require
modification. Align the supplied template with the
front surface of the deck and edge of discharge
opening. Figure 3-1 Mark the deck by tracing the
inside edge of the template and trim the opening.
Figure 3-1 Grind cut edges smooth and paint all bare
metal.
4. 48"/54" Decks only: Attach the chute baffle to the
catcher chute. Do not tighten hardware at this time.
Figure 3-2
Attach the catcher chute and chute plate to deck.
Adjust baffle to fully close off the deck discharge
opening. Tighten all hardware. Figure 3-2
112678 FRAME BRACE, RH 1
054502 NT .375-16 8
080655 CS .375-16 X 1.50 HX G5 2
767962 FW .531 X 1.063 X .09 6
112707 SHIELD 1
008193 NT .500-13 UNT LK 3
111544 WEIGHT PLATE 6
111462 DEFLECTOR 1
077859 CS .500-13 X 3.25 HX G5 2
112655 CATCHER SUPPORT 1
602677 6.00" X 31.0" FLEX TUBE 1
N/A 2 BAG CATCHER 1
034272 NT .312-18 3
086660 NT .375-16 NY 2
025395 CB .375-16 X 1.00 2
036236 CS .312-18 X 1.00 3
768523 FW .343 X .687 X .051 6
602595 CATCHER CHUTE 1
112468 CATCHER BAFFLE 1
112462 CATCHER CHUTE BRACE 1
602416 MOWER BLADE (20.50") 1
112680 FRAME BRACE, LH ROPS 1
112681 FRAME BRACE, RH ROPS 1
077859 CS .500-13X3.250 HX G5 4
023317 NT .500-13 UNT LK G8 ZN 4
773275 BUSHING SPACER 2
000398 CLAMP 1
016410 CS .375-16 X 2.00 G5 ZN 1
016899 NT .375-16 HXFLK ZN 1
Part No. Description Qty
Figure 3-1
Figure 3-2
Align
Trim
Template
Catcher
baffle
FW .343 x .687
NT.375-16
Nylok
FW .343 x .687
CB .375 x 1
Catcher
chute
48"/54" Decks
Chute brace
NT .312-18
FW .406 x .812
CS .312 x 1

112601_1211 3-3
5. 42"/46" Decks: Attach the catcher chute and chute
plate to deck. Tighten all hardware. Figure 3-3
6. Raise the front of the mower and deck up until the
blades can be accessed easily. Place the mower on jack
stands and do not allow the mower to move. Chock the
rear wheels.
WARNING: Mower blades are sharp and can cut.
Wrap the blade(s) or wear gloves and use extra cau-
tion when servicing them.
7. 42"/46" Decks: Remove the right side blade and
replace with the new blade (not included with the
catcher). Torque blades to 118 ft.-lbs (160.01 Nm).
48" Decks – Remove the right and center blades and
replace with the blade included with the catcher.
Torque blades to 118 ft.-lbs (160.01 Nm)
54" Decks – Remove the right blade and replace with
the blades included with the catcher. Torque blades to
118 ft.-lbs (160.01 Nm). Figure 3-4
WARNING: Failure to correctly torque the bolt
may result in the loss of the blade which can cause
serious injury.
8. Remove the jack stands and lower the mower.
WARNING: Allow the engine to cool before pro-
ceeding to the next step.
9. Remove the muffler guard from the engine. Figure 3-5
10. Attach the deflector to the muffler along with the
muffler guard using the existing hardware. Figure 3-5
11. Attach the hitch plate mount to the mower’s hitch
plate. Figure 3-6
Figure 3-3
Flex tube 42"/46" Decks
CB .375 x 1
Catcher
chute
Chute
brace
NT.375-16
Nylok
FW .406 x .812
Figure 3-4
Figure 3-5
Blade
Existing hardware
Torque to 118 ft.-lbs.
Deflector
Muffler guard
Shield
FW .343 x .687
NT .312-18
FW .343 x .687
CS .312 x 1

3-4 112601_1211
12. Attach the catcher support to the hitch plate mount.
Figure 3-6 13. Attach the shield to the catcher support. Figure 3-5 14. For mowers with serial numbers prior to 1101000,
(frames without ROPS pockets), attach the right and
left frame braces to the catcher support and the mower
frame. Figure 3-7
15. For mowers with serial numbers higher than 11010000
(frames with ROPS pockets), remove hardware
attaching ROPS. Attach the right and left frame braces
to the catcher support and the mower frame, using
supplied hardware. Torque hardware to 55 ft.-lbs (74.6
N-m). Figure 3-8
16. For mowers with Kawasaki engines and with serial
numbers higher than 11010000 (frames with ROPS
pockets), remove the throttle cable stand-off bracket
and clamp from the engine. Figure 3-9
NOTE: Retain these parts as they will be used if the
catcher is ever removed from the mower.
Attach the throttle cable, using the new clamp, spacer,
and hardware, to the right frame brace. Figure 3-10
17. Slide the lid assembly onto the frame mounting tube.
Figure 3-11
18. Slide the upper tube end onto the deck chute. Figure 3-
12
19. Slide the upper tube end onto the catcher lid inlet tube.
Figure 3-12
20. Secure with clamp on catcher lid inlet tube. Figure 3-
12
21. Attach the weights to the front of the mower. Figure 3-
13
Figure 3-6
Figure 3-7
Catcher
support
Hitch plate
mount
CS .5 x 1.25
FW .406 x .812
FW .531 x 1.063
CS .375 x 1
Mowerhitch
plate
FW .531 x 1.063
FW .406 x .812
NT.375-16
NT .5-13
CS .375 x 1.5
Frame
brace
Catcher
support
Mower
frame
FW .406 x .812
FW .406 x .812
FW .406 x .812
CS .375 x 1
NT.375-16
NT.375-16
Frame
brace
Figure 3-8
CS .5 x 3.25
NT .5-13*
Catcher
support
Mower
frame
*Torqueto
55 ft-lbs
(74.6 N-m)
FW .531 x 1.063
FW .406 x .812
FW .406 x .812
CS .375 x 1
NT.375-16
Frame
brace
Frame
brace

112601_1211 3-5
22. Place the bags in the catcher assembly, making sure
that the non-mesh side of the bag is towards the
operator, close the hood and fasten in place using the
elastic latch. Figure 3-11 and Figure 3-14
23. Reconnect the negative battery cable.
WARNING: Do not operate deck without discharge
chute or complete catcher system in place.
Figure 3-9
Figure 3-10
Figure 3-11
Remove bracket, clamp and
hardware from engine
Bushing NT .375-16
HXFLK
Clamp
FW .406 x .812
CS .375 x 2
Frame
brace
Lid assembly
Bags Mesh side of
bag to face
rearward
Figure 3-12
Figure 3-13
Upper
tube
Inlet
tube
Clamp
Weight
plate
FW .531 x 1.063
NT .5-13
CS .5 x 3.25

3-6 112601_1211
Figure 3-14
Elastic
Latch
Frame
edge

112601_1211 4-1
OPERATION
Vacuum Pickup and Collection
Follow normal mower start-up and operating procedures as
outlined in the mower owner’s manual. The rear catcher will
operate when the mower deck clutch switch is engaged. To stop
the rear catcher, return the deck clutch switch to the disengaged
position.
Proceed to mow in the normal manner and occasionally
glance at the upper tube. When the bags are full the speed of
debris through the tube will decrease. When the bags are filled,
move the deck clutch switch to the disengaged position and
drive the machine to the unloading area.
It is best that the bags be unloaded before the discharge chute
and tube areas become clogged. If clogging occurs, it will be
necessary to clean the discharge chute and tube areas of all
material before starting to mow again.
WARNING: Make certain the engine is turned off, the
steering control levers are in the park brake position
and the ignition key is removed from the ignition
switch and be sure blades have stopped before clean-
ing the discharge chute and transfer tube areas.
WARNING: Never place hands or feet into the dis-
charge area. The mower blade is relatively close to the
housing and will cause severe injury. Use a probe to
clean debris from catcher chute adapter area.
WARNING: Never engage mower deck unless catcher
transfer tube is clamped in place on rear catcher lid
intake tube and inserted into catcher chute outlet tube.
Figure 4-3
Unloading the Catcher
WARNING: Park the unit on a level surface, disen-
gage the deck clutch switch, place the steering control
levers in the park brake position and shut the engine
off. Make certain the deck clutch switch is in the dis-
engaged position before unloading.
Get off the mower. Unhook the elastic latch from the catcher
frame. Raise the catcher lid, remove the bags and dump them,
Figure 4-1.
Return the bags to the catcher assembly, making sure that the
non-mesh side of the bag is towards the operator, close the
catcher lid and re-hook the elastic latch. Figure 4-1 and Figure
4-2.
Figure 4-1
Figure 4-2
Lid assembly
Bags Mesh side
of bag
Elastic
latch
Frame
edge

4-2 112601_1211
Figure 4-3
Upper
tube
Inlet
tube
Clamp

112601_1211 5-1
MAINTENANCE & STORAGE
Transfer Tube Maintenance
WARNING: Never work on the mower deck when the
engine is running.
WARNING: Clean flammable material from
machine. Prevent fires by keeping engine compart-
ment, top of deck, exhaust area, battery, hydraulic
lines, fuel line, fuel tank and operator’s station
clean of accumulated trash, grass clippings, and
other debris. Always clean up spilled fuel and oil.
The tube and discharge chute should be kept clean and free of
any accumulation of matted clippings or other obstructions.
Occasional clogging may also occur when working in heavy,
wet or matted grass.
WARNING: Prevent objects being thrown and the
accumulation of grass clippings and other debris in
engine compartment by NEVER operating mower
deck unless:
• Both bags are installed.
• Hood is lowered and latched.
• Upper tube is in place on the discharge chute out-
let and on the catcher lid intake tube and
clamped. Figure 5-1 and Figure 5-2
To service the upper tube, remove the tube from the unit. The
tube can be cleaned by using soapy water and washing the
inside of the tube with a pressure washer. Rinse with water.
To clean the bags, hand wash with soap and water; rinse with
clean water.
Storage
When your mower is to set idle for a period of time, scrape
and remove the matted grass material from inside the hood and
clean the bags.
Check for loose or missing hardware, tighten or replace. Also
check for badly worn or damaged parts, consider replacing them
at this time. Touch up chipped paint areas, your dealer has
aerosol spray paint available.
Figure 5-1
Figure 5-2
Upper
tube
Inlet
tube
Clamp
Hoodintake
tube
Clamp
Discharge
chute outlet
Upper
tube

5-2 112601_1211

112601_1211 6-1
Illustrated Parts List
Table of Contents
2 Bag Catcher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Plastic Lid—602603. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Frame Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
42"/46" Deck Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
48" Deck Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
54" Deck Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

6-2 112601_1211
2 Bag Catcher
1
2
6
3
4
5
7
8
8
9