Excel Two Bag Catcher User manual

124505 REV A
Excel Two Bag Catcher
48"/54" Decks
Operator’s Manual
200 South Ridge Road • Hesston, Kansas • 67062

REV A 124505

124505 REV A
Table of Contents
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
To The New Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Using This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Warranty Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Parts and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Safe Operation and Service Precautions. . . . . . . . . . . . . . . . . . . . 2-1
Safety and Instruction Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Assembly Instruction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Packing List - Catcher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Vacuum Pickup and Collection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Unloading the Catcher Bags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Transporting Mower With Catcher . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Converting To Side Discharge Mode . . . . . . . . . . . . . . . . . . . . . . . 4-3
Placing the Flip-up Deck in the Service Position . . . . . . . . . . . . . 4-4
Maintenance & Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
2-Bag Catcher Warranty Policy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

REV A 124505

124505 1-1 REV A
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
Dealer warranty registration
Your Dealer must register this attachment on-line within
ten (10) days following date of purchase to validate your
warranty protection. As the new equipment owner, you
should confirm that your Dealer has registered your
attachment with Excel Industries, Inc., manufacturer of
Hustler®Turf Equipment, Inc. and Big Dog®mowers
(“Manufacturer”).
Lowe’s®customer warranty registration
Lowe’s®customers must register this attachment on-line at
http://www.hustlerturf.com/raptor_warranty_registration
within ten (10) days following date of purchase.
IMPORTANT: The mower and any attachment that
displays a model and serial identification number plate must
be registered with Excel Industries, Inc., manufacturer of
Hustler®Turf Equipment, Inc. and Big Dog®mowers
(“Manufacturer”). Failure to register the attachment can void
the warranty.
IMPORTANT: Any unauthorized modification, alteration,
or use of non-approved attachments voids the warranty and
releases Manufacturer and Hustler®Turf Equipment, Inc. or
Big Dog®Mower Company from any liability arising from
subsequent use of this equipment. Do not use or operate any
attachment not approved by Hustler®Turf Equipment, Inc. or
Big Dog®Mower Company.
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.

REV A 1-2 124505

124505 2-1 REV A
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.
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 and mechanics should read this manual, and
be instructed about safe operating and maintenance
procedures.
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 attachment 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 mower.
Safe Operation and Service Precautions
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.
Never use the catcher with Flex Forks®installed on the
mower.
Before proceeding:
•Park the mower on level ground.
•Disengage the deck clutch.
•Place the steering control levers in the park brake
position.
•Stop the engine.
•Remove the ignition key.
•Wait for the engine and all moving parts to come
to a complete stop.
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 the mower deck when the mower’s
engine is running.
Never operate machine with bagger lid in the raised
position except for unloading.
Never attempt high speed maneuvering in crowded or
congested areas.
Always be aware that the catcher hangs off the rear of
the mower, thereby increasing the length of the
mower. Use caution when backing up or turning when
the catcher is mounted to the mower.
When the catcher is used, any rapid movement of the
control levers in either direction could result in a
reaction of the mower that can cause serious injury.
Always operate with complete catcher system,
mulching system or side discharge chute in place and
in the lowest position.
Never operate the mower with the catcher system
installed without the bags being properly installed and
the catcher lid in the lowered position.
Always keep clear of the mower blades and
attachments during their operation.
Turn off the blades when not mowing.
– denotes immediate hazards which WILL result in
severe personal injury or death.
– denotes a hazard or unsafe practice which COULD
result in severe personal injury or death.
DANGER
WARNING

REV A 2-2 124505
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 the machine. Prevent
fires by keeping the 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
recommended parts when necessary.
Never direct discharged material toward anyone. Avoid
discharging material against a wall or obstruction.
Material may ricochet back toward the operator.
Always disengage the blades and wait for them to stop
before crossing gravel drives, walks or roads.
Safety and Instruction Decals
The decals are designed to give the operator brief
information needed in the daily operation and service of the
mower. These decals are not intended to be used in place of
this manual but instead are to be used as an extension of
this manual. These decals should not be removed or
obliterated. Replace these decals if they become unreadable.
•It is the owner’s responsibility to make certain that the
operators and mechanics read and understand this
manual and all decals before operating this mower.
•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 decals.
•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 operators/
mechanics 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.
Refer to the mower’s operator’s manual for illustrations
showing the various safety decals that are located on the
mower. A brief explanation, for those requiring one, is shown
to help the operator understand the meanings of these
decals.
Specific safety warning decals are located on the
equipment near the immediate areas of potential
hazards. These decals should not be removed or
obliterated. Replace them if they become non-
readable.
•Read Operator’s Manual and Safety Warning Decals before
attempting to operate this machine.
•Under normal usage this bag material is subject to deterioration
and wear, and should therefore be frequently checked for bag
replacement.
WARNING

124505 2-3 REV A
WARNING: Thrown objects!
•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.
Part Number 604221
DANGER:
Rotating blades, pulleys & belts
•Keep shields and covers in place
while machine is in operation.
•Keep hands, feet and clothing
away from rotating pulleys and
belts.
604221

REV A 2-4 124505

124505 3-1 REV A
ASSEMBLY INSTRUCTION
These instructions apply to the assembly of the Excel Two
Bag Catcher on the following mowers:
Hustler®Raptor®Flip-Up 48/54
BigDog®Blackjack 48/54
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 through 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.
Required Tools
The following is a list of the tools required to assemble the
catcher to the mower.
•Tape measure
•One 3/8” combination wrench or socket
•Two 9/16” combination wrench or socket
•Torque wrench (with 118 ft.-lbs range) with a
15/16” hex socket
Packing List - Catcher
NOTE: Refer to the Parts Manual section (starting on 7-1) of
this manual for more detailed parts information.
Assembly
NOTE: Refer to illustrated parts listings when assembling
the unit.
NOTE: Do not remove the mower’s discharge chute. The
discharge chute does not need to be removed when attaching
this catcher to the mower.
PART NO. DESCRIPTION QTY.
781567 NT .500-13 NL G5 2
604887 CE .375 X 3.00 WITH BALE 2
N/A CATCHER FRAME 1
029629 CS .375-16 X .75 HX FLK 4
605662 TENSION ROD 2
016899 NT .375-16 HX FLK ZNYC 6
029751 CS .375-16 X 1.00 HX FLK 2
121489 WEIGHT PLATE 2
768523 FW .343 X .687 X .051/.080H 2
036236 CS .312-18 X 1.00 HX G5 2
025395 CB .375-16 X 1.00 G5 ZNY 4
767954 FW 0.379 x 0.813 x 0.063 4
054502 NT 0.375-16 HX G5 4
120864 LATCH SUPPORT 1
604475 BUNGEE LATCH 1
068551 NT .250-20 HX ZY NL 1
704916 CS .250-20 X 1.25 HX G5 1
768515 FW .281 X .625 X .051/.080H 2
552460 CATCHER BAG 2
796649 CATCHER BLADE (48" DECK) 1
602446 CATCHER BLADE (54" DECK) 1
N/A DECK CHUTE 1
552396 CATCHER LID 1
604387 UPPER CHUTE 1
Allow engine and muffler to cool before assembling
the catcher to the mower.
WARNING

REV A 3-2 124505
1. Before proceeding:
•Park the mower on level ground.
•Disengage the deck clutch.
•Place the steering control levers in the park brake
position.
•Stop the engine.
•Remove the ignition key.
•Wait for the engine and all moving parts to come
to a complete stop.
•Disconnect the negative battery cable.
2. Place the deck in the service (flip-up) position. Refer to
the mower’s operator’s manual for more information.
3. Remove the right side blade and replace it with the
new blade. The catcher is provided with one blade for
each deck size. Use the appropriate blade as indicated
by the label on the blade and discard the other blades.
Figure 3-1
Torque blade bolt to 118 ft-lbs (160 N•m).
IMPORTANT: Only use a torque wrench when
tightening and torquing the blade bolts.
NOTE: Retain the original blade as it will be re-used when
the mower is converted back to the side discharge mode.
4. Lower the deck from the service (flip-up) position.
5. Attach the catcher frame to the rear of the mower. Do
not tighten the mounting bolts at this time. Figure 3-2
6. Insert the tension rods through the holes in the
catcher frame and secure in place with the nuts
shown. Figure 3-2
7. Attach the tension rods to the mower frame. Figure 3-2
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. Follow the instructions
supplied with the vehicle stands.
Mower blades are sharp and can cut. Wrap the
blade(s) or wear gloves and use extra caution when
servicing them.
Failure to correctly torque the bolt may result in the
loss of the blade which can cause serious injury.
WARNINGWARNINGWARNING
A. Blade B. Existing hardware
Figure 3-1
A
Torque to
118 Ft.-lbs.
B

124505 3-3 REV A
A. Catcher frame
B. Tension rod
C. Nut .50-13 NL
D. Cap screw .375-16 X .75 HX FLK
E. Nut .375-16 HXFLK
Figure 3-2
A
C
D
B
E
B
E

REV A 3-4 124505
8. Push down on the catcher frame and tighten the lower
frame bolts. Pushing down on the catcher frame while
tightening these bolts will provide the correct tension
on the tie rods. Figure 3-3
NOTE: Check for mower air cleaner access. Adjust the
catcher frame and tension rods as needed for air cleaner
servicing.
9. Attach the latch support to the catcher frame.
Figure 3-4
10. Attach the bungee latch to the latch support.
Figure 3-4
11. There is one tab located at the rear side of the deck
that will need to be bent inward. Use a hammer and
screwdriver to bend the tab inward enough to allow the
steel hooks of the bungee latch on the outlet tube to
be inserted into the slot. Figure 3-5, Figure 3-6 &
Figure 3-7
A. Push frame down here B. Tighten frame bolts
Figure 3-3
B
A
A. Latch support
B. Catcher frame
C. CB .375-16 X 1.00
D. FW .379 X .813
E. NT .375-16 HX
F. Bungee latch
G. CS .25-20 X 1.25
H. FW .281 X .625
I. NT .25-20 HX NL
Figure 3-4
A
I
HF
H
G
C
C
B
DE

124505 3-5 REV A
12. Raise the deck discharge chute to the full up position
(90o) and slide the outlet tube into position.
It will be necessary to force the discharge chute to the
90oposition. The chute will contact the mower fender
before the 90oposition is attained. Push on the
discharge chute until the chute is open enough to allow
the tab of the outlet tube to be inserted into the slot in
the discharge chute bracket of the deck. The downward
spring force of the discharge chute helps to secure the
outlet tube to the deck by locking the bump on the outlet
tube with the cams of the discharge chute. Figure 3-8 &
Figure 3-9
Secure the outlet tube in place with the bungee latches.
Figure 3-5
A. Discharge chute
B. Outlet tube
C. Bungee latch
D. Tab
E. Chute stop
Figure 3-5
A. Tab B. Discharge chute
Figure 3-6
A
D
C
E
B
C
B
A
A. Hammer
B. Screwdriver
C. Tab
Figure 3-7
Outlet Tube Tab Not Installed Correctly
A. Discharge chute
B. Outlet tube tab
C. Discharge chute
bracket slot
Figure 3-8
A
B
C
C
A
B

REV A 3-6 124505
13. Place the bags on the catcher frame by inserting the
bag frame hook into the catcher frame slot.
Figure 3-10
14. Attach the catcher lid to the catcher frame using the
CE .375 x 3.00 with bale pins. Close the catcher lid.
Figure 3-11
NOTE: It is easier for two people to attach the catcher lid
to the catcher frame than it is for one person.
15. Slide the end of the transfer tube into the opening in
the catcher lid. Figure 3-12
16. Attach the transfer tube to the outlet tube by aligning
the slot on the transfer tube with the knob on the
outlet tube and hooking the bungee latch through the
loop of the transfer tube. Figure 3-13 & Figure 3-14
17. Remove the existing hardware from the front of the
mower and attach the weight plate to the front of the
mower using the hardware supplied with the catcher.
Figure 3-15
18. Reconnect the negative battery cable.
Outlet Tube Tab Installed Correctly
A. Discharge chute
B. Ridge on outlet tube
C. Outlet tube tab
D. Discharge chute
bracket slot
E. Cam of discharge
chute
Figure 3-9
Do not operate deck without discharge chute or
complete catcher system, including the weight plate,
in place.
A
B
C
D
E
WARNING
A. Bag
B. Bag frame hook
C. Catcher frame slot
Figure 3-10
A
B
C

124505 3-7 REV A
A. Catcher lid B. CE .375 X 3.00 with bale pin
Figure 3-11
A
B
B

REV A 3-8 124505
A. Catcher lid
B. Transfer tube
C. Bungee latch
D. Outlet tube
Figure 3-12
A. Transfer tube slot
B. Outlet tube knob
C. Bungee latch
Figure 3-13
A
B
C
D
B
A
B
C
A. Transfer tube
B. Bungee latch
C. Outlet tube
Figure 3-14
A. Weight plate (2)
B. FW .281 X .625
C. CS .250-20 X 1.25 HX
G5
Figure 3-15
A
B
C
B
A
B
C

124505 4-1 REV A
OPERATION
Vacuum Pickup and Collection
Follow normal mower start-up and operating procedures as
outlined in the mower operator’s manual. Whenever the deck
clutch switch is engaged there will be debris moving through
the catcher system.
The following list contains useful information when using
the catcher:
•When catching, use the left side of the mower for
trimming to prevent damage to the discharge chute
and outlet tube.
•Catching with the cutting height set too low may
prevent adequate air movement under the deck. This
will cause clogging of the catching system.
•During peak growing times it may be necessary to cut
the grass more often. If the grass is too long it may
need to be cut twice. First, mow the grass with the
cutting height set at a high setting to cut off the upper
parts of the grass. Next, lower the cutting height to the
preferred finished cut height and mow the area again.
This will help reduce clogging.
•To help reduce clogging mow by slightly overlapping
the previously cut area.
•Proceed to mow in the normal manner with the engine
throttle set to the “FAST” position. Control the
mower’s ground speed by using the steering control
levers. In tall and/or wet grass the high engine speed
and slower ground speed will help prevent clogging.
•When catching on slopes mow going downhill when
possible. It is necessary to reduce ground speed when
operating on a slope.
•If debris begins to blow out in front of the outlet tube
or a trail of debris is visible along the right edge of the
cutting path, either the catcher is full or the outlet tube
is clogged.
•As you mow visually check how full the bags are, when
the right bag looks full 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.
•When the grass is wet it may be necessary to mow it
first in the side discharge mode. Then, after the
clippings have dried, go back over the area with the
catcher installed and pick up the clippings.
•To minimize clogging, reduce your mower ground
speed as necessary or wait until there is less moisture
in the grass.
Remember, as the bags fill more weight is added
to the back of the mower. Any rapid movement of
the control levers in either direction could result in
a reaction of the mower that can cause serious
injury.
•Do not stop or start suddenly when mowing
on slopes. Avoid uphill starts.
•Disengage the blades if you stop the mower
when going uphill and proceed to back off
the slope slowly.
•Maintain an even mowing speed when
operating on slopes.
•Do not stop on a slope.
WARNING
Prevent objects being thrown and the accumulation
of grass clippings and other debris in engine
compartment by NEVER operating the mower deck
unless:
• Both bags are installed.
• Catcher lid is lowered.
• Outlet tube is in place and secured on the
discharge chute outlet and deck. Figure 4-1
• Transfer tube is secured in place, with the
three bungee latches, on the outlet tube and is
inserted into the catcher lid. Figure 4-1
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. Be sure blades have stopped before
cleaning the discharge chute and transfer tube
areas.
Never place hands or feet into the discharge area.
The mower blade is relatively close to the housing
and will cause severe injury. Use a probe to clean
debris from the catcher outlet tube.
WARNINGWARNINGWARNING

REV A 4-2 124505
Unloading the Catcher Bags
Get off the mower. Raise the catcher lid and remove the
bag by lifting the bag frame at the rear of the bag and the bag
frame handle. Proceed to dump the bag. Figure 4-2 &
Figure 4-3
Return the bags to the catcher frame and close the catcher
lid. Figure 4-3
Never engage the mower deck unless the catcher
transfer tube is secured in place, with the bungee
latch, on the outlet tube and is inserted into the
catcher lid. Figure 4-1
A. Outlet tube
B. Transfer tube
C. Catcher lid
Figure 4-1
Park the unit on a level surface, disengage 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 disengaged position before unloading.
WARNING
A
B
C
WARNING
A. Catcher lid
B. Bag frame
C. Catcher bag
D. Bag frame handle
Figure 4-2
A. Catcher Frame B. Bag
Figure 4-3
A
B
D
C
A
B