Excel Two Bag Catcher 48/54/60 Decks Operator’s Manual
Excel Two Bag Catcher48"/54"/60" DecksOperator’s Manual200 South Ridge Road Hesston, Kansas 67062119651REV D
REV D119651
Table of ContentsGeneral Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1To the New Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Using This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Warranty Registration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Parts and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11-11-11-1Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Safe Operation and Service Precautions . . . . . . . . . . . . . . . . . . 2-1Safety and Instruction Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Assembly Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Vacuum Pickup and Collection. . . . . . . . . . . . . . . . . . . . . . . . . .Unloading the Catcher Bags . . . . . . . . . . . . . . . . . . . . . . . . . . .Transporting Mower With Catcher . . . . . . . . . . . . . . . . . . . . . . .Converting To Side Discharge Mode . . . . . . . . . . . . . . . . . . . . .4-14-24-24-2Maintenance & Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1Two Bag Catcher Warranty Policy. . . . . . . . . . . . . . . . . . . . . . . . . . 6-1Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1119651toc-1REV D
REV Dtoc-2119651
GENERAL INFORMATIONTo the New OwnerWarranty RegistrationThe purpose of this manual is to assist owners and operatorsin maintaining and operating the Excel Two Bag Catcher. Pleaseread it carefully; information and instructions furnished can helpyou achieve years of dependable performance.Your Excel Dealer must register the unit on-line within ten(10) days following date of purchase to validate your warrantyprotection. As the new equipment owner, you should confirmthat your Excel Dealer has registered your catcher with ExcelIndustries, Inc.IMPORTANT: Any unauthorized modification, alteration,or use of non-approved attachments voids the warranty andreleases Excel Industries, Inc. from any liability arising fromsubsequent use of this equipment. Do not use or operate anyattachment not approved by Excel Industries, Inc.Using This ManualGeneral operation, adjustment and maintenance guidance isoutlined for both the experienced and novice Excel user.Operating conditions vary considerably and cannot all beaddressed individually. Through experience, however, operatorsshould find no difficulty in developing good operating skillssuitable to most conditions.Directions used in this manual, for example RIGHT or LEFT,refer to directions when in operator position and facing forward,unless otherwise stated.Photographs and illustrations used were current at the time ofprinting, but subsequent production changes may cause yourmachine to vary slightly in detail. Excel Industries, Inc. reservesthe right to redesign and change the machine as deemednecessary, without notification. If a change has been made toyour machine which is not reflected in this operator’s manual, orthe parts manual, see your Excel Dealer for current informationand parts.119651Parts and ServiceUse original Excel replacement parts only. These parts areavailable through your local Excel Dealer. To obtain prompt,efficient service, always provide the following informationwhen ordering parts:1. Correct part description and number, as given in the partsmanual supplied with your owner’s packet.2. Correct model number.All warranty repair and service must be handled through anauthorized Excel Dealer. Arrangements should be made throughyour local service center.1-1REV D
REV D1-2119651
SAFETY PRECAUTIONS This safety alert symbol is used to call attention to a messageintended to provide a reasonable degree of PERSONALSAFETY for operators and other persons during the normaloperation and servicing of this equipment. DANGER – denotes immediate hazards which WILL result insevere personal injury or death. WARNING – denotes a hazard or unsafe practice which COULDresult in severe personal injury or death. This manual uses two other words to highlight information.IMPORTANT calls attention to special mechanical informationand NOTE emphasizes general information worthy of specialattention.All operators and mechanics should read this manual, and beinstructed about safe operating and maintenance procedures. Ifthe operators or mechanics cannot read and understand English,it is the owner’s responsibility to explain this material to them.Improper use or maintenance by the operator or owner canresult in injury. To reduce the potential for injury, comply withthese safety instructions and always pay attention to the safetyalert symbol “ ”, which means DANGER or WARNING “personal safety instructions.” Failure to comply with theinstructions may result in personal injury or death.Incorrect usage of this attachment may result in severeinjury. Personnel operating and maintaining it should betrained in the proper use and should read the manualscompletely and thoroughly before attempting to set-up,operate, adjust, or service this mower.Safe Operation and Service Precautions All operator’s should be familiar with the mower’s operator’s manual, particularly the operational and safetyinstructions contained in this manual. Evaluate the terrain to determine what accessories andattachments are needed to properly and safely performthe job. Only use accessories and attachments approvedby 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 oper1196512-1 ator’s seat for any reason including emptying the catcherbags or unclogging the chute.Always be aware of any obstructions, especially smallchildren, when backing or unloading the bags.Always keep safety shields and covers in place, exceptfor servicing.Never work on mower deck when the engine is running.Never operate machine with the catcher lid in the raisedposition except for unloading.Never attempt high speed maneuvering in crowded orcongested areas.Always be aware that the catcher hangs off the rear of themower, thereby increasing the length of the mower. Usecaution when backing up or turning when the catcher ismounted to the mower.When the catcher is used, any rapid movement of thecontrol levers in either direction could result in a reactionof the mower that can cause serious injury.Always operate with complete catcher system, mulchingsystem or side discharge chute in place and in the lowestposition.Never operate the mower with the catcher systeminstalled without the bags being properly installed andthe catcher lid in the lowered position.Always keep clear of the mower blades and attachmentsduring their operation.Turn off blades when not mowing.Stop the engine before removing the grass catcher orunclogging the discharge chute. Never clear the dischargechute with the engine running. Turn off the engine and besure the blades have stopped before cleaning. Use a stickto clear a plugged discharge area. Never use your hand!Clean flammable material from machine. Preventfires by keeping engine compartment, exhaust area,battery, fuel line, fuel tank and operator’s stationclean of accumulated trash, grass clippings, and otherdebris. Always clean up spilled fuel and oil.Grass collection system components are subject to wear,damage and deterioration, which could expose movingparts or allow objects to be thrown. Frequently checkcomponents and replace with manufacturer’s recommended parts when necessary.Never direct discharged material toward anyone. Avoiddischarging material against a wall or obstruction. Material may ricochet back towards the operator. Always disengage the blades and wait for them to stop beforecrossing gravel drives, walks or roads.Safety and Instruction DecalsThe decals are designed to give the operator brief informationneeded in the daily operation and service of the mower. Thesedecals are not intended to be used in place of this manual butinstead are to be used as an extension of this manual. Thesedecals should not be removed or obliterated. Replace thesedecals if they become unreadable.REV D
A brief explanation, for those requiring one, is shown to help theoperator understand the meanings of these decals. It is the owner’s responsibility to make certain that theoperators and mechanics read and understand this manualand all decals before operating this mower. It is also the owner’s responsibility to make certain thatthe operators and mechanics are qualified and physicallyable individuals, properly trained in the operation of thisequipment. All operators and mechanics must become familiar withthe safe operation of the equipment, operator controlsand decals. Never let children or untrained people operate or servicethe equipment. Local regulations may restrict the age ofthe operator. The owner/user can prevent and is responsible for accidents or injuries occurring to themselves, other people orproperty. The owner should also ensure that the operators/mechanics know that they are responsible for their own safety aswell as the safety of other persons within the vicinity.Remember, the operator is responsible for accidents orhazards occurring to other people or their property. Read Operator’s Manual and Safety Warning Decals beforeattempting to operate this machine. Under normal usage this bag material is subject to deterioration and wear, and should therefore be frequently checked forbag replacement.WARNINGSpecific safety warning decals are located on the equipment near the immediate areas of potential hazards. Thesedecals should not be removed or obliterated. Replacethem if they become non-readable.Refer to the mower’s operator’s manual for illustrationsshowing the various safety decals that are located on the mower.WARNING:Thrown objects! Never operate the mower deck with sidedeflector damaged, altered, removed orin raised position, except when theentire grass catcher attachment ormulching system is being used.DANGER:Rotating blades, pulleys & belts 604221Part Number 604221REV D2-2 Keep shields and covers inplace while machine is in operationKeep hands, feet and clothingaway from rotating pulleys andbelts.119651
ASSEMBLY INSTRUCTIONParts ListThese instructions apply to the assembly of the ExcelTwo Bag Catcher to an Excel 48", 54" or 60" mower.It is intended that these units be installed by trained Excelservice personnel. If additional assistance is required, contactthe Excel Customer Service Department.Directions given in these instructions, for example left andright, refer to direction while seated on the mower.Before proceeding, read through the following instructions tofamiliarize yourself, while at the same time identify andinventory kit parts supplied.Unpack and inspect all parts. Notify carrier of any shippingdamages immediately.PART NO.DESCRIPTIONQTY.N/A2 BAG LID1N/ACATCHER CHUTE1N/A1.6 BUSHEL BAG2BLADE, 16.50"-CAT-F-CW (48" DECK)1796649BLADE, 18.50"-CAT-F-CW (54" DECK)1602416BLADE, 20.50"-CAT-F-CW (60" DECK)1793935117394CATCHER FRAME1604387UPPER CHUTE1604301TIE ROD2117303LS SUPPORT GUSSET1117304RS SUPPORT GUSSET1029629CAP SCREW (CS) .375-16 X .75 HX FLK 6016899NUT .375-16 HX FLK ZNYC6086660NUT .375-16 HX ZY NL2023036HAIR PIN .148 X 2.69 ZN2604887CE .375 x 3.00 WITH BALE2604806PLASTIC CAP - TANK1000331WIRE TIE2120864LATCH SUPPORT1025395CB .375-16 X 1.00G5 ZNY4054502NT .375-16 HX G5 ZNY4068551NT .25-20 HX ZY NL1604475ELASTIC STRAP1704916CS .25-20 X 1.25 HX G51767954FW .379 X .813 X .063 SAE4768515FW .281 X .625 X .051/.080 HD ZN/YL2Required ToolsThe following is a list of the tools required to assemble thecatcher to the mower. Tape measure One 3/8" combination wrench or socket Two 9/16" combination wrench or socket Torque wrench (with 118 Ft.-lb. range) with a 15/16" hexsocketNOTE: Refer to the Parts Manual section (starting on page 71) of this manual for more detailed parts information.AssemblyNOTE: Refer to illustrated parts listings when assembling theunit.WARNINGAllow engine and muffler to cool before assembling thecatcher to the mower.1196513-1REV D
4. Remove the jack stands and lower the mower.5. Remove the tie rods from the catcher frame. The tie rodsare embedded with the catcher frame for shippingpurposes only.6. Attach the catcher frame to the rear of the mower. Do nottighten the mounting bolts at this time. Figure 3-2NOTE: Some mower models have a taller rear engineguard. If a catcher is being attached to one of these models, it will be necessary to remove the engine guard. Figure 3-3WARNINGNever work under the machine or attachment unless it issafely supported with jack stands. Make certain machineis secure when it is raised and placed on the jack stands.The jack stands should not allow the machine to movewhen the engine is running and the drive wheels are rotating. Use only certified jack stands. Use only appropriatejack stands, with a minimum weight rating of 2000pounds to block the unit up. Use in pairs only. Follow theinstructions supplied with the vehicle stands.1. Park the mower on a flat surface. Always place the deckclutch switch in the disengaged position, place thesteering control levers in the park brake position, shut offthe ignition switch and remove the key from the switch.Disconnect the negative battery cable.2. Raise the front of the mower and deck up until the bladescan be accessed easily. Place the mower on jack standsand do not allow the mower to move. Chock the rearwheels.BladeExistinghardwareWARNINGTorque to118 Ft.-lbs.Mower blades are sharp and can cut. Wrap the blade(s) orwear gloves and use extra caution when servicing them.Figure 3-13. Remove the right side blade and replace it with the newblade. The catcher is provided with one blade for eachdeck size. Use the appropriate blade as indicated by thelabel on the blade and discard the other blades. Figure 3-1Torque 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-usedwhen the mower is converted back to the side dischargemode.7. Raise the seat platform.8. Unbolt the mower’s fenders from the mower frame.There are four bolts per fender that will need to beremoved. Figure 3-5This allows the fenders to be moved to provide access tothe mower frame. It is not necessary to remove thefenders from the mower.NOTE: It will be necessary to unscrew the fuel cap fromthe fuel tank fill neck and slide the plastic cap over the fillneck opening. The plastic cap will slide over the fuelcap’s tether line. This will allow the left fender to moveenough to allow access to the hole in the mower frame.Figure 3-4WARNINGFailure to correctly torque the bolt may result in the lossof the blade which can cause serious injury.REV D3-2119651
Hair pinCatcher frameMowerframeView AKeyholeTie rodFendersupportbracketNut .375-16HXFLKSupportgusset RHNut .375-16 NYLKSupportgusset RHRefer toView ACap Screw .375-16 x .75Nut .375-16 HXFLKSupportgusset RHCap Screw .375-16 x .75Figure 3-2Tall engineguardFigure 3-31196513-3REV D
WARNINGFill neckFuel capWhen performing this step heed the warnings listedbelow: Do not smoke while the fuel cap is not properlysecured to the fuel tank fill neck. Extinguish all cigarettes, cigars, pipes and other sources of ignition. Use extreme care when handling gasoline which isextremely flammable and vapors are explosive. Afire or explosion from fuel can burn you and othersand can damage property. Do not remove the fuel cap with engine runningor while engine is hot. Clean up any fuel spills. If fuel is spilled on clothing, change clothing immediately.TetherRemove these boltsPlastic capFenderFuel capTetherRemovethis boltFenderFigure 3-5Plastic cap9. Attach the support gussets to the mower frame. The slotsin the support gussets must align with the keyhole slots inthe fender support bracket. Assemble the hardware asshown with the cap screw inserted from the bottom.Figure 3-2 View AIMPORTANT: Be sure not to cut or pinch the fuel linewhen installing gussets.10. Thread a .375-16 nylon locking nut onto each of the tierods to the dimension shown in Figure 3-2 & Figure 3-6FenderTie rodFuel tankFigure 3-4Nut .375-16 NYLK1” 1/16”(19mm)NOTE: It is not necessary to remove the control panelfrom the right fender. There should be sufficient access tothe frame with the fender loose.Figure 3-611. Insert one tie rod through the key hole slot in the fendersupport bracket and into the slot in the support gusset.REV D3-4119651
Make sure the nut on the tie rod is inserted through theslot in the support gusset. Figure 3-2 & Figure 3-6The nut end of the tie rod can be easily inserted throughthe upper end of the slot if positioned horizontally thenangled upwards after the nut clears the support gusset.Figure 3-2 & Figure 3-6IMPORTANT: Be certain that the nut does not catch orpinch the vapor line.Then, insert the tie rod through the proper hole in thecatcher frame and secure with a hair pin. Figure 3-2Repeat for the other side.12. Push down on the catcher frame and tighten the lowerframe bolts. Pushing down on the catcher frame whiletightening these bolts will provide the correct tension onthe tie rods. Figure 3-713. Secure the vapor lines using the zip ties as shown. Youmust secure the vapor lines to prevent them from rubbingon the tie rods. Remove the excess zip tie. Figure 3-8 &Figure 3-9IMPORTANT: Make sure the vapor line does notbecome pinched and retains its original routing as itcomes out of the top of the fuel tank. Figure 3-10SupportgussetTie rod & nutVent linePush the catcherframe down hereLeft side vent line - original routingLeft side vent line - new routingTie rod & nutVent lineBracketTighten frame boltsZip tieFuel lineTie vapor line to bracket enough to pullvapor line away from the tie rod threads.Figure 3-814. Re-attach the fenders to the mower frame. Do notovertighten the mounting hardware. Figure 3-5Figure 3-71196513-5REV D
SupportgussetVent lineTie rod & nutZip tieVent lineFuel lineRight side vent line - original routingFigure 3-1016. Attach the latch support to the catcher frame as shown inFigure 3-11.NOTE: If the four (4) mounting holes are not present inthe catcher frame, locate and drill four (4) .406" diameterholes in the frame per Figure 3-11.17. Attach the elastic strap to the latch support. Orientate theelastic strap as shown. Figure 3-11Zip tieVent lineTie rod & nutThrottlecableRight side vent line - new routingFigure 3-915. Remove the plastic cap from the fill neck opening andscrew the fuel cap onto the fill neck. Figure 3-4WARNINGNever operate the mower without the fuel cap threadedtightly onto the fill neck.REV D3-6119651
12.09”12.09”Section A-A.406” dia. holes(4 places)1.21”3.05”NT .375-16A-AFW .379x.813x.063CB .375-16 x 1.00Elastic strapNT .250-20Latch supportCS .250-20 x 1.25FW .281x.625x.0551/.080Figure 3-1118. There is one tab located at the rear side of the deck thatwill need to be bent inward. Use a hammer andscrewdriver to bend the tab inward enough to allow thesteel hooks of the elastic latch on the outl
119651 3-1 REV D ASSEMBLY INSTRUCTION These instructions apply to the assembly of the Excel Two Bag Catcher to an Excel 48", 54" or 60" mower. It is intended that these units be installed by trained Excel
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