FECON Field Campaign: FC-082 BULLHOG FUSION UPDATE

Document Information

• Campaign ID: FC-082
• Subject: Bullhog Fusion Controller Mounting System Update
• Models Affected: All Bullhog Fusion mulchers (BH74 Fusion, BH85 Fusion)
• Serial Numbers Affected:
BH74 Fusion: 00BH074015283 through 00BH074015804
BH85 Fusion: 00BH085011295 through 00BH085011408
• Issue Date: 06/23/2025
• Termination Date: 12/23/2025
• Location: FECON, LLC – 3460 Grant Drive, Lebanon, OH 45036

Issue Description

FECON has identified a need to update the controller mounting system on the Bullhog Fusion mulchers. Furthermore, this field campaign details the replacement of the existing controller mounting assembly with an improved mounting system. Additionally, this update includes updated hardware and components for enhanced reliability and performance.

Warning

Before proceeding with this update, proper installation procedures must be followed to prevent damage to controllers. Moreover, it is critical to use the proper hardware for each component. Otherwise, incorrect hardware can cause damage to the controllers.

Required Parts

To complete this field campaign successfully, the following parts are required:

For Fusion mulchers with FGT rotor

First, order (1) FC-082-FGT Kit which includes:

• 010-83-001 Controller weldment (qty 1)
• 010-55-007-01 Fusion Controller, FGT rotor (qty 1)
• 010-81-128 Cover (qty 1)
• 074-49-321 Fusion Update Hardware Kit (qty 1)
• 010-55-012-01 Capacitor jumper (qty 1)
• 60166-1 Isolators (qty 4)
• 010-85-014 Standoff spacer (qty 4)
• 010-81-179 Controller spacer (qty 2)

For Fusion mulchers with DCR rotor

Similarly, order (1) FC-082-DCR Kit which includes:

• 010-83-001 Controller weldment (qty 1)
• 010-55-007-02 Fusion Controller, DCR rotor (qty 1)
• 010-81-128 Cover (qty 1)
• 074-49-321 Fusion Update Hardware Kit (qty 1)
• 010-55-012-01 Capacitor jumper (qty 1)
• 60166-1 Isolators (qty 4)
• 010-85-014 Standoff spacer (qty 4)
• 010-81-179 Controller spacer (qty 2)

Time Estimate

Once you have gathered all required parts, repair completion should not exceed 1 hour.

Warranty Procedure

After completing the repair, dealers must follow these warranty steps:

• First, dealers must place an order for the Update Kit and submit a warranty claim for parts and labor
• Next, a separate warranty claim must be submitted for each serviced unit
• Also, all warranty claims should include detailed information about repairs performed
• Finally, for questions or assistance, contact the FECON service department

Repair Procedure

Now that you have the required parts and understand the warranty process, follow these detailed repair steps:

Tools Required

First, ensure you have the following tools ready:

• Socket wrenches
• Torque wrench
• Basic hand tools

Safety Warning

Before beginning any work, use caution when doing service work on Bullhog Fusion mulchers. Additionally, check the Operation-Maintenance and Service manuals for your machine. Furthermore, review complete safety information before starting work.

Controller Removal and Preparation

To start the repair process, follow these initial steps:

1. First, open the top covers of the Bullhog to access the drive motor and Fusion components
2. Next, remove the cover bolts to access the controllers
3. Then, locate the capacitor attached to the controller cover and unplug from the main harness
4. After that, install the capacitor jumper (part # 010-55-012-01) into the harness
5. Subsequently, remove the capacitor from the cover and discard
6. Following this, unplug the RCU telematic controller
7. Then, remove the (4) bolts from the mounting plate to allow clearance to unplug the Fusion controller
8. Once the mounting plate is loose from the body, remove the RCU telematics unit
9. Next, leave the Fusion Controller attached to the mounting plate and return to FECON
10. Finally, discard all of the original hardware

New Controller Installation

After completing the removal process, proceed with installing the new controller:

11. First, locate the new controller mounting plate (part # 010-83-001) with the new Fusion Controller pre-installed
12. Then, use hardware packets A and B to attach the RCU unit to the new controller mounting plate
13. Next, locate the mounting spacers (part # 010-81-179) and install between the mounting plate and the bulkhead plate of the mulcher
14. Additionally, check the orientation of the spacers – the straight edge should be to the outside
15. Following this, separate the 2-piece bushings and install the metal sleeve through the mounting plate
16. Then, install the top half of the bushing over the metal sleeve from the front of the mounting plate
17. Subsequently, torque the mounting plate bolts to 37 ft/lbs.
18. After that, connect the harness to the RCU and controller
19. Next, install the mounting plate to the mulcher bulkhead using hardware packs C, E and F
20. Finally, note: Hardware pack D is not used on the Bullhog Fusion mulchers – discard this pack

Final Assembly

Once the new controller is properly installed, complete these final assembly steps:

21. First, install the antenna wires into the colored ports in the RCU:
o Blue wire into Blue port
o Purple wire into Purple port
22. Then, install the controller cover (part # 010-81-128) and torque to 37 ft/lbs.

Final Steps

Finally, reverse disassembly steps to restore the machine to operating condition and complete the repair. Additionally, ensure all covers are properly secured and all connections are tight.

Technical Support

If you need help during this process, contact FECON service department at:

• Phone: 800.528.3110
• Email: service@fecon.com
• Website: www.fecon.com

SEO Keywords

FECON Bullhog Fusion, controller mounting system update, BH74 Fusion, BH85 Fusion, FC-082 field campaign, controller weldment replacement, RCU telematic controller, Fusion controller update, mulcher repair, FECON service kit.

Additionally, this update helps with units not completing the learn cycle.