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1. McCULLOCH Service Manual 32cc String Trimmer Power Head NOTE These materials are for use by trained technicians who are experienced in the service and repair of outdoor power equipment of the kind described in this publication and are not intended for use by untrained or inexperienced individuals These materials are intended to provide supplemental information to assist the trained technician Untrained or inexperienced individuals should seek the assistance of an experienced and trained professional Read understand and follow all instructions and common sense when working on power equipment This includes the contents of the product s Operators Manual supplied with the equipment No liability can be accepted for any inaccuracies or omission in this publication although care has been taken to make it as complete and accurate as possible at the time of publication However due to the variety of outdoor power equipment and continuing product changes that occur over time updates will be made to these instructions from time to time Therefore it may be necessary to obtain the latest materials before servicing or repairing a product The company reserves the right to make changes at any time to this publication without prior notice and without incurring an obligation to make such changes to previously published versions Instructions photographs and illustrations used in this publication are for reference use only and may not depict actual m2. back side of the engine has a round steel washer The screw on the carburetor side of the engine cover has no washer 4 6 With the engine cover removed the spark arres tor and muffler are accessible See Figure 4 6 gt Muffler NN NN P NN NN SS Spark arrestor BN Ay Figure 4 6 4 7 The spark arrestor is easily removed for cleaning or replacement using a phillips head screw driver or a nut driver NOTE The spark arrestor consists of a screen a cover and a screw It is available as a kit 13 Figure 4 8 4 9 Rotate the bale upward to liberate the muffler muffler gasket and port gasket See Figure 4 9 Exhaust port Figure 4 9 NOTE The exhaust port provides an ideal win dow into the cylinder to inspect the condition of the piston skirt and the cylinder wall 4 10 Bale fits just beneath the largest cooling fin on the cylinder and hooks into the cylinder Rotate it to unhook it 4 11 Clean the muffler and port if necessary using care not to damage the piston or knock carbon into the cylinder McCulloch 32cc Trimmer 4 12 Install the muffler using a new gasket See Figure 4 12 gt Y gt gt pa a r y a y Figure 4 12 4 13 Install the engine and air filter covers and con nect the high tension lead to the spark plug 5 FUEL SYSTEM Carburetor repair is beyond the scope of this manual but service
3. head Itis used on the straight shaft trimmers and rotates in the opposite direction of the small one 7 f o Single length method Figure 2 5 McCulloch 32cc Trimmer 2 6 Align the arrows on the spool with the arrows on the housing See Figure 2 6 Arrows E marked fg i i ka eng Figure 2 6 2 7 Insert a length of trimmer line through each eye let There are two sheaves for line in the spool separated by a narrow groove The line must enter the narrow groove See Figure 2 7 Center groove Figure 2 7 2 8 From the eyelet the line will be channeled up under the bump knob by a set of ramps in the spool See Figure 2 8 Ramps Bump knob removed for clarity 4 Bump knob Figure 2 8 2 9 The ends of the line are looped through the anchors to hold them in place then pulled tight NOTE With the arrows aligned the line can also be installed from the inside out by removing the bump knob 2 10 The final step is to rotate the spool in the direc tion indicated by the arrows drawing the line into the head See Figure 2 10 AA Inset arrow on spool marked for clarity Figure 2 10 2 11 Stop winding when each end of the line is about 6 long 2 12 Press the bump knob and pull on the line to manually test the trimmer head Do not push the housing off it s seat while testing 2 13 If repair is required remove the bump knob and
4. information is available from Walbro and Zama the manufacturers whose carburetors are used on McCulloch products 5 1 The fuel filler cap contains a polymer stone tank vent If it becomes blocked the tank may pressurize when heat soaked flooding the engine 5 2 The opposite situation may occur if the engine is run with a blocked tank vent Air will be unable to enter the tank to replace the fuel that is con sumed by the engine This will create a vacuum and fuel starvation will occur See Figure 5 2 ICCULLOCIHA 32cc GAS POWERHEAD 0097 330321 3303AX PRIMER CHOKE AMORCEUR ETRANGLEUR gt CEBADO AHOGADOR 4 14 Test run the unit before returning it to service NOTE The engine can be test run briefly with the muffler removed Hearing protection is strongly suggested Extended running 30 sec onds or more is not recommended without the engine cover and muffler in place primer Figure 5 2 5 3 The air filter cover is easily removed using aT 25 driver See Figure 5 3 Figure 5 3 14 McCulloch 32cc Trimmer
5. starter pawls on the flywheel are worn or damaged remove the flywheel See Figure 3 33 Spacer Nut Flywheel Figure 3 33 NOTE In particular look for rounded edges on the corners of the pawls that engage the teeth on the pulley McCulloch 32cc Trimmer 3 34 Remove the spacer and tube from the crank shaft 3 35 Remove the nut from the crankshaft using a deep 11 16 socket See Figure 3 35 Tube Spacer Crankshaft Nut 3 36 Pry up on one thick section of the flywheel and strike the opposite side with a soft dead blow hammer See Figure 3 36 Threads for clutch rotor Figure 3 36 3 37 Lift the flywheel off of the crankshaft using cau tion not to lose the flywheel key 3 38 If the flywheel has any chips cracks or broken vanes discard it Re using a damaged flywheel presents a burst hazard 10 3 39 If the pawls are damaged they are available as a pair with mounting hardware in kit form See Figure 3 39 E y gt ad b yA gt I 7 5 a in A Figure 3 39 3 40 Release the retainers on the back side of the fly wheel to remove the starter pawls See Figure 3 40 Pawl i in ers NS gt E y Ay pee DR Es e e f Figure 3 40 3 41 After replacing the pawls or the flywheel care fully seat the key and flywheel back on the crankshaft 3 42 Install the nut and torque it to xx in Ibs then place the spacer and tube ba
6. 3 Secure the clutch housing to the starter housing Position the throttle cable and stop switch wires as they were in Figure 3 11 Insert the white plastic sleeve into the grip Connect the carburetor end of the throttle cable then assemble the throttle trigger housing Install the power head on the boom 12 4 EXHAUST If the fuel oil mixture is too rich the exhaust port and muffler may accumulate deposits of carbon These deposits will hinder high R P M engine performance and increase operating temperatures Eventually they may lead to a no start situation There is a character istic flat tone to the exhaust noise that accompanies a blocked exhaust 4 1 The engine cover must be removed to gain access to the muffler See Figure 4 1 Air filter cover Engine cover Figure 4 1 4 2 Disconnect the high tension lead form the spark plug 4 3 Remove the air filter cover using a T 25 driver See Figure 4 3 QP Engine gt cover screw Air filter Figure 4 3 4 4 This will allow access to the screw that secures the carburetor side of the engine cover 4 5 Remove the three screws that secure the engine cover using a T 25 driver See Figure 4 5 McCulloch 32cc Trimmer 4 8 The muffler can be easily removed by unhooking the spring and bale that retain it See Figure 4 8 Figure 4 5 NOTE the screw on the exhaust side of the engine has a plastic washer The screw on the
7. ck over the crank shaft McCulloch 32cc Trimmer 3 43 Removing the starter housing will also allow 3 46 As the starter housing goes on connect the access to the ignition module If the ignition short lengths of stop switch wire that are inside module is removed for any reason the air gap the starter housing to the ignition module and must be adjusted with the flywheel securely fas clip the throttle cable into the hole in the engine tened See Figure 3 43 case See Figure 3 46 Male spade arming vw AS ES gt for stop switch wires Ae Figure 3 43 Figure 3 46 3 44 Set the air gap to 014 using a non magnetic 3 47 Secure the starter housing to the engine feeler gauge 3 48 Install the clutch rotor and drum 3 45 After the starter is assembled carefully position See Figure 3 48 the starter housing throttle cable and stop switch wires and install the starter housing to the engine See Figure 3 45 Stop switch wire Throttle cable N dl gt 4 T N Figure 3 48 Figure 3 45 11 McCulloch 32cc Trimmer 3 49 3 50 3 51 3 52 3 53 3 54 Connect the stop switch wires in the clutch hous ing to the male spade terminals on the ends of the stop switch wires in the starter housing and position the throttle cable as the clutch housing is lowered into place See Figure 3 49 Figure 3 49 NOTE The wires and cable should be posi tioned as they were in Figure 3 1
8. odel and component parts Copyright 2005 MTD Products Inc All Rights Reserved MTD Products LLC Product Training and Education Department PRINTED IN USA FORM NO 769 00942 10 2003 McCulloch 32cc Trimmer 1 INTRODUCTION 2 3 Another trimmer head that is used on McCulloch North American distribution rights to the McCulloch pe ill ells AO te product line are new to MTD for the 2004 season The Cohesd p P See Fjaure 2 3 P trimmers are similar in some ways to the MTD South g li West RYOBI products that we have offered for the past three years The architecture of both units is based on a cantilever crankshaft The McCulloch is piston ported while the MTDSW engine has a reed valve Some of the service techniques are similar but not identical 2 TRIMMER HEADS 2 1 One trimmer head available on the McCulloch products is nearly identical to the MTDSW Tap N Go The operating principle is the same but the parts are different enough that they are not fully interchangeable See Figure 2 1 N cCulloch trimmer head with simplified loading McCulloch versio of small tap n s a Figure 2 3 2 4 A refill consists of 15 20 of 080 trimmer line 2 5 To install line cut it to length Two equal length half portions may be used or one full length line may be installed then trimmed after installation N See Figure 2 5 Figure 2 1 2 2 There is also a McCulloch version of the large tap n go
9. s ing can be removed 3 20 Take out the four screws holding the starter housing to the engine using a T 25 driver See Figure 3 20 Figure 3 20 McCulloch 32cc Trimmer 3 21 3 22 Unplug the stop switch wires from the ignition module as the starter housing is removed from the engine See Figure 3 21 Stop switch wires Starter housing Figure 3 21 NOTE There are two sets of stop switch wires The set inside the starter housing connects to the ignition module The set of stop switch wires in the clutch housing connects the set inside the starter housing to the stop switch The throttle cable is best left in the starter hous ing as it is removed This can be done by simply rotating the starter housing out of the way See Figure 3 22 Starter housing removed Throttle cable Figure 3 22 3 23 Alternatively the throttle cable could be discon nected from the engine by squeezing the tabs and removing it along with the starter housing See Figure 3 23 eeze tabs Figure 3 23 NOTE If a throttle cable needs replacement attach a line to the carburetor end of the old cable before removal to facilitate fishing the replacement cable into place 3 24 Remove the baffle from the starter housing using a 1 25 driver NOTE The starter pulley is held in place by the baffle There are no other fasteners on it 3 25 Once the baffle is removed the starter pulley can be carefully lifted ou
10. s grip and Throttle housing to boom Positioning mark Figure 3 2 3 3 3 4 Air filter cover To separate the powerhead from the boom remove the screw at the top of the grip using a T 25 driver then withdraw the boom See Figure 3 3 Trigger housing and grip slip off of boom ra Screw removed Figure 3 3 Remove the air filter cover using a T 25 driver to gain access to the connection between the throt tle cable and the throttle arm on the carburetor See Figure 3 4 wcoULLocH 2cc GAS POWERHEAD 9097 330321 3303AX PRIMER I AMORCEUR ETRANGLEUR gt CEBADO AHOGADOR Figure 3 4 3 5 Disconnect the throttle cable from the carburetor by unhooking the Z fitting at the carburetor end of the cable See Figure 3 5 1 iw Vi Throttle arm on carburetor nr E E gt Z fitting on end of throttle cable Figure 3 5 3 6 After the powerhead is separated from the boom and the throttle cable is slackened the housing that contains the stop switch and throttle trigger can be separated from the grip NOTE Alternatively instead of removing the complete powerhead and grip from the boom the clutch housing can be separated from the starter housing Ifthis approach is taken the stop switch wires must be disconnected as the two sections are separated The throttle cable will pull out of the starter housing and clutch housing as the powerhead is removed Because of the difficul
11. t to access the recoil spring See Figure 3 25 EN E wires Figure 3 25 NOTE If the starter rope is not broken it will be necessary to relieve tension from it before removing the starter pulley 3 26 Examine the pulley and spring for wear and damage Look for straightened ends on the spring Look for rounded edges on the teeth of the starter pulley See Figure 3 26 Starter pulley y Spring cover Figure 3 26 3 27 When installing new starter rope use about 6 of 3 16 starter rope 3 28 After the starter pulley is removed the starter spring can be lifted out of the starter housing complete with the steel cartridge that contains it See Figure 3 28 Starter spring in cartridge Notches Me 9 end of spring Plastic shield 15720 Figure 3 28 3 29 There is a plastic shield that fits between the starter pulley and the starter spring McCulloch 32cc Trimmer 3 30 As the starter is reassembled apply a sparing amount of white lithium grease to the friction sur faces of the starter pulley 3 31 Pay close attention to the routing of the stop switch wires 3 32 Wind tension onto the starter rope after the pul ley is in place but before the baffle is installed It will be necessary to use caution nut to pull upward on the rope dislodging the pulley from the spring Light thumb pressure on top of the pulley is advised See Figure 3 32 Figure 3 32 3 33 If the
12. ty of routing the throttle cable back through the housings a wire or string should be connected to the z fitting so that the throttle cable can be fished back into place McCulloch 32cc Trimmer 3 7 Remove the two screws from the trigger housing cover using a T 15 driver See Figure 3 7 Stop switch Trigger housing cover screws Trigger housing Trigger housing cover Figure 3 7 3 8 Push the front part of the housing forward to remove it See Figure 3 8 Grip Trigger housing slips out of grip Stop switch contacts Stop switch mounted on cover plate Figure 3 8 3 9 The throttle trigger will be released from its pivot point and the stop switch will remain with the rear portion of the housing NOTE The stop switch contacts two rub strips to ground out the ignition module One rub strip is connected to the primary windings of the mod ule the other leads to ground McCulloch 32cc Trimmer 3 10 The trigger housing can be pulled free of the grip 3 12 The grip and clutch housing can be separated after the trigger and rear housing are removed from the engine by removing the four screws See Figure 3 10 that fasten them together using a T 25 driver Channel for stop switch wire 3 11 Channel for throttle cable Figure 3 10 NOTE The throttle cable and stop switch wires are held in adjacent channels by a white plastic sleeve that is inserted in the grip Pull the white sleeve o
13. ut of the grip and unplug the stop switch wires from their connections to the contact strips in the trigger housing See Figure 3 11 Remove sleeve Figure 3 11 See Figure 3 12 Clutch housing Starter housing NOTE The grip is integral with the clutch housing Figure 3 12 3 13 Remove the grip and clutch housing and unplug the stop switch wires from their connections on the engine See Figure 3 13 yp Channel for stop P switch wires Channel for throttle cable Figure 3 13 NOTE Pay attention to the routing of the throttle cable and stop switch wires 3 14 Disconnect the H T lead from the spark plug and remove the spark plug using an 5 8 wrench 3 15 Pack the cylinder full of starter rope to act as a piston stop 3 16 Remove the clutch drum using a T 25 driver See Figure 3 16 Clutch drum Figure 3 16 3 17 After the clutch drum is removed the clutch rotor can be removed using MTDSW clutch removal tool 791 180919 See Figure 3 17 Crankshaft Throttle cable Clutch REAN Spade terminals or stop switch wires Figure 3 17 NOTE a hammer and soft drift can be used if the MTDSW tool is unavailable McCulloch 32cc Trimmer 3 18 The flat side of the clutch rotor seats against a tube that surrounds the crankshaft See Figure 3 18 Flat side of clutch rotor faces starter housing Figure 3 18 3 19 With the clutch rotor removed the starter hou
14. withdraw the spool See Figure 2 13 Ratchet wedges Figure 2 13 2 14 Check for tangled line damaged tabs on the spool worn ribs on the spool missing spring broken ratchet wedges 2 15 Replace the spool if it is worn or damaged NOTE Bump knobs are a wearable item and are replaced in the course of normal use 2 16 The housing is not fastened to the boom It sim ply rests over a hexagonal drive collar See Figure 2 16 Drive collar Figure 2 16 McCulloch 32cc Trimmer 2 17 The ratchet wedges can be serviced by remov ing the three screws holding the black cover to the top of the housing See Figure 2 17 Small springs behind Holes for screws Cover Figure 2 17 2 18 Carefully remove the springs and pull out the wedges See Figure 2 18 Figure 2 18 McCulloch 32cc Trimmer 2 19 When properly installed the wedges should be spring loaded They retract when the ribs on the back of the spool pass them then extend to keep the spool from rotating backwards See Figure 2 19 3 2 Figure 2 19 RECOIL STARTER Next to the cutting head this is probably the most common service item on the trimmer It is similar in principle to the MTDSW starter but the routing of the throttle and stop switch cables necessitates a slightly different approach The throttle trigger stop switch and grip can all be removed from the boom in unit with the power head See Figure 3 2 Screw hold
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