Case IH MC3100PR User manual

operation manual
MC3100PR
MC6500ER
MC9000ER
MODEL NUMBERS
609.702

2
table of contents
Introduction
4 Using the Operators Manual
Product Identification
5 Generator
5 Engine
Safety
6 Safety Rules
6 Hazard Symbols and Meanings
9 Ground Fault Circuit Interrupter Protection
Generator Components
13 3100W Component Chart
14 6500W Component Chart
15 9000W Component Chart
Preparing the Generator
16 Grounding the Generator
Pre-Operation Checklist
17 Engine Oil
17 Fuel
18 General Recommendations
18 Fuel Type
18 Gasoline/Alcohol Blends
18 Gasoline/Ether Blends
18 Check Component Parts
19 Check Generator Surroundings
Starting the Generator
19 Recoil Start
21 Electric Start

3
table of contents
Introduction
4 Using the Operators Manual
Product Identification
5 Generator
5 Engine
Safety
6 Safety Rules
6 Hazard Symbols and Meanings
9 Ground Fault Circuit Interrupter Protection
Generator Components
13 3100W Component Chart
14 6500W Component Chart
15 9000W Component Chart
Preparing the Generator
16 Grounding the Generator
Pre-Operation Checklist
17 Engine Oil
17 Fuel
18 General Recommendations
18 Fuel Type
18 Gasoline/Alcohol Blends
18 Gasoline/Ether Blends
18 Check Component Parts
19 Check Generator Surroundings
Starting the Generator
19 Recoil Start
21 Electric Start
Operation
22 Using Electric Power
22 AC Application
23 DC Application
23 Connection of Cable
23 Safety Precautions While Charging
24 Wattage Information
25 Spark Arrester
25 How To Remove The Spark Arrester
25 Clean The Spark Arrester Screen
Stopping the Generator
26 Stopping the Generator
26 Oil Sensor
Troubleshooting
27 Troubleshooting Chart
Maintenance
28 Maintenance Schedule
28 Daily Inspection
28 Periodic Maintenance
29 Changing Engine Oil
29 Servicing The Air Cleaner
29 Cleaning and Gapping Spark Plug
29 Cleaning Fuel Strainer
29 Periodic Operation and Inspection
Transporting
30 Transporting
Storage
31 Preparation for Storage
Warranty
32 Warranty Statement

4
Using the Operator’s manual
The operating manual is an important part of your generator and should
be read thoroughly before initial use, and referred to often to make sure
adequate safety and service concerns are being addressed.
Reading the owner’s manual thoroughly will help avoid any personal injury
or damage to your machine. By knowing how best to operate this
machine you will be better positioned to show others who may also
operate the unit.
This manual contains information for the complete range of CASE
generators, and was written to take you from the safety requirements
to the operating functions of your machine. You can refer back to the
manual at any time to help troubleshoot any specific operating functions,
so store it with the machine at all times.
Attention: Read through the complete
manual prior to the initial use of your
generator.
introduction

5
product identification
Record Identification Numbers
Generator
If you need to contact an Authorized Dealer or Customer Service line
(1-855-850-6668) for information on servicing, always provide the
product model and identification numbers.
You will need to locate the model and serial number for the machine and
record the information in the places provided below.
Date of Purchase:
Dealer Name:
Dealer Phone:
Product Identification Numbers
Model Number:
Serial Number:

6
The safety alert symbol ( ) is used with a signal word (DANGER,
CAUTION, WARNING), a pictorial and/or a safety message to alert you
to hazards.
DANGER indicates a hazard which, if not avoided, will result in death or
serious injury.
WARNING indicates a hazard which, if not avoided, could result in death
or serious injury.
CAUTION indicates a hazard which, if not avoided, might result in minor
or moderate injury.
NOTICE indicates a situation that could result in equipment damage.
Follow safety messages to avoid or reduce the risk of injury or death.
Hazard Symbols and Meanings
Save these Instructions
Safety Rules
safety
This is the safety alert symbol. It is used
to alert you to potential personal injury
hazards. Obey all safety messages that
follow this symbol to avoid possible
injury or death.
explosion
kickback read manual
fire electric shock
toxic fumes

7
safety
WARNING
Generator exhaust contains carbon monoxide, a
poisonous gas that can kill you.
You CANNOT smell or see this gas.
• Use the generator outdoors, away from open windows, vents, or
doors that could allow the carbon monoxide gas to come indoors.
Keep the generator at least 1 meter (3 feet) away from any structure
or building during use.
• NEVER use a generator indoors, including in homes, garages,
basements, crawl spaces, and other enclosed or partially-enclosed
areas, even with ventilation. Opening doors and windows or using
fans will not prevent carbon monoxide build-up in the home.
• Never use a generator in enclosed or partially-enclosed spaces.
Generators can produce high levels of carbon monoxide very quickly.
When you use a portable generator, remember that you cannot smell
or see carbon monoxide. Even if you can’t smell exhaust fumes, you
may still be exposed to carbon monoxide.
• NEVER operate the generator in an explosive atmosphere, near
combustible materials or where ventilation is not sufficient to carry
away exhaust fumes. Exhaust fumes can cause serious injury or death.
• If you start to feel sick, dizzy, or weak while using a generator, get
to fresh air RIGHT AWAY. DO NOT DELAY. The carbon monoxide
from generators can rapidly lead to full incapacitation and death.
• If you experience serious symptoms, get medical attention
immediately. Inform medical staff that carbon monoxide poisoning
is suspected. If you experienced symptoms while indoors, have
someone call the fire department to determine when it is safe to
re-enter the building.

8
safety
WARNING
Fuel and its vapors are extremely flammable and
explosive.
Fire or explosion can cause severe burns or death.
When Adding or Draining Fuel
• Observe all safety regulations for the safe handling of fuel. Handle
fuel in safety containers. If the container does not have a spout, use
a funnel.
• Do not overfill the fuel tank, leave room for the fuel to expand.
• Do not refill fuel tank while the engine is running. Before refueling the
generator, turn it off and let it cool down. Gasoline spilled on hot
engine parts could ignite.
• Fill the tank only on an area of bare ground. While fueling the tank,
keep heat, sparks and open flame away. Carefully clean up any spilled
fuel before starting engine.
• Always fill fuel tank in an area with plenty of ventilation to avoid
inhaling dangerous fumes.
• NEVER store fuel for your generator in the home. Gasoline, propane,
kerosene, and other flammable liquids should be stored outside of
living areas in properly-labeled, non-glass safety containers. Do not
store them near a fuel-burning appliance, such as a natural gas water
heater in a garage. If the fuel is spilled or the container is not sealed
properly, invisible vapors from the fuel can travel along the ground and
can be ignited by the appliance’s pilot light or by arcing from electric
switches in the appliance.

9
safety
WARNING
The GFCI may not function unless the generator is properly
grounded. Follow the correct procedure specified in the section
labeled GROUNDING INSTRUCTIONS.
Ground Fault Circuit Interrupter Protection
These generators are equipped with a GFCI (Ground Fault Circuit
Interrupters) 120V duplex receptacles for protection against the hazards
of electrical shock from defective attachments such as, tools, cords,
and cables.
A GFCI is a device that interrupts electricity from either the utility or
generator by means of a special type of circuit breaker that determines if
a current flow to the ground occurs.
A GFCI can be used only with generators that have the neutral wire
internally bonded to the frame, and the frame properly grounded to the
earth. A GFCI will not work on generators that do not have the neutral
wire bonded to the frame, or on generators which have not been properly
grounded. All CASE generators have internally bonded ground wires.

10
safety
DANGER
Improper grounding can result in a risk of electrocution.
Check with a qualified electrician for your local
requirements if you are in doubt as to whether the unit
is properly grounded.
This generator is equipped with a grounding terminal for added
protection. Using the ground path from the generator to an
external ground source as instructed in the section labeled “Grounding
Instructions” in the Preparation section of this manual can be
necessary. Please consult a qualified electrician for local regulations.
The generator is a potential source of electrical shock if not kept dry.
Keep the generator dry and do not use in rain or wet conditions. To
protect from moisture, operate it on a dry surface under an open,
canopy-like structure. Dry your hands if wet before touching the
generator.
Plug appliances directly into the generator. Or, use a heavy duty,
outdoor-rated extension cord that is rated (in watts or amps) at least
equal to the sum of the connected appliance loads. Check that the
entire cord is free of cuts or tears and that the plug has all three
prongs,especially a grounding pin.
NEVER try to power the house wiring by plugging the generator into
a wall outlet, a practice known as “back feeding”. This is an extremely
dangerous practice that presents an electrocution risk to utility workers
and neighbors served by the same utility transformer. It also bypasses
some of the built-in household circuit protection devices.
If you must connect the generator to the house wiring to power
appliances, have a qualified electrician install the appropriate
equipment in accordance with local electrical codes.
This product has been designed with internal grounding or floating
bonded neutral. If it should malfunction or breakdown, grounding pro-
vides a path of least resistance for electric current to reduce the risk of
electric shock.

11
safety
• Do not enclose the generator or cover it. The generator may become
overheated if it is enclosed. If generator has been covered to protect if
from the weather during non use, be sure to remove it and keep it well
away from the area during generator use.
• Operate the generator on a level surface. It is not necessary to prepare
a special foundation for the generator. However, the generator will
vibrate on an irregular surface, so choose a level place.
If the generator is tilted or moved during operation, fuel may spill and/or
the generator may tip over, causing a hazardous situation.
Proper lubrication cannot be expected if the generator is operated on a
steep incline or slope. In such a case, piston seizure may occur even if
the oil is above the upper level.
• Pay attention to the wiring or extension cords from the generator to the
connected device. If the wire is under the generator or in contact with
vibrating part, it may break and possibly cause a fire, generator burnout,
or electric shock hazard. Replace damaged or worn cords immediately.
• Do not operate in rain, in wet or damp conditions, or with wet hands.
The operator may suffer severe electric shock if the generator is wet due
to rain or snow. If wet, wipe and dry it well before starting. Do not pour
water directly over the generator, nor wash it with water.
• Be extremely careful that all necessary electrical grounding procedures
are followed during each and every use. Failure to do so can be fatal.
• DO NOT smoke while charging a battery. The battery emits flammable
hydrogen gas, which can explode if exposed to electric arcing or open
flame. Keep the area well ventilated and keep open flames / sparks away
when charging a battery.
• The engine becomes extremely hot during and for some time after
operation. Keep combustible materials well away from generator area.
Be very careful not to touch any parts of the hot engine especially the
muffler area or serious burns may result.
• Keep children and all bystanders at a safe distance from work area.
Important Safety Instructions
WARNING
To reduce the risk of injury, read this operator’s manual
completely before using.
When using this product, the following basic
precautions should always be followed.

12
safety
• It is absolutely essential that you know the safe and proper use of the
power tool or appliance that you intend to use. All operators must read,
understand and follow the tool / appliance owners manual. Tool and
appliance applications and limitations must be understood. Follow all
directions given on labels and warnings. Keep all instruction manuals
and literature in a safe place for future reference.
• Use only “LISTED” extension cords. When a tool or appliance is used
outdoors, use only extension cords marked “For Outdoor Use”.
Extension cords, when not in use should be stored in a dry and well
ventilated area.
• Always switch off generator’s AC circuit breaker and disconnect tools
or appliances when not in use, before servicing, adjusting, or installing
accessories and attachments.
• Make sure the engine is stopped before starting any maintenance,
servicing or repair.
NOTE: Make sure maintenance and repair of the generator are performed
by properly trained personnel only.
SAVE THESE INSTRUCTIONS

LOW OIL INDICATOR
TÉMOIN DE NIVEAU D’HUILE
13
Read this operator’s manual and safety
rules before operating your generator.
generator components
1. Control Panel
2. Fuel Tank
3. Fuel Gauge
4. Oil Drain Plug
5. Recoil Starter
6. Tank Cap
7. Frame
8. Air Cleaner
9. ON/OFF Switch
1.
14.
15.
16.
5.
8.
4. 9. 10. 13.
17. 12. 11.
2.6.7. 3.
10. DC Connection
11. DC Breaker
12. Hourmeter
13. 120V 3 Prong Twistlock
14. Ground
15. 120V GFCI
16. AC Breaker
17. Oil Dipstick

LOW OIL
INDICATOR
TÉMOIN DE
NIVEAU D’HUILE
14
Read this operator’s manual and safety
rules before operating your generator.
generator components
1. Control Panel
2. Fuel Tank
3. Fuel Gauge
4. Oil Drain Plug
5. Recoil Starter
6. Tank Cap
7. Frame
8. Air Cleaner
9. Battery
10. ON/OFF Switch
11. Auto throttle
1.
17.
18.
19.
19.
15.
16.
9.
20.
5.
10.
22.
8.
4. 11. 12.
13.21. 14.
2.6.7. 3.
12. DC Connection
13. DC Breaker
14. Hourmeter
15. 120V 3 Prong Twistlock
16. 240V 4 Prong Twistlock
17. Ground
18. 120V GFCI
19. AC Breaker
20. Wheel Kit
21. Oil Dipstick
22. Handles

LOW OIL
INDICATOR
TÉMOIN DE
NIVEAU D’HUILE
15
Read this operator’s manual and safety
rules before operating your generator.
generator components
1. Control Panel
2. Fuel Tank
3. Fuel Gauge
4. Oil Drain Plug
5. Recoil Starter
6. Tank Cap
7. Frame
8. Air Cleaner
9. Battery
10. ON/OFF Switch
11. Auto throttle
1.
17.
18.
19.
19.
15.
16.
9.
20.
5.
10.
22.
8.
4. 11. 12.
13.21. 14.
2.6.7. 3.
12. DC Connection
13. DC Breaker
14. Hourmeter
15. 120V 3 Prong Twistlock
16. 240V 4 Prong Twistlock
17. Ground
18. 120V GFCI
19. AC Breaker
20. Wheel Kit
21. Oil Dipstick
22. Handles

16
Grounding Instructions
The ground terminal on the frame can be used to connect the generator
to a suitable ground source. The ground path should be made with #8
size wire. Connect the grounding wire securely to the ground terminal.
Connect the other end of the wire securely to a suitable ground source.
A metal underground water pipe in direct contact with the earth for at
least 10 feet can be used as a grounding source. If a pipe is unavailable,
an 8 foot length of pipe or rod may be used as the ground source.
The pipe should be 3/4” diameter or larger and the outer surface must
be noncorrosive. If a steel or iron rod is used it should be at least 5/8”
diameter and if a nonferrous rod is used it should be at least 1/2” diam-
eter and be listed as material for grounding. Drive the rod or pipe to a
depth of 8’. If a rock bottom is encountered less than 4’ down, bury the
rod or pipe in a trench. All electrical tools and appliances operated from
this generator, must be properly grounded by use of a third wire or be
“Double Insulated”.
It is recommended to:
1. Use electrical devices with 3 prong power cords.
2. Use an extension cord with a 3 hole receptacle and a 3 prong plug at
the opposite ends to ensure continuity of the ground protection from
the generator to appliance.
We strongly recommend that all applicable regulations relating to ground-
ing specifications be checked and followed.
preparing the generator
DANGER
Improper connection of the equipment grounding
conductor can result in a risk of electrocution.
Check with with a qualified electrician if you are in doubt as to whether
the unit is properly grounded for your local regulations.

17
pre-operation checklist
Engine Oil
Before checking or refilling oil, be sure generator is located on stable and
level surface with engine stopped. This generator uses SAE 10W30 oil.
1. Remove oil dipstick and check the engine oil level.
2. If oil level is below the lower level line, refill with suitable oil to upper
level line. Do not screw in the oil dipstick when checking oil level.
3. Change oil if contaminated.
Fueling
WARNING
Explosive Fuel! Gasoline is extremely flammable and its
vapors can explode if ignited.
• DO NOT refuel while smoking or near open flame or other such
potential fire hazards.
• Store gasoline only in approved containers, in well ventilated,
unoccupied buildings and away from sparks or flames.
• DO NOT fill the tank while the engine is hot or running, since spilled
fuel could ignite if it comes in contact with hot parts or sparks from
ignition.
• DO NOT start the engine near spilled fuel.
• NEVER use gasoline as a cleaning agent.
WARNING
Always check the level of the engine oil prior to starting
the generator.
• Failure to do so could cause the engine to seize if the oil is low or
empty.
High Mark
Low Mark
Operating Range

18
1. If fuel level is low, refill with unleaded automotive gasoline.
2. Check fuel gauge while filling.
3. When using the generator for the first time or stopping due to the fuel
running out, pull the recoil handle several times after filling the tank.
General Recommendations
• Purchase gasoline in small quantities and store in clean, approved
containers.
• To minimize gum deposits in your fuel system and to insure easy
starting, do not use gasoline left over from the previous season.
• Do not add oil to the gasoline.
• Consider adding fuel stabilizer before running or starting the generator.
Fuel Type
• For best results use only clean, fresh, unleaded gasoline with an octane
rating of 87 or higher.
Gasoline/Alcohol Blends
Gasohol (up to 10% ethyl alcohol, 90% unleaded gasoline by volume) is
approved, as a fuel. Other gasoline/alcohol blends are not approved.
Gasoline/Ether Blends
Methyl Tertiary Butyl Ether (MTBE) and unleaded gasoline blends (up
to a maximum of 15% MTBE by volume) are approved as a fuel. Other
gasoline/ether blends are not approved.
Check Component Parts
Check following items before starting engine:
1. Fuel leakage from fuel hose, etc.
2. Bolts and nuts for looseness.
3. Components for damage or breakage.
4. Generator not resting on or against any adjacent wiring.
pre-operation checklist
WARNING
DO NOT overfill the tank, leave room for the fuel to
expand.

19
1. Make sure all appliances are disconnected from the generator.
2. Move engine choke switch to the START (ON) position. (When the
engine is warm or temperature is high, start engine with the switch in
the OFF position).
Recoil Start
starting your generator
CAUTION
When starting the engine with the recoil start, set the toggle switch in
the “ON” position before pulling the starter handle.
CAUTION
Do not connect appliances with defective power cords and/or plugs.
Be sure appliances are not connected to generator when starting up.
Starting the generator with an appliance connected could result in
damage to the generator and/or appliances and personal injury.
pre-operation checklist
WARNING
Keep area clear of flammables or other hazardous
materials.
• Keep generator at least 3ft (1m) away from buildings or other
structures.
• Only operate generators in a dry, well ventilated area.
• Keep exhaust pipe clear of foreign objects.
• Keep generator away from open flame. No Smoking!
• Keep generator on a stable and level surface.
• Do not block generator air vents with paper or other material.
Check Generator Surroundings
When listening to the radio near the generator, the radio sound may
be disturbed on account of the radio wave condition and the radio
performance.

20
3. Pull the recoil starter handle slowly until passing the compression point
(resistance will be felt), then return the handle to its original position
and pull briskly.
starting your generator
4. After starting, allow the recoil starter handle to return to its original
position with the handle still in your hand.
NOTE: If the engine fails to start after several attempts, repeat the starting
procedures mentioned above with the engine choke switch placed in the
OFF position.
5. After 20 to 30 seconds of warm-up is completed, turn the engine
choke switch to “OFF” position.
7. Test the GFCI receptacle on the unit. Push the test button. The reset
button should pop out and there should be no power at the receptacle.
Apply a test load or lamp to each receptacle to verify. IF THE RESET
BUTTON DOES NOT POP OUT, DO NOT USE THE RECEPTACLE.
SEE SERVICE PROVIDER FOR SERVICE IMMEDIATELY.
8. If GFCI receptacle tests correctly, firmly push the reset button to
restore power. A distinctive click should be heard or felt when this is
complete. IF THE RECEPTACLE DOES NOT RESET PROPERLY, DO
NOT USE THE RECEPTACLE. SEE SERVICE PROVIDER FOR
SERVICE IMMEDIATELY.
9. Loads can now be applied to unit.
Pull Briskly