SAINT-GOBAIN CertainTeed Volu-Matic 200 Original instructions

1
Operation Manual
And Safety Information
Volu-Matic 200
Parts – Service – Accessories
863.294.3206 / 800.237.7841
www.certainteedmachineworks.com
PLEASE READ THIS MANUAL BEFORE PLACING YOUR NEW
VOLU-MATIC 200 INSULATION BLOWING MACHINE INTO SERVICE

2
WARNING
Carbon monoxide poisoning from engine exhaust
can be fatal. Make sure exhaust is routed away
from air intake flanges and that the truck body is
well ventilated.
WARNING
Do not smoke when refueling the tank or operating
the machine. Fumes from fuel are explosive and can
be fatal. Follow all safety precautions when handling
any type of fuel.
WARNING
Recommended hose size, type, and length must be
used to achieve maximum results. CertainTeed
Machine Works cannot guarantee performance of
the Volu-Matic 200 machine if hoses are undersized,
worn, damaged, or hoses other than those we
recommend are used.
NOTE
On PTO models, keep in mind that a weak truck
battery may not be powerful enough to run the
machine. Keep the truck battery and charging
system in very good shape.
NOTE
Decals included in the PTO box should be displayed
on the truck as indicated by the instructions provided
by the manufacturer.
Warning & Notes

3
SPECIFICATIONS................................................................................................................................................................4
ACCESSORY AND INSTALLATION KITS...................................................................................................................5
INTRODUCTION..................................................................................................................................................................6
SAFETY...................................................................................................................................................................................8
OPERATION........................................................................................................................................................................ 12
PREVENTIVE MAINTENANCE.................................................................................................................................... 22
TROUBLESHOOTING..................................................................................................................................................... 28
PARTS DRAWINGS ......................................................................................................................................................... 32
WARRANTY ....................................................................................................................................................................... 53
Table of Contents

4
Specifications
MODELS:
Gasoline Engine Driven Insulation Blowing Machine
• Kohler Command Gasoline Engine – 19 HP twin cylinder air cooled
Power Take-O Driven Insulation Blowing Machine
ALL MACHINES:
18” airlock feeder, air volume control system, electro-magnetic clutches, four speed transmission.
HEIGHT: 69"
LOAD HEIGHT: 59"
LENGTH: 72"
WIDTH: 48.25"
WEIGHT: 1300 lbs
ELECTRICAL: 12V DC
BLOWER VOLUME: 270 cfm @ 2 psi
BLOWER PRESSURE: 7 psi maximum
MAXIMUM FEED RATES FOR CORRECT PRODUCT COVERAGE:
Cellulose: 70 - 80 lbs per minute @ 2.0 psi.
Fiberglass: 25 - 35 lbs per minute @ 3.5 psi.
Rockwool: 35 - 55 lbs per minute @ 4.5 psi.

5
P/N DESCRIPTION QUANTITY
ACCESSORY KIT
210986
150 Foot Long Remote Control Cord – P/N 210893 1 EA
Operation Manual 1 EA
Stator Bar Cover Plate – P/N 210031 1 EA
INSTALLATION KIT
211949
Hose Sleeve, 4" – P/N 210993 1 EA
Worm Drive Hose Clamp, 4" – P/N 162485 2 EA
Marine Exhaust Hose, 4" X 24" – P/N 210945 1 EA
Accessory and Installation Kits
GASOLINE ENGINE DRIVEN INSULATION BLOWING MACHINE
Check the accessory and installation kits included with new delivered machines that the following items were received for operation.
The following items are available through CTMW and required for installation:
210987 Engine Air Intake and Exhaust Kit 1 EA
210961 Blower Outside Air Intake Kit 1 EA
P/N DESCRIPTION QUANTITY
ACCESSORY KIT
210988 150 Foot Long Remote Control Cord – P/N 210893 1 EA
Operation Manual 1 EA
Stator Bar Cover Plate – P/N 210031 1 EA
INSTALLATION KIT
211950
Marine Exhaust Hose, 4" X 24" – P/N 210945 1 EA
PTO Drive Belt Idler Support B – P/N 209899 1 EA
3TB50 Pulley, (Uses P1 Bushing) – P/N 160263 1 EA
Holder, Circuit Breaker – P/N 162000 1 EA
Hose Sleeve, 4" - P/N 210993 1 EA
PTO Idler Rollere Take Ip Arm – P/N 209916 1 EA
Bushing, Idler, 5/8" - P/N 162487 1 EA
Worm Drive Hose Clamp, 4" – P/N 162485 2 EA
Gearbox PTO Idler Spacer - P/N 210544 1 EA
Breaker, Circuit 20A – P/N 159034 1 EA
POWER TAKE-OFF DRIVEN INSULATION BLOWING MACHINE
The following items are available through CTMW and required for installation:
209924 PTO Brg.U-T Short Bolt-On Mnt. 1 EA
209925 PTO Brg.U-T Short Bolt-On Mnt. 1 EA
210166 Under Truck PTO Tie Plate 1 EA
209329 End Yoke, 1.25, Drilled & Tapped 2 EA
210141 Jackshaft 1 EA
162819 EXP, 1.25 P/B, V3, Mach & U/Truck 1 EA
162818 Non-EXP, 1.25 P/B, V3 & U/Truck 1 EA

6
Introduction
HOPPER
AREA
EMERGENCY
STOP BUTTONS
FRONT PANEL
BLOWING HOSE
CONNECTION
SAFETY
GUARD

7
VOLU-MATIC 200
Several safety features are on the Volu-Matic 200 machine to ensure operator safety. Study the safety
section thoroughly so that all the features concerning safety are understood. Keep all these features
functional during machine operation.
This introduction is presented to provide a basic description of the function and purpose of the Volu-Matic 200.
The Volu-Matic 200 machine is principally designed to blow insulating materials into attics of residential and
commercial buildings, and can also be configured to spray side walls. The insulation material manufacturer’s
instructions prevail when it comes to installing their product, since they guarantee the final results.
The Volu-Matic 200 machine is normally mounted in the back of a contractor’s truck and can be powered
either by a small industrial engine or by the truck engine via a power take o (PTO) box. The belt driven
power train that drives all machine mechanisms, includes electromagnetic clutches that provide separate
control of various functions on the machine. To allow the person installing the insulation full control of the
machine, a 12-volt electrical remote control system is provided, which operates either through the provided
hard wire remote cord and toggle switch, or with an optional radio frequency remote control unit. The
Volu-Matic 200 controls provide independent control of both the air that blows the material down the hose
to its destination, and the machine mechanisms that condition and feed the insulating material into that air
stream. The machine can be set at dierent speed settings with the transmission to match the applicators
ability and/or material characteristics.
The 12-volt electrical circuit is powered by the machine’s small industrial engine, or by the truck battery when it
is PTO driven. The electrical control circuit is protected with a 20 amp circuit breaker. A light illuminates when
the master switch is turned on, indicating that power is on for both the blower relay and remote control
receptacle. When the remote cord switch is moved toward the cord, power is sent through the blower relay,
causing the blower clutch to engage. When the remote cord switch is moved toward the end of the housing,
power flows to the blower and mechanism relays, causing both clutches to engage. The toggle switch in the
remote cord housing is labeled to identify these machine functions. The switches on the optional radio
frequency remote control unit are labeled on the transmitter to identify these machine functions.
The hopper area where material is deposited into the machine has a circulator to open and stir the material,
and an auger at the bottom for material feed. Material exits the auger and is conditioned by the shredder
before entering the airlock feeder. The airlock feeder deposits the material into the air stream where it enters
the hose and flows to the hose exit.
Another feature on the Volu-Matic 200 machine is a slide gate that when adjusted is used to control both
feed rate and material conditioning. Air volume is controlled independently with a manually operated valve,
to help optimize material coverage.

8
Safety
The Volu-Matic 200 Insulation Blowing Machine has
full guarding and electrical disconnects for your safety.
Every Volu-Matic 200 machine has this warning displayed
in a prominent place. Do not remove, modify, or deface
the warning label!
WARNING: if any foreign object should enter the
machine; push an emergency stop button in (o), turn
o the master switch, unplug the remote control cord,
and shut the machine engine or power source down
before retrieving the object. Never reach into the
machine while it is operating.

9
Other wrning signs, cution signs,
nd dnger signs re displyed so
tht the opertor is wre of other
hzrds ssocited with the use
of the mchine. You will see the
following wrnings on the mchine.
Do not remove, modify, or defce
the wrning lbels!
The purpose of this sign is to make the operator
aware that they may lose balance and fall.
This warning sign is displayed on the truck
after installation of a PTO driven machine.
Decals included in the PTO box should be
displayed on the truck as indicated by the
instructions provided by the manufacturer.
Use the installation instructions if you
install the machine.

10
All Volu-Matic 200 machines are factory equipped with side, front, and rear guards. The top of the machine does
not require guarding when correctly mounted in the contractor’s truck, as shown in the installation instructions.
The front guard 1 is designed to hinge up for access to your machine for maintenance and troubleshooting. This
guard must never be opened while your Volu-Matic 200 machine is in operation - there are shafts under the
guard, which are still rotating. If this guard is opened, a safety switch 2is mounted to the guard which will stop
chain driven mechanisms, plus the blower, and the engine for those models. If the mechanisms do not shut o or
stop when the guard is lifted up, you should request that maintenance be performed on the safety interlocks.
For PTO models, you will have to push the reset button 3 in order to restart the machine after the guard is closed.
If the safety switch or guard should become damaged, replace them to ensure safety while operating your
Volu-Matic 200 machine.
The front guard
1
is designed to hinge up for access to your machine for maintenance and troubleshooting.
This
12
5
4

11
There are two emergency stop buttons 4& 5that will completely shut the machine down. Either red
button will stop all machine mechanisms when pushed in (o) overriding all other controls. If the
mechanisms do not shut o or stop when either button is pushed, request that maintenance be
performed on the safety system. The emergency
stop buttons must be twisted out (on) for normal
operation. Knowledge of the location and function
of these emergency stops is emphasized.
These buttons should be used for any of the
following type of emergencies:
– unauthorized individual getting too close
to the machine.
– objects falling into machine.
– a machine component breaks.
– a material hose becomes disconnected.
– anything requiring immediate stopping
of the machine.
For PTO models, you will have to push the reset
button 3in order to restart the machine after the
emergency stop buttons are twisted back out (on)
and front guard is closed for machine operation.
If any safety switch interlock should become damaged,
replace it; keep your machine safe.
During machine operation, always turn o the “rocker type” master switch 6 (light indicates switch is on),
and unplug the remote cord from the receptacle 7before removing any guards for any reason!
During machine operation, always stand on the floor to deposit material into the hopper. Under no
circumstances should your hand, arm, stick, broom or any other object be used to move or force feed
material down into the hopper. The Volu-Matic 200 machine is a self-feeding design requiring no outside
assistance for smooth flow.
Operators should wear hearing protection if the machine noise makes them uncomfortable or noise
level exceeds acceptable standards. CertainTeed Machine Works recommends that the operator wear
an “approved” dust mask or respirator for their protection. Safety features are incorporated into the
Volu-Matic 200 machine to protect from serious injury. Operate your machine according to the outlined
instructions in this manual with all safety features in place and working properly. Operating the machine
in an unsafe manner can result in serious injury or death.
3
6
7

12
Operation

13
PRELIMINARY CHECKS
1. Check the following table for the proper hose size, type, and length for a particular operation. All hose
couplings must be thin wall, 1/16 inch maximum, to minimize restrictions. Thin wall couplings can be
purchased from CertainTeed Machine Works.
Note: Follow fiber manufacturer instructions for hose setup
2. Make sure hopper is free of foreign materials.
3. Check for presence of oil from the blower, transmission, and gearbox indicating a leak. On engine models,
check for presence of oil from engine indicating a leak. Check the maintenance section for proper levels
and type of oil used in each component.
4. Check material conditioning slide and air bleed valve position. Check the recommended start settings
chart for proper position.
5. Make sure all guards are in place and securely latched.
WARNING: always operate your machine with the truck sitting on a level surface. Operating the machine
when the truck is not level will lead to failure of some machine components. The oil level in the blower,
transmission, and gearbox, may not lubricate internal parts properly when the truck is sitting on an incline.
OPERATION MATERIAL HOSE DIAMETER HOSE LENGTH
Open Blow
Cellulose
Fiberglass
Rockwool
3-1/2" Minimum 150' Minimum
Side Wall
Cellulose
Fiberglass
Rockwool
2-1/2" Minimum
3" Minimum
3" Minimum
150' Minimum

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PRELIMINARY START-UP CHECKS
1. Make sure hopper is free of foreign materials.
2. Clear the area in front of the airlock feeder outlet 11 for testing.
3. Move the toggle switch 9to the center (o) position and plug
the remote cord 10 shipped with newly delivered machines into
the receptacle 7 . This is a twist lock connection.
4. Put transmission into proper gear.
5. Twist emergency stop buttons 4& 5out (on) and make sure
front guard is on for operation.
6. On engine driven models, start the engine in accordance with
manufacturer’s literature and increase engine speed until the
throttle is at full speed. The engine should run at 3600 rpm.
On PTO model machines, start the truck and engage the PTO
at a low idle in accordance with truck manufacturer’s literature.
Bring the truck up to the recommended speed established
during installation. Always engage and disengage the PTO
at a low idle.
PTO OVER SPEED WARNING:
The gearbox that powers the drive train on the machine is designed to run at a nominal 1500 rpm. This
speed should be held within 25 rpm so that machine components are operating at the correct design speed.
Over speeding the machine can and will damage shafts, bearings, and clutches driven by the gearbox, as
well as the gearbox itself. This is especially true if the truck is moved before the PTO attachment is
disengaged after operating the machine. Remember, the gearbox rotates at all times the PTO is engaged.
7. Turn on the master switch 6 ; light indicates the switch is on.
8. Push reset button 3 on PTO models for next step.
9. Cycle the toggle switch in the remote cord housing toward the cord and the blower will come on, check
that air does exit the airlock outlet. With the blower operating satisfactorily, cycle the switch toward the
end of the housing and the blower and machine mechanisms will operate simultaneously.
10. Become knowledgeable about the components of the Volu-Matic 200 machine. Engage and disengage
the remote cord noticing the drives start and stop. With machine running, push one emergency stop
button and check that the drives stop. Twist emergency stop button out, push the reset button and start
the machine again. Repeat the process opening the front guard. Push in the other emergency stop button
and check that the drives stop. If the remote toggle switch was cycled o, then cycle the toggle switch
for the drives to come on.
4 5
11
6
3
7
9
10

15
11. For any problems encountered during preliminary start-up procedures, check the Troubleshooting section
or call CertainTeed Machine Works at 800-237-7841.
Warning: If at any time the drives do not stop when an emergency stop button is push in (o), or if any
swing gate is open, request that maintenance be performed on the safety interlocks.
VOLU-MATIC 200 RECOMMENDED START SETTINGS CHART
Note 1: Use these settings as a starting guide only. Variations between materials of the same type and
variations between batches from the same manufacturer may require dierent settings than those suggested.
Remember, the material manufacturer’s instructions prevail since they guarantee the final results.
Note 2: air pressure settings for side wall operation are for dense pack, net fill, and drill & fill of outside
walls of older structures. Spraying side walls will result in higher pressure based on water in the air stream.
GENERAL INSTRUCTIONS:
1. Set the industrial engine speed or truck speed for machine operation. Reduce machine speed approximately
20 percent for side wall operation.
2. Vary the air bleed pressure first. If you cannot get the desired results by opening or closing the air control
lever handle, then...
3. Vary the slide gate next. If you cannot get the desired results by closing or opening the slide gate, then...
4. Go to the next highest or lowest speed on the transmission. If you cannot get the desired results changing
the speed, then...
5. Add or remove stator bar. If you cannot get the desired results by adding or removing the stator bar, then
start with varying the air pressure again.
OPERATION MATERIAL GATE SETTING TRANSMISSION
GEAR AIR BLEED PRESSURE
Open Blow
Cellulose 16" 3rd 2.0 – 3.5 psi
Fiberglass 12" 3rd 2.0 – 3.5 psi
Rockwool 12" 2nd 4.5 – 5.5 psi
Side Wall
Cellulose 8" 1st 1.0 – 2.5 psi
Fiberglass 8" 2nd 1.0 – 2.5 psi
Rockwool 6" 1st 1.5 – 1.75 psi

16
GETTING STARTED
1. Use the preliminary and startup checks
as a check list on your Volu-Matic 200
machine each day before proceeding to
the job site. At the job site, connect hose
at the through wall connection firmly
with band clamps and make sure the
hose does not have a short radius bend.
A short radius bend will result in poor
coverage, excessive hose and feeder
wear, and/or plugged hoses. Use thin
wall couplings and reducers, 1/16 inch
maximum, to minimize restrictions.
Proper hose selection is important to
optimize insulation volume and coverage.
A rough bore corrugated hose is necessary
for blown fibers since smooth bore rubber
or plastic will roll shredded material into
small tight balls. Your Volu-Matic 200
machine has been engineered, when
properly adjusted, to condition fibers for
optimum coverage. Improper hose
selection will degrade fibers conditioned
by the machine and reduce insulation value
in blown material. Do not deviate from
hose diameters, types, or length, as
specified in the table.
THIS
NOT THIS
The Volu-Matic 200 machine will not
perform to specifications when held back
by undersized and restrictive hoses,
couplings, reducers, and/or nozzles that are
used for sidewall spray operations. For
open blow operations, use a 25 foot to 50
foot length of 4 inch diameter hose at the
machine connection. For sidewall spray
operations, make sure the nozzle that you
use has an opening that is at least the same
square inch area or greater than the hose
selected. The nozzle should also have a
body wall that is not greater than 1/16 to
1/8 inch in thickness and with a smooth
tapered entrance.
For maximum open blow
operation, connect a
minnimum of 25 ft 4" hose
to airlock feeder outlet.
Use 4 - 3.5 Reducer when
using the minimum
recommended hose
diameter of 3.5".
4" or 3.5" blowing hose,
minimum 150 feet.
Note: Hose connections are
generally made at the truck box
Through wall connection
Established at installation.
For side wall operation,
connect hose to airlock feeder
as shown in the drawing
Note: Add 3 - 2.5 reducer for
side wall operation using 2.5
inch hose.
4 inch rubber hose sleeve
4 - 3.5 reducer
3.5 inch rubber
hose sleeve
3.5 - 3 reducer
3 inch blowing hose,
minimum 150 ft.

17
2. Make sure the emergency stop buttons are pushed in (o) and the remote cord toggle switch is in the
center (o) position.
3. Use the recommended start settings chart to adjust machine for the type of insulation you are using and
particular operation. The material manufacturer’s instructions prevail since they guarantee the final results.
4. Air flow rate may be controlled with the air bleed control valve 13 while monitoring system pressure on
the air gauge 14 . The system back pressure must be read while the Volu-Matic 200 machine is operating
with full length and proper hose while material is being blown. Always start the adjustment with the air
bleed control valve in the fully closed position. See Fig. down below. If the air flow and pressure deliver
the desired results with the valve closed, then do nothing to the valve. As you begin to open the valve, air
is bled o from the exit of the blower preventing flow of all air to the airlock feeder. As you open the
valve, be careful to not open completely during open blow or the blowing hose could clog because of
insucient air volume.
5. To adjust the slide gate 15 , refer to the chart and select the proper setting for the material to be blown and
particular operation. Lift the handle 8out of the notch and move to the left to open the slide gate. Place handle
in notch that matches with the desired setting on the scale 16 . The scale is calibrated in inches of opening.
CAUTION: As you open the valve, be careful not to open completely during open blow or the blowing
hose could clog because of insucient air volume.
15
8
1613
14

18
6. To adjust the transmission 17 , refer to the chart and select an appropriate gear for material and type of
operation. Shift the lever 18 into gear in accordance with decal instructions on the machine front panel.
Since the transmission is not synchronous, it may be necessary to pull the gears through by hand using
the pulley 19 so that gears mesh allowing you to change them. This should never be attempted or gears
shifted while the machine is operating.
WARNING: Never attempt to change gears while the Volu-Matic 200 machine is in operation. Always
change gears when the machine is completely shut down. Failure to do so can result in serious personal
injuries or a severely damaged transmission.
Gears Decal Instructions
19
17 18

19
7. Load the machine from a standing position on the floor depositing bags of material on the shelf 20.
Do not build scaolding or use a foot stool to load material into the Volu-Matic 200 machine. This moves
the operator closer to the rotating components in the hopper and provides a way to lose balance and fall.
Load three to four bags of material into the hopper being particularly careful not to leave pieces of bag in
the material since this will clog and stall the machine.
WARNING: Do not attempt to remove any foreign object from the machine until it Is completely shut
down; master switch turned o, emergency stop buttons pushed in, remote control cords unplugged,
and the PTO disengaged or engine shut down. Failure to do so will result in serious injuries by the
rotating components in the hopper or on the machine.
8. Twist emergency stop buttons out (on) and swing gates closed for operation and then push
the reset button.
9. Take the end of the blowing hose and remote control cord to the job’s starting point. Engage remote
control cord for air and material to begin the insulation blowing process.
10. Upon completion of open blow operation, use air only function for the following:
• clear all material out of hose.
• level o insulation mounds.
• blow o duct work and clear out air handler drip pan.
• blow material from recessed lights.
• blow material out of sots.
20
STAND ON FLOOR
TO LOAD MATERIAL
INTO THE HOPPER!
Hopper Area

20
COVERAGE
Coverage may be defined as the maximum allowable square feet covered per bag at a minimum specified depth
and weight per square foot at a given “R” value. A manufacturer might recommend that the material be blown at
a rate of 72.5 sq. ft. per bag at a depth of 11.5” and a weight 0.427 lbs per sq. ft. to achieve an insulation value of
R-30. Fiber must be worked or conditioned by your Volu-Matic 200 machine to achieve coverage.
Coverage decreases when feed rates are too low or too high and material is overworked by the machine
mechanisms (or the wrong hose is used) rolling the fibers into tight little balls. Coverage will also decrease if feed
rates are too high, allowing material to pass through the machine before it has been opened to the proper density.
A stator bar 22 is installed in the shredder housing of every new machine. The stator bar can help increase
coverage, but it can also decrease coverage and slow the feed rate of the machine. Adjustments can be made
by removing or adding the stator bar. If the stator bar is not used, the cover plate must be installed in its place.
This adjustment should be done only after various settings of the air bleed control valve, slide gate, and
transmission speed do not gain desired results.
22