PUCKETT MFG 540 Mode d’emploi

509 Plantation Park Drive

Loganville, Georgia 30052 USA

Telephone 770/554-2400

Fax 770/554-6540

Model 540

Serial Number

13720504

Puckett Mfg. Inc.

Model 540

Operational,

Parts,

Service

Manual

Table Of Contents

3-6 Operating Instructions

7-8 Important Notes

9-10 Safety Precautions

11 Service Recommendations

12 Operational Parts List

13-14 Screed Parts List

15 Track Parts List

16 Hopper Parts List

17 Rear & Sidegate Parts List

18 Kubota Engine Parts List

PRESTART CHECKLIST - DIESEL

1.) Check fuel gauge. Fill tank before paving and as necessary.

2.) Check engine oil level, replenish as necessary. See Engine Manual.

3.) Check washdown tank fluid. Replenish as necessary.

4.) Check oil cooler, air intake screen, or radiator for debris clean as necessary.

5.) Check air cleaner for cleanliness and make sure that components are tight to prevent

intake of unfiltered air.

6.) Change filter elements per schedule in engine manual.

7.) Check hydraulic pump variable speed control lever for full travel.

8.) Check for and remove as necessary any asphalt buildup in exhaust ports located to

the front and rear on each end of the screed.

9.) Make general inspection of machine for loose bolts and/or components.

10.) Check safety guards to insure they are in place and secure.

STARTING PROCEDURE - DIESEL

1.) Place all hydraulic control levers in “neutral” position.

2.) Place hydraulic pump variable speed control lever in “neutral” position.

3.) Pull throttle to 1/4 open.

4.) Turn ignition key to “heat” position and hold for 15 seconds and release.

5.) Turn ignition key to “start” position until engine starts. Release key, it will

automatically return to “run” position.

NOTE: This engine may take up to 30 seconds to start in cold weather. If engine

does not start in 20 to 30 seconds, stop cranking (release key) and reheat.

Should the engine refuse to start on the third try, refer to the Engine Manual.

STOPPING PROCEDURE - DIESEL

1.) Place both drive controls in “neutral” position.

2.) Lower hopper to full “down” position.

3.) Lower screed to full “down” position.

4.) Place all hydraulic control levers in “neutral” position.

5.) Push throttle to “idle” position.

6.) Turn ignition key to “off” and remove key.

OPERATION AT THE JOBSITE

1.) With washdown hose and spray nozzle, spray washdown fluid on hopper, push

rollers, screed extensions (front wall and underneath) and all other areas that will be

in contact with asphalt material. This should be done at the beginning, during the

paving day, and at the end of each day, so as to prevent unnecessary buildup of

asphalt on the paver.

NOTE: Do not wash down paver with fluid just before loading on trailer, as paver

tracks may become wet and slip on trailer ramps while attempting to load paver.

2.) Place throttle in “3/4 open” position. This will serve to preheat the screed in

preparation to lay asphalt material.

3.) Using right and left track control levers maneuver paver in position for laying

asphalt.

4.) With paver in position, move screed control lever to “down” position and hold until

screed lift cylinder is fully extended. This will permit the screed to float free.

Screed should be lowered onto a starting pad of asphalt or blocks of the desired

paving thickness.

5.) Move right and left manually adjusted depth control screws up or down, as required

to a neutral or free position. Slowly turn the screws toward the “up” position until a

slight amount of tension is felt. The screed is now set to lay asphalt to the

approximate thickness of the starting pad or blocks onto which the screed has been

lowered.

6.) Move right and left flow gate control levers to the “closed” position and hold until

both gates are fully closed.

7.) Have dump truck back up to the front of paver until the truck tires are 1-2 inches

from push rollers. Move paver forward until paver push rollers contact rear tires of

truck. Do not raise screed.

8.) Move hopper control lever to the “up” position and hold until the hopper almost

touches the frame or dump body of the truck..

9.) Signal truck driver to slowly raise dump body allowing asphalt to flow from the

truck into the hopper. Be prepared to lower hopper to prevent truck dump body

from striking and damaging hopper as the truck body is raised. Fill hopper with

asphalt.

10.) If area to be paved is level and pushing truck is desired, place the hydraulic pump

variable speed control lever forward approximately 1/3. Select Low on the two-

speed selector valve. Throttle should be set at approximately ¾ open position.

Signal driver to leave truck dump body raised a sufficient height to allow asphalt to

flow slowly but continuously into the hopper.

11.) With the right and left extension control levers, adjust to the desired paving width if

the desired width is more than basic screed width.

12.) Move the right and left extension control levers to the “open” position and hold

until flow gates are completely open. Asphalt will then gravity feed down to and

form a head of asphalt at the leading edge of the screed.

13.) Move the right and left track control levers to the “forward” position. Continue

forward, laying asphalt and pushing the truck approximately 12 - 18 inches. If

vibration is desired on the screed, move vibrator control lever to “on” position

approximately the same time the track control levers are moved to the “forward”

position.

14.) Move both track control levers to “neutral” position, stopping the paver. Always

move vibrator control to “off” position when stopping forward motion of the paver.

It may be necessary to signal the truck driver to stop, if the truck is moving. The

truck should not be in gear nor should the driver “ride” the brakes.

Recommendation – advise the truck driver of the procedure in pushing the truck

with the paver.

15.) Check thickness/depth of asphalt in the 12-18 inch mat and make necessary

adjustment using the right and/or left manually adjusted depth control screws. Make

adjustments, up or down, gradually to avoid porpoising effect of ripples in the mat

as a result of adjusting too much in either direction. If the base on which the asphalt

is being laid is on grade and level, only infrequent adjustments will be required after

initial asphalt thickness/depth setting is made.

16.) Move right and left track control levers to “forward”, continuing to pave until

truck is empty and hopper is approximately 50% full. RECOMMENDATION –

leave small head of asphalt at leading edge of screed while waiting for next load of

asphalt. If wait is longer than 10-15 minutes, pave 12-18 inches further and again

leave a small head of asphalt. Repeat in 10-15 minutes intervals using asphalt

remaining in hopper until next load arrives.

17.) If the paver is to used independently of the dump truck, follow steps 1-9 of this

section.

18.) After the hopper is fully loaded, signal the truck driver to lower the dump body,

stopping the flow of asphalt to the paver. Simultaneously, the paver operator should

move the hopper control lever to the “up” position raising the hopper to avoid

asphalt spills from the front of the hopper.

19.) Paver operator should then signal the truck driver to move forward to the next place

to reload the paver. This next reloading place may be directly in front of the paver

at a point where the paver operator expects the hopper to be emptied or another

location on the jobsite.

IMPORTANT NOTES

A.) When Loading and Unloading operator must use Low Gear and Low Pump

Speed with the Engine RPM’s at “1/2” Throttle. Use Low Gear when Parking

the Machine.

B.) To shift machine to High Speed, Engine Throttle must be at 1/2 open and Pump

Speed Control Lever must be set at 1/3.

C.) Right side auger, right side extension, hopper, right track and left track control

levers are provided for two-man operation, to avoid making “blind” joints and for

paving in two directions, reducing cycle time.

D.) The hydraulic screed vibrator should be operated only when the paver is moving to

avoid undue compaction in the mat when the paver is stopped.

E.) Do not raise the hopper against the truck frame or the dump body of the truck.

Using Tailgate Chains is recommended to prevent damage to Backwall and

Hopper Wings.

F.) When pushing a truck on level ground, the truck should not be in gear and the truck

brakes should not be held. The paver will not push a truck with the brakes on.

G.) The tow independently operated augers need only be used when the extensions are

out and then only “off and on”. The augers are used only for keeping the extended

area fully charged with asphalt. Do not leave the augers operating continuously

unless required.

H.) If the hopper is loaded and the operator wishes to close the flow gates to transport

material to an area inaccessible to the truck, reposition paver for next pass, etc., the

following procedure should be employed. Always lower the hopper as low as

possible without spilling asphalt. Close one flow gate and then the other flow gate.

Lowering the hopper substantially decreases the weight being lifted by each flow

gate.

I.) The following procedure should be used if the asphalt truck drives away from the

paver when loading or pushing the truck, resulting in a large asphalt spill in front of

the paver.

1. Stop paver.

2. Lower the hopper as low as possible without spilling more asphalt.

3. Close one flow gate and then the other flow gate.

4. Windrow spilled asphalt material to the center and in front of the paver, making

sure asphalt is removed from the path of the paver tracks.

5. Move right and left track control lever to “forward”, continuing to pave with

asphalt previously gravity fed from the hopper. As the asphalt heads from the

hopper begins to run thin, the windrow asphalt should be at the leading edge of

the screed. If this is the case, continue to pave using the windrow asphalt,

opening both flow gates as the windrow asphalt begins to run thin. If this is not

the case, open both flow gates approximately 1/3, maintaining a full head of

asphalt at leading edge of the screed until the leading edge of the screed strikes

the windrow asphalt. Continue to pave.

Failure to follow this procedure; in the event of asphalt spills will result in

asphalt buildup and eventual damage to the flow gate cylinders and the tracks.

Asphalt material inside the tracks, if allowed to build up, will eventually result

in stretched and broken tracks.

J.) Do not pull paver unless tow valves on drive pump is turned ¼ round and both track

control levers are in the “forward” position (in gear). Do not pull paver backwards.

K.) When paving uphill, lower hopper as needed, placing more weight directly over

tracks to increase traction.

SAFETY PRECATIONS

WARNING - LETHAL EXHAUST GAS! - An engine discharges carbon monoxide

when running, which may cause death if inhaled for even a short period of time-operate

only where deadly exhaust gases can be safely dissipated.

WARNING - DANGEROUS FUELS! - Never add fuel to tank while engine is running.

Stop engine and allow it to cool thoroughly to prevent fuel from igniting on contact with

hot parts of ignition spark.

WARNING - MOVING, HOT PARTS! - Careless operation of power equipment

creates hazards to life and limb. Never operate with safety guards removed. Keep hands,

feet and clothing away from moving and hot parts. Remember that an engine gets hot

while running, and exhaust system components get extremely hot. Always disconnect

positive battery cable from battery to prevent unintentional starting while working on

equipment. Never tamper with governor setting to gain more power – the governor

establishes safe operating limits. Over speed not only shortens engine life but can be

extremely hazardous. Keep people safely away from the operating area and be especially

watchful for children. Stop the engine whenever you leave the equipment. Do not allow it

to idle unattended.

WARNING - EMERGENCY STOPS! - Emergency stops are accomplished by moving

both right and left track control levers to the “neutral” position. Know how to make

emergency stops – do not allow inexperienced persons to operate your equipment.

WARNING - PINCH POINT! - Keep head and all body parts clear of area under raised

hopper floor. Always place the floor safety prop under raised hopper floor before

working or reaching into area under floor. Also, keep all personnel clear of machine

controls when someone is working or reaching under hopper floor.

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