PUCKETT MFG 540 Guide

509 Plantation Park Drive
Loganville, Georgia 30052 USA
Telephone [phone]
Fax [phone]
Model 540
Serial Number
13720504

1
Puckett Mfg. Inc.
Model 540
Operational,
Parts,
&
Service
Manual

2
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

3
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.

4
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.

5
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.

6
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.

7
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.

8
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.

9
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.

10
SAFETY PRECAUTIONS
FOR
PROPANE HEATED SCREED
GENERAL SAFETY PROCEDURES
1.) A propane screed heater is to be used only to pre-heat the screed before starting the
paver engine. The propane heater must not be used when the engine is running.
2.) This equipment is designed to be used only with propane gas.
3.) Wrench tighten all fittings.
4.) Never use oil or grease for lubrication.
5.) Do not use oxygen with equipment.
6.) Keep cylinder upright at all times.
7.) Keep equipment free from dirt and oil.
8.) Use a regulator on supply cylinder.
9.) Check equipment carefully each time before lighting.
10.) Always light with a striker, never with matches.
11.) Do not operate in an enclosed area or near flammable material.
12.) Close all valves when not in use.
13.) Comply with all federal, state, and local regulations when operating this equipment
PROPANE CHART:
Flame temp. with air…………………….………………… 2950 Degrees Fahrenheit.
Weight per cubic ft. of gas………………………………… 8.59 lbs.
Cubic ft. of air needed to burn 1 cubic ft. of gas………….. 24
BTU’s per pound of gas……….………………………….. 21,600

11
Service Recommendations
1.) Hydraulic Filter Elements – Change every 2 years or 500 hours whichever
occurs first.
2.) Engine Oil Filter Elements – First Change at 50 hours – every 200 hours after
first change..
3.) Fuel Filter – Change every 400 hours.
4.) Air Filter – Check Weekly – Clean as needed. Change as needed.
5.) Hydraulic Fluid Level - Check monthly and after any loss of fluid. Dipstick is
located in front of machine under the floor. Fluid level should be touching the
bottom of the Dipstick to ½” up. Use Dextron III or equal. Caution: Do No
Overfill
6.) Grease the following fitting on a daily basis.
a. Swivel Bolts on Depth Adjustment Assemblies – 2 each.
b. Bearing on Bottom of Depth Adjustment Assemblies – 2 each.
c. Side Gates – 4 each.
d. Track Sideboard-Inside and Outside – 8 each.
e. Hopper Cylinder Clevis Pins – 2 each.
7.) Check all bolts, nuts, and fasteners – tighten as needed.
8.) Check radiator fluid, engine oil, and engine fuel daily.

12
540 Operational Parts List
Part # Description Qty per
Model UM Notes
661400 Hydraulic Drive Pump 1 EA
540
551350 Accessory Pump 1 EA
540
550350 Engine Throttle 1 EA
Cable
550375 Hydraulic Pump Control Cable 1 EA
(fast/slow)
550225 5/16-24 Adjustable Clevis 2 EA
w/pins
375000 Washdown Pump 1 EA
12-volt
015450 Washdown Sprayer and 1 EA
Hose Assembly
560300 Washdown Sprayer 1 EA
Only
547800 Drive Valve 1 EA
2-stack
550550 Accessory Valves 1 EA
9-stack
045800 Breather Cap 2 EA
Fuel & Washdown Tanks
051576 Pressure Tank Cap 1 EA
(Hydraulic Pressure Tank)
558600 Fuel Sight Gauge Assembly 1 EA
540
252160 Fuel Gauge Dial Face 1 EA
Only
558400 Battery 1 EA
70-675
061400 Hydraulic Oil Cooler 1 EA
061405 Hydraulic Oil Cooler Mounting 2 EA
Kit
547000B Decal Kit - Complete 1 EA
Blue Color
586410 No Start Safety Switch 1 EA
409000 Switch - Washdown Pump 1 EA

13
540 Screed Parts List Page 1 of 2
Part # Description Qty Per Model UM Notes
542000 540 Bare Screed 1 EA Includes *** items
Assembly
662524 2-1/2 x 24 Hydraulic Cylinder 2 EA Seal Kit # 559700
for Extensions
349450 Paver Hydraulic Vibrator Motor 1 EA
MGG20030-BA1A3
542400 8' Screed Wear Plate 1 EA ***
1/4 x 13 x 96
543600 540 Right Hand Operator's 1 EA ***
Platform
543500 540 Left Hand Operator's 1 EA ***
Platform
414200 Screed Turnbuckle for 2 EA
Crown/Invert Adjustment
544000 Screed Extension Assembly 1 EA
Left Hand-540
565000 Screed Shoe Assembly 1 EA
Left Hand
664150 Extension Strikeoff Assembly 1 EA
Left Hand-540/560
544500 Screed Extension Assembly 1 EA
Right Hand-540
565500 Screed Shoe Assembly 1 EA
Right Hand
664160 Extension Strikeoff Assembly 1 EA
Right Hand-540/560
178000 Screed Extension Shoe 2 EA
Strap
015900 Screed Joint Shoe Nut 4 EA
3/8"
546100 540 Screed Pull Arm Assembly 1 EA
Left Hand
546150 540 Screed Pull Arm Assembly 1 EA
Right Hand
018700 Propane Nozzle Mounting Cap 2 EA
Assembly

14
540 Screed Parts List Page 2 of 2
Part # Description Qty Per Model UM Notes
563000 Depth Adjustment Assembly 2 EA
with Bearing
024200 4-Bolt Flange 2 EA
Bearing
013050 Depth Adjustment Screw Bracket 2 EA
Assembly
312230 Depth Adjustment Nut 1" 2 EA
Thread
289010 Depth Adjustment Swivel Bolt 2 EA
with Grease Fitting 1/2 x 1
142175 Depth Adjustment Swivel 4 EA
Spacer
033100 1/2-13 x 1 Hex Head Bolt 2 EA
Grade 5 Plated
545100 540 Exhaust Pipe Assembly 1 EA
Engine to Screed
055200 1-5/8" Muffler Clamp 2 EA
199800 Screed Lift Cylinder 1 EA Seal Kit #559600
359500 Cylinder Clevis Pin 2 EA
550955 Cylinder Clevis Pin Clip 2 EA
359580 Screed Lift Cylinder Pin 1 EA
Bushing
542050 Screed Lift Chain 1 EA
Assembly

15
540 Track Parts List
Part # Description Qty per Model UM Notes
556500 540/550 Track Pad & Chain Assy 2 EA
38 Links
550940 500 Series Track Pad & Link 1 EA
Single Pad & Link
550925 500 Series Track Chain 1 EA
(Single Link)
652050 Track Pad Only 1 EA
(Single Pad)
24500 Insert Bearing for Trackroller 8 EA
1-15/16"
556350 Trackroller Bearing 4 EA
Housing
556700 Trackroller Bearing Shaft 4 EA
1-15/16"
552200 Rear Track Drive Sprocket Assy 2 EA
500 Series Paver
550800 Gearbox Track Hub 2 EA
(Auburn)
407000 5/8 x 2-5/8 Stud 12 EA
Track
618329 Gearbox Wheel Stud 18 EA
(Auburn)
552300 Front Track Idler Sprocket Asy 2 EA
500 Series Paver
552800 500 Front Idler Sprocket Axle 2 EA
1-15/16"
550510 Track Tension Adj Cyl Assembly 2 EA Seal Kit #559600
3" x 2"
421025 Breather Vent 1/4" 2 EA
Pipe Thread
556460 Track Adj Cyl Support 2 EA
Axle
556750 Track Top Slide Support 4 EA
Spacer
540100 Hydraulic Track Drive Motor 2 EA Seal Kit #550170
540
551150 Track Motor Relief 1 EA
Valve

16
540 Hopper Parts
Part # Description Qty per Model UM Notes
540850 Hopper Spill Prevention Belt 1 EA
540
540855 540 Inside Wing Mat Belt 2 EA
Left or Right
584110 540 Hopper Belt Mounting 1 EA
Strap
555140 500 Push Roller 2 EA
Assembly
024000 1" Pillow Block Bearing 4 EA
Push Roller
017185 Paving Alignment Assembly 1 EA
(rod, guide tube, & chain)
550700 Hopper Lift Cylinder 2 EA Seal Kit #559500
3” x 10”
359535 Clevis Pin for Hopper Lift Cylinder 4 EA
With clip

17
540 Rear and Side Gate
Parts List
Part # Description Qty per Model UM Notes
Rear Gate Parts
542300 540 Left Hand Auger 1 EA
32-1/2"
542350 540 Right Hand Auger 1 EA
32-1/2"
550190 Auger Motor 2 EA
Hydraulic
311600 Auger Hub for 2 EA
Hydraulic Motor
542375 Auger Bearing 2 EA
(2-bolt)
311800 Auger Hub for 2 EA
Bearing
550575 Rear Gate Cylinder 2 EA Seal Kit #559700
with Extended Rod
359500 Hydraulic Cylinder Pin 2 EA
with clip
550955 Hopper Clevis Pin Clip 2 EA
(clip only)
541401 L.H. 540 Gate Assembly 1 EA
(Weldment Only)
541406 R.H. 540 Gate Assembly 1 EA
(Weldment Only)
Side Gate Parts
546225 540 L.H. Side Gate Assembly 1 EA
(Weldment Only)
546250 540 R.H. Side Gate Assembly 1 EA
(Weldment Only)
199400 Side Gate Cylinder 2 EA Seal Kit #559800
with Clevis on each End
359500 Hydraulic Cylinder Pin 2 EA
with clip
550955 Hopper Clevis Pin Clip 2 EA
(clip only)

18
540 Kubota Engine Parts List
Part # Description Qty per Model UM Notes
547525 Fuel Filter Assembly 1 EA
Kubota 1105 engine
557500 Fuel Filter Element 1 EA
Kubota 1105 Engine
557600 Oil Filter Element 1 EA
Kubota 1105 Engine
558000 Air Cleaner Assembly 1 EA
Donaldson 1105 Engine
557750 Air Filter Element 1 EA
Donaldson 1105 Engine
550875 Engine Alternator 1 EA
Kubota (40 amp)
550860 Alternator Belt 1 EA
Kubota Engine
561390 Starter 1 EA
Kubota 1105 Engine
561385 Fuel Shutdown Solenoid 1 EA
Kubota Engine
561380 Engine Wiring Harness 1 EA
Kubota 1105 Engine
551345 Radiator Assembly 1 EA
Kubota 1105 engine
552100 Radiator Isolator Mount Kit 1 EA
Kubota Engine
552075 Engine Mount Isolator 4 EA
RAB-0
587200 Kubota Engine Switch 1 EA
with Keys
587250 Kubota Engine Switch Key 1 EA
2 per pack