Wacker's DPU 4045H, DPU 5045H repair manual PDF, 158 pages filed under OEM number 0215959, strips either vibratory plate down to a bare exciter housing and walks it back together in factory sequence. Disassembly and assembly fill most of the book, moving from the covers and centrifugal clutch through the Bowden cable, diesel engine, guide handle head, and exciter shafts, with each rebuild closing on bearing fits and thread-locker call-outs. A malfunction chapter ties weak advance or reverse travel back to the hydraulic control, and metric plus SAE torque tables finish the book in Nm and ft-lb. Measure your exciter V-belt first; at 15.5 mm wide it is done, and when the eccentric weights go back on, torque the cheese head screw to 295 Nm with a 14 mm Allen. Guess at either number and you pay for the teardown twice. Bookmarked and text-indexed, this PDF goes wherever the plate is working.
What's Inside This Wacker DPU 4045H, DPU 5045H Repair Manual
| System | Pages | Key Topics |
|---|---|---|
| Introduction | 7-8 | Symbols Used |
| Safety Information | 9-10 | Principle, Service/Maintenance |
| Technical Data | 11-12 | Operating Weight, Advance/Reverse Travel, Exciter, Drive Motor, Hydraulic |
| Jigs | 13-14 | Pressing Tool, Strap Wrench, Die, Press-Fit Pipe, Safety Device |
| Disassembly | 15-72 | - |
| V-Belt/Clutch | 79-84 | V-Belt, Clutch Drum, Centrifugal Clutch, Deep Groove Ball Bearing, V-Belt Pulley |
| Bowden Cable | 85-90 | Pipe Clamp, Transmitter, Actuator, Angle Joint, Lever |
| Diesel Engine | 91-96 | Lever, Bracket, Angle Joint, Seal |
| Upper Mass | 97-100 | Hose Pipe, Hollow Screw, Seal, Pipe Clamp |
| Apron | 101-104 | Fitting, Cover, Plate, Hexagonal Bolt |
| Guide Handle | 105-108 | Bellows, Locking Pin, Compression Spring, Vibration Dampers |
| Guide Handle Head | 109-114 | Control Piston, Compression Spring, Guide, Gear Rack, Spacer, O-Ring |
| Base Plate and Exciter | 115-120 | Vibration Dampers, Shockmount Support, Support Plate, Shock Bushing, Exciter |
| Exciter Shafts | 121-138 | Cylindrical Roller Bearing, Gear Rack, Shaft, Eccentric Weight, Gear, Feather Key |
| Hydraulic Line | 139-142 | Screwed Socket, Connection Flange, Pipe Clamp, Hose Pipe |
| Bleeding the Hydraulic Line | 143-144 | Oil Fill Screw, Control Handles, Hydraulic Oil, Control Piston Chamber |
| Hydraulic Line | 145-146 | Bleeding the Hydraulic Line |
| Maintenance | 147-152 | Maintenance Schedule, Engine Oil, Hydraulic Control, Exciter Oil, Exciter V-Belt |
| Malfunction | 153-154 | Reverse Travel Speed, Advance Travel Speed, Hydraulic Oil, Engine Start, Vibration |
| Torque Values | 155-158 | Metric Thread, Sae Thread, Bolt Type, Ft Lb, Nm |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| V-belt replacement limit | 15.5 mm | p. 84 |
| Cheese head screws (10) torque | 10 Nm | p. 131 |
| Cheese head screw (29) torque | 295 Nm | p. 133 |
| V-belt replacement width | 15.5 mm | p. 151 |
| Operating weight (without support plates) | 367 kg | p. 11 |
| Engine displacement | 413 cm3 | p. 11 |
| Fuel consumption | 1.5 l/h | p. 11 |
| Tank capacity | 5.0 l | p. 11 |
| Torque: Protective frame screws | 86 Nm | p. 78 |
| Torque: Belt guard screws | 49 Nm | p. 79 |
| Torque: Exciter housing binding screws | 120 Nm | p. 119 |
| Torque: Eccentric weight screws | 295 Nm | p. 135 |
Wacker DPU 4045H, DPU 5045H Common Problems This Manual Covers
Wacker DPU 4045H no reverse travel, forward works fine, handle control feels soft
Check the hydraulic oil level in the guide handle head first; low oil or trapped air kills reverse. Top up and bleed the hydraulic line following the procedure on page 145. Chock the machine before working under it, this plate weighs 367 kg. If bleeding fails, inspect the control piston in the guide handle head.
Manual Section: Bleeding the hydraulic line p. 145Losing hydraulic oil, level drops after every shift, oil weeping around centre pole
Inspect the hose pipe and hollow screw connections on the upper mass for leaks, procedures start on page 97. Replace crushed seals rather than overtightening. If you pull the protective frame for access, torque its screws to 86 Nm on reassembly. Refill the hydraulic control, then bleed the line per page 143 before running.
Manual Section: Hydraulic Line p. 139Forward and reverse travel speed too low, plate crawls even at full throttle
Measure the V-belt width before anything else; replace it once it wears below 15.5 mm, the check is on page 151. Inspect the clutch drum and V-belt pulley for glazing and wear, covered from page 79. Torque the belt guard screws to 49 Nm when you button it back up.
Manual Section: V-Belt/Clutch p. 79Diesel engine will not start, no click from starter, key does nothing
Test battery voltage and the ignition lock contacts before condemning the starter; a worn lock is a known failure on these plates. Work through the engine start fault table on page 153. Verify fuel supply too: the tank holds 5.0 l and the engine burns about 1.5 l/h, so an empty tank sneaks up fast.
Manual Section: Malfunction p. 153No vibration, engine revs fine but base plate stops compacting mid pour
Check the exciter V-belt first; a snapped or slipping belt is the usual cause, replacement is covered starting on page 151. If the belt is good, pull the exciter and inspect the eccentric weights and bearings, procedures start on page 121. Torque the eccentric weight screws to 295 Nm and the exciter housing binding screws to 120 Nm on reassembly.
Manual Section: Exciter Shafts p. 121Frequently Asked Questions
What are the torque specifications for the engine mount bolts on the Wacker DPU 4045H and DPU 5045H?
The four cheese head screws (2) used for the engine mount must be tightened to a torque of 86 Nm. p. 95
What is the procedure for bleeding the hydraulic control system?
To bleed the hydraulic control, remove the apron, place the guide handle in a vertical position, and open the filler hole (26). Loosen the hollow screw (27) and slowly press the control handle (6) into the advance position until hydraulic oil leaks bubble-free from the hollow screw. p. 149
What is the required oil capacity for the exciter?
The exciter requires 0.75 liters of Fuchs Titan Unic 10W40 MC oil. p. 150
What is the maintenance interval for changing the exciter oil?
The exciter oil should be changed every 250 hours of operation. p. 147
What are the valve clearance specifications for the engine?
The valve clearance for the engine should be set at 0.1 mm for the inlet valve and 0.2 mm for the outlet valve when the engine is cold. p. 147
Will this Wacker DPU 4045H Repair Manual download right away?
A single searchable PDF file of 158 pages, downloadable right after payment. Nothing ships, nothing waits in the mail.
Does this Wacker DPU 4045H manual allow printing?
You can. The PDF is unlocked and carries no copy protection, so print the sections you want and keep the file as your backup.
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