This Wacker Neuson Repair Manual is a 202 page factory guide for the reversible vibratory plate range, covering the DPU 5545, the DPU 5045H, the DPU 5045H 750 wide, and the DPU 5045H manual start versions. The text layer is intact, so the PDF is searchable and printable.
These plates produce 50 kN of centrifugal force and run on a 6.1 kW diesel engine, with an operating weight around 387 kg. The manual walks through the full teardown and reassembly of the clutch and V-belt drive, the exciter, the centre pole and HAV drawbar, the Bowden cable, and the battery and wiring.
It closes with a maintenance schedule, a fault finding chart, the wiring diagram, and complete tightening torque tables, giving an owner or repair shop what is needed to service or rebuild the machine.
What's Inside This Repair Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety & Precautions | 6-9 | Safety Instructions, Technical Data |
| Machine Identification & Specifications | 10-15 | Operating Weight, Power Transmission, Exciter, Drive Engine, Electrical System, Hydraulic Control, Applications, Description of Function |
| Operation | 16-21 | Starting Requirements, Switching Off, Compaction Without Extension Plates, Emergency Manual Starting, Mechanical Oil Pressure Control |
| Tools & Clutch/Cover Service | 22-49 | Press-Out Tool, Strap Wrench, Removing/Installing Side Covers and Battery, Disassembling Clutch and Replacing V-Belt, Assembling Clutch and Installing V-Belt, Removing Bowden Cable |
| Engine & Centre Pole Overhaul | 50-107 | Removing/Installing Diesel Engine, Removing/Installing Upper Mass, Removing/Installing Complete Centre Pole, Disassembling/Assembling Centre-Pole Head, Disassembling/Assembling Base Plate and Exciter, Removing/Installing Exciter Shafts |
| Switches, Wiring & Hydraulic Line | 108-121 | Removing/Installing Switches and Wiring Harness, Removing/Installing Hydraulic Line, Bleeding the Hydraulic Line |
| Version Changes | 122-127 | Version 101: EPA-Compliant Engine, Version 102: Modified Exciter, Version 103: Centre-Pole Latch Modification |
| Hav Drawbar Assembly | 128-161 | Center Pole Head, Control Piston, Gear Shaft, Compression Spring, Spacer, O-Ring, Pre-Assembly of the Drawbar, Assembly of the Dust Cover, Assembly of the Center Pole Support, Assembly of the Control, Pre-Assembly of the Bowden Cable, Assembly of the Bowden Cable in the Machine |
| Hav Drawbar Battery & Instrument Panel | 162-175 | Battery Guard, Jump Start Cables, Wiring Harness, Positive/Minus Pole Line, Cable Binder, Battery Cover, Housing, Coiled Helix Cable, Display Unit, Ignition Starter Switch, Operating Hour Meter |
| Hav Drawbar Disassembly | 176-191 | Center Pole Head, Control Piston, Compression Spring, Drawbar Pipe, Lock Coupling, Rubber-Metal Shockmount, Square Pipe, Vibration Damper, Battery Guard, Wiring Harness, Battery Cover, Ignition Starter Switch |
| Maintenance | 192-195 | Maintenance Schedule, Engine Oil, Battery, Hydraulic Control, Exciter, Check Oil Level, Exciter Vee-Belt |
| Troubleshooting | 196-197 | Forward Speed Too Low, Reverse Speed Too Low, No Reverse Motion, Loss of Hydraulic Oil, Charge Control Lamp Will Not Extinguish, Engine Does Not Start |
| Wiring Diagrams | 198-199 | Socket Plug, Starter Button, Wiring Harness, Indicator, Battery, Multifuse Overcurrent Switch |
| Tightening Torques | 200-202 | Metric Fasteners, Imperial Fasteners, Torque Values, Foot-Pounds, Newton-Meters |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Hydraulic Failure Remedy | Top up hydraulic oil, bleed system, replace defective parts if necessary, and correct oil level according to mark. | p. 196 |
| V-belt Replacement Criteria | Replace when width is less than 15.5 mm. | p. 42 |
| Bowden Cable Actuator Thread Projection | approx. 35 mm | p. 50 |
| Bowden Cable Adjuster Nut Position | rear nut to approx. 50 mm | p. 51 |
| Battery Voltage | 12 V | p. 10 |
| Battery Capacity | 55 Ah | p. 10 |
| Battery Buffer/Protector Replacement | Remove defective battery buffers (10) using a screwdriver and replace. | p. 28 |
| Rotary Shaft Seal Replacement (Exciter) | Remove if defective; can be used only once. Install with suitable tool and manual press, coat outside with oil. Pack space between dust excluder lip and sealing lip with Alvania R 2 grease. | p. 92 |
| Clutch Seal Replacement Criteria | Check at regular intervals and replace if necessary. | p. 43 |
