All 202 pages of this Wacker Neuson DPU 5545 repair manual PDF (OEM #510005945/02) cover the DPU 5545, DPU 5045H, DPU 5045H 750-wide, and manual-start variants of these vibratory plates. Inside: disassembly and assembly procedures, exploded views, and a complete HAV drawbar rebuild sequence covering center pole head, Bowden cable routing, and battery box wiring harness. You also get wiring diagrams with socket-plug and multifuse overcurrent switch detail, a fault diagnosis chart for hydraulic oil loss and no-start conditions, plus tightening torque tables for both metric and imperial fasteners. Replace your V-belt when the width drops below 15.5 mm; the rotary shaft seal packing calls for Alvania R 2 grease between the dust excluder and sealing lip. Your plate is down. Get the factory answer, not a forum guess. Bookmarked and searchable; pull it up on your phone and start wrenching.
What's Inside This Wacker Neuson DPU 5545, DPU 5045H, 5045H - 750 wide, 5045H - manual start 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 |
Wacker Neuson DPU 5545, DPU 5045H, 5045H - 750 wide, 5045H - manual start Common Problems This Manual Covers
Wacker Neuson DPU 5545 will not vibrate or compaction force feels very weak under load p. 195
Drain the exciter housing and inspect for metal shavings. Refill with fresh exciter oil to the correct level as shown on page 195. If the plate still refuses to vibrate, pull the exciter shafts and inspect the deep groove ball bearings for excessive play.
Manual Section: 19 MaintenanceMachine loses travel power, hesitates, or will not move forward and reverse properly p. 42
Remove the belt guard and measure the drive belt across its widest point. Replace the V-belt if the width measures less than 15.5 mm. Check the clutch components on page 42 for heavy grooving or glazing before installing the new belt.
Manual Section: Clutch and V-belt RepairElectric start system fails to crank the engine or turns over very slowly in cold weather p. 27
Clean the battery terminals and verify the voltage reads at least 12 V. Tighten the connections as noted on page 27. Inspect the rubber battery buffers and replace them using a flathead screwdriver if they show signs of cracking.
Manual Section: 6 Disassembly / assemblyHeavy oil leakage pouring from the exciter housing or rotary shaft seal area p. 92
Remove the defective rotary shaft seal using a suitable puller. Install the new seal with a manual press. Pack the space between the dust excluder lip and sealing lip with Alvania R 2 grease per page 92. Refer to the tightening torque table on page 200 for the correct M10 socket-head screw values.
Manual Section: Exciter Shafts RepairFrequently Asked Questions
What are the torque specs for Wacker Neuson DPU 5545 vibration plate bolts?
The manual provides detailed tightening torques for various bolts on the vibratory plate. For example, an M10 socket-head screw requires a tightening torque of 83 Nm (61 ft lb), while an M16 screw requires 355 Nm (262 ft lb). Specific values are listed in tables based on bolt size and type.
Why won't a Wacker Neuson DPU 5045H start after refueling?
If the Wacker Neuson DPU 5045H does not start after refueling, it might be due to an inefficient engine oil supply or the fuel tank running dry. You need to fill the fuel tank, check the lubricant level, and activate the mechanical oil pressure control by depressing hand lever "1" for approximately 5 seconds.
What format is this manual?
You get a 202-page searchable PDF that downloads instantly after checkout. Open it on your laptop, tablet, or phone and bring it right to the shop floor.
Am I able to print pages from this manual?
Yes. The PDF has no DRM restrictions, so you can print any page or section you need for your shop. Works with any standard printer.
Are there wiring harness diagrams in this Wacker Neuson DPU 5545, DPU 5045H?
Complete wiring diagrams are included, covering electrical circuits, harness routing, socket-plug connections, and the multifuse overcurrent switch for the Wacker Neuson DPU 5545, 5045H, 5045H - 750 wide, 5045H - manual start.
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