Humbaur Rexus 5000 Series User manual

MACHT’S MÖGLICH
Part 2 - REXUS
All-poly box trailer
Operating
Instructions
en
5000 series

2 Version 2019/01 REXUS operating instruction manual (Part 2)
Notes on use / target group
PART 2 - Original - "REXUS" Operating Instruction Manual
This "REXUS" operating instruction manual Part 2 is intended for you as the user of a ready-to-use trailer.
It provides detailed steps on how to handle the REXUS trailer.
It contains all the relevant details on safe operation, care / cleaning, maintenance / servicing, troubleshooting and
decommissioning / disposal.
This specific operating instruction manual (Part 2) for your trailer is provided on the enclosed CD. You can also download it from
www.humbaur.com in the section: Download - Operating Instructions.
PART 1 - "Trailers up to 3.5 to General Points"
For all other general information on trailers up to 3.5, see the operating instruction manual, "Trailers up to 3.5 to
(General Points - Part 1)".
• Together, PART 1 and PART 2 form the complete documentation for your trailer, which you, as the user, should have at your
disposal.
Read these operating instruction manuals carefully and completely before using your trailer for the first time and observe all the
instructions, safety information and warnings. Comply with the steps for handling.
• Non-observance of any of the documentation can cause injuries to you and to other persons and can cause material damage.
• Non-observance may invalidate your guarantee entitlement.
• Keep this operating instruction manual in a safe place for the entire service life of your trailer.
• We advise you store the operating instruction manuals in the driver's cab and to keep them on hand in case you need to consult them.
• They should be passed on to the new user / owner if you rent out or sell your trailer.
Furthermore, as a road user, you are obliged to observe all national regulations for driving a vehicle and trailer and to comply
with your obligations as the owner of a commercial vehicle.
• This includes carrying out regular maintenance and care tasks and periodically subjecting your trailer to a full technical inspection.
• Observe any special stipulations that are specific to your country.
Name and address of dealer:
Name:
Address:
Telephone:
►►
►►Please enter the name of your dealer.
Name and address of manufacturer:
Humbaur GmbH
Mercedesring 1
86368 Gersthofen
Germany
Tel. [phone]
Fax [phone]
[e-mail]
www.humbaur.com

REXUS operating instruction manual (Part 2) Version 2019/01 3
Index
1 Identification 4
1.1 Declaration of Conformity 4
2 Product description 4
2.1 Components 5
2.2 REXUS with ramp wall 6
2.3 REXUS with double wing doors 6
2.4 REXUS with sales hatch 6
2.5 REXUS as animal transporter 6
2.6 Standard equipment 7
2.7 Optional accessories 7
3 Intended use 8
4 Foreseeable misuse 8
5 General Safety Instructions 9
6 Loading and Unloading 9
6.1 Load distribution 9
6.2 Load securing 10
6.3 Supports (optional) 12
6.4 Ramp wall 14
6.5 Double wing door (optional) 16
6.6 Sales hatch (optional) 18
6.7 Access door 18
7 Driving 20
7.1 Skylight (optional) 20
7.2 Lights 21
8 Parking 22
8.1 Parking an uncoupled trailer 22
9 Cleaning / Maintenance / Servicing 23
9.1 Care / Cleaning 23
9.2 Maintenance / Servicing 23
10 Troubleshooting 25
11 Decommissioning / disposal 25
11.1 Decommissioning 25
11.2 Disposal 25

4 Version 2019/01 REXUS operating instruction manual (Part 2)
1 Identification
►►Put a cross next to the type of trailer you have
acquired.
►►Read the general operating instruction manual
for trailers up to 3.5 to (PART 1).
Product name: REXUS all-poly box trailer
5000 Series:
Equipment:
Type 1: REXUS with ramp wall o
Type 2: REXUS with double wing doors o
Type 3: REXUS with sales hatch o
Type 4: REXUS as livestock transporter o
1.1 Declaration of Conformity
Humbaur GmbH hereby confirms that all
relevant EU directives for the registration and
safe use of trailers of the 5000 series of REXUS all-poly box
trailers with accessories have been complied with.
You can request a detailed EU declaration of conformity from us
separately.
Possible range of colours
2 Product description
The Rexus is characterised by an attractive appearance, itself
marked by the possible ranges of colours and details, such as
decorative brackets, alloy wheel rims and mudguards.
The Rexus can be fitted with a ramp wall or with a double wing
door.
There is an access door on the front right side of the trailer as
standard.
The Rexus is available for different applications. For example,
it can be used as a sales trailer or as m/c transporter or also as an
animal transporter.
The cargo bed, which is made from laminated wood, is 21 mm thick
and can additionally be produced with the following coatings:
Floating screen floor or aluminium tread plate.

REXUS operating instruction manual (Part 2) Version 2019/01 5
Illustrated examples
12 1311
1 2 34
6
7
8
9
10
5
Front view
19 20 21
15
16
17
14
18
22
Rear view
2.1 Components
1. Hand brake lever
2. Electric systems plug
3. Automatic jockey wheel
4. Handle
5. All-poly body
6. Ball head coupling
7. Drawbar support
8. Safety cable
9. V drawbar
10. Wheel chock
11. Decorative bracket
12. Front reflector / white reflector
or front position lamp
13. Wheel (tyre)
14. 3rd brake light
15. Support surface
16. Locking espagnolette lock
17. Espagnolette lock
18. Ramp wall
19. Tail lights
20. Number plate light
21. Gas strut
22. Access door
Accessories / extensions are sepa-
rately explained in the partial de-
scription below or in the operating
instruction manual "Trailers up to
3.5 to" (General Points - Part 1).

6 Version 2019/01 REXUS operating instruction manual (Part 2)
2.2 REXUS with ramp wall
2.3 REXUS with double wing doors
2.4 REXUS with sales hatch
2.5 REXUS as animal transporter

REXUS operating instruction manual (Part 2) Version 2019/01 7
2.6 Standard equipment
Tie-down ring on cargo bed Access door
Alloy wheel rims Jockey wheel
13-pin plug 3rd brake light
Floor plate 21 mm
2.7 Optional accessories
AKS safety coupling Breast/breech bar
Barred tie rail Slotted tie rail
Spare wheel/holder Motorcycle stand/strap
Prop stands ClickFix ground stand
Floating screen floor Aluminium tread plate

8 Version 2019/01 REXUS operating instruction manual (Part 2)
Tie-down ring in tie-down Folding rings
groove 0.2 / 0.4 t
Skylight Interior light
3 Intended use
• M/c transporter in motorcycle stand and corresponding
tie-down.
• Animal transport secured with breast/breech bars.
• Rexus with side sales hatch and individual layout.
• Loading / unloading and transporting of materials and
goods as fixed / linked load units.
• Transporting of load units, with the exception of hazardous
goods, e.g. explosive, chemical or liquid materials.
• Form and force-fitting load securing by means of tie rails
and round locking bars in body, as well as tie-down rings
on the cargo bed.
4 Foreseeable misuse
• Driving with the motorcycle stand not screwed onto the
cargo bed.
• Driving with unsecured motorcycle.
• Driving with the ramp wall not completely closed.
• Driving with insufficiently load securing.
• Driving with unsecured double wing doors, access doors,
sales hatch and ramp wall.
• Loading the trailer whilst the ramp wall is not completely
lowered
• Transporting people.
• Driving onto the ramp wall with vehicles exerting high
point loads, e.g. vehicles with small wheels such as fork
lifts, mobile lifting platforms, etc.
• Driving onto the ramp walls with steel-tracked vehicles.
• Non-observance of the safety instructions in the operating
instruction manual "Trailers up to 3.5" (Part 1).

REXUS operating instruction manual (Part 2) Version 2019/01 9
5 General Safety Instructions
CAUTION
Folding ramp wall!
After unlocking, the ramp wall can fall down
uncontrollably, e.g. from load pressure - risk of
collision!
This can result in feet being crushed.
►►Stand to the side when unlocking the ramp wall.
►►Relieve the load pressure beforehand, if necessary.
►►Allow the ramp wall to fall to the floor if the gas struts
are defective.
Never try to stop it.
►►Keep your feet away from the area round the
ramp wall.
►►Keep people away from the area around
the ramp wall during unfolding.
►►Use .
CAUTION
Swivelling double wing doors!
After unlocking, the double wing doors can swiv-
el uncontrollably, e.g. by load pressure / gust of
wind - risk of collision!
►►Keep yourself and other people clear of the swivel area.
►►Unlock the double wing doors carefully and press against
them, if necessary.
►►Relieve the load pressure beforehand, if necessary.
Swivelling sales hatch!
After unlocking, the sales hatch can swivel up
uncontrollably - risk of collision!
►►Keep yourself and other people clear of the swivel area.
Observe the other general safety recommendations in
the operating instruction manual "Trailers up to 3.5"
(General Points - Part 1).
6 Loading and Unloading
6.1 Load distribution
Before loading, check the max. load capacity that you
are able to transport with your trailer.
Check that the max. permissible body dimensions of
your trailer are not exceeded.
The load distribution works directly on the road handling of the
towing vehicle tension.
NOTICE
Poor / one-sided load distribution of the goods!
Strongly uneven / point load distribution can lead to over-
stresssing and damage to the trailer components.
►►Before loading your trailer, check which load objects are
the heaviest.
►►Position the heaviest objects centrally on the cargo bed
and in the area of the axles.
►►Distribute the goods evenly over the cargo bed
- Avoid point / one-sided load distribution.
Correct load distribution
kg
Load in axle region
The trailer and the towing vehicle are stable with all wheels on
the ground.
Incorrect load distribution
kg
Load too far forward (to motor vehicle)
The trailer tilts forwards; the towing vehicle tilts backwards =
the max. drawbar load has been exceeded.
Incorrect load distribution
kg
Load too far backwards (to motor vehicle)
The trailer tilts backwards; the towing vehicle tilts forwards =
the drawbar load is too low or negative.

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6.2.2 Slotted tie rail with fittings
1 2 3
Slotted tie rail with fittings
1. Slot
2. Slotted tie rail
3. Fitting
1
2
3
Fitting
1. Tie-down ring
2. Strap
3. Anchoring
Positioning fitting
►►Position the fittings along the slotted tie rail.
►►Press the strap and, at the same time,
place the fitting in the slot of the rail.
►►Check that the fitting has snapped into the slotted tie rail.
Goods can be tied down on the fittings.
6.2.3 Combined anchor rail with round locking bars
1
2
3
Round locking beam deployed
1. Combined anchor rail
2. Round locking bar
3. End journals
Place unused round locking bars into the combined
anchor rail during the journey.
6.2 Load securing
For relevant safety information for load securing, refer to
the section “General load securing“ in the operating
instruction manual “Trailers up to 3.5 to - General part 1“.
6.2.1 Tie-down points
1
2
Tie-down points on the cargo bed
1. Tie-down ring
2. Cargo bed
Tie-down ring, max 400 daN (kg)
Sticker for tie-down force
Correct load securing

REXUS operating instruction manual (Part 2) Version 2019/01 11
6.2.4 Barred tie rail
1
2
3
Barred tie rail with inserted round locking bar
1. Ramp wall
2. Barred tie rail
3. Round locking bar
Operating the round locking bar
Removing the round locking bar
►►Press the locking bar together so that the end journals are
disengaged from the tie rail.
►►Carefully guide the other end journals out of the tie rail.
►►Swivel the locking bar slightly upwards or to the side so
that it does not damage the interior walls.
►►Place the locking bar horizontally in a place secure
from damage - not in the danger area (work zone).
Positioning end journals
►►Place the end journals on the bar.
►►Ensure that the locking bar sits flush.
The locking bar is installed and secured.
6.2.5 Motorcycle stand
1
2
3
Motorcycle stand mounted on the cargo bed
1. Motorcycle stand
2. Screws
3. Cargo bed
►►Position the motorcycle stand according to the size of
your motorcycle and align it as centrally as possible.
Please take note of the motorcycle stand manufacturer's
mounting instructions! Use the fastening elements
supplied or insert suitable screws.
►►Check the screws of the motorcycle stand so that no lines
are damaged under the chassis.
►►If possible, screw the motorcycle stand into a lateral
bracing.
The motorcycle stand must be screwed safely and
securely! If necessary, have the motorcycle stand
installed in a specialist workshop.
Tying -down motorcycles
Motorcycle in motorcycle stand
►►Centrally position the motorcycle on the motorcycle stand.
- Where necessary, first adjust the motorcycle stand.
►►Use suitable tie-down straps to tie down the motorcycle
to the floor at the 4 tie-down points.
Observe the motorcycle stand manufacturer’s instruc-
tions and those of the motorcycle manufacturer.

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6.2.6 Breast / breech bar
Functional explanation
• The breast / breech bars are used to stabilise and hold your
animals.
• When transporting several small animals, these can be
used as partition bars.
WARNING
Unsecured breast / breech bars!
The animal may fall during the drive or get frightened by bars
sliding around - lurching / accident risk!
►►Check that the breast and breech bars are attached
and secured on both sides before driving off.
1
3
2
Unsecured breast / breech bars
1. Breech bar
2. Holder
3. Breast bar
1
2
3
Unsecured breast / breech bars (detail)
1. Locking
2. Safety hook
3. Hole
Position the breast / breech bars according to the size of
your animal.
Hooking in
►►Hook the locking mechanism in the holders.
►►Guide the safety hooks through the holes of the locking
mechanism.
The breast/breech bars are secured.
6.3 Supports (optional)
NOTICE
Load the trailer with the supports
completely extended!
The axle compresses during loading! The entire weight of the
trailer lies on the supports. Supports will be damaged!
►►Do not crank down / place the supports right down to
the floor before loading (approx. 4-6 cm air between
supports and floor).
6.3.1 Prop stands
1
2
3
4
Prop stands lowered
1. Handle
2. Cylinder body
3. Rotary knob
4. Holder
CAUTION
Loosely tightened rotary knob!
During loading/unloading, the prop stand can
slide down and your trailer may tip!
►►Before loading/unloading, check that the rotary knob
is tightened.
Lowering for loading
►►Undo the rotary knob. While doing so hold the prop
stand on the handle.
►►Lower the cylinder body down so that an air gap of ap-
prox. 4-6 cm remains between floor and supports.
►►Tighten the rotary knob.
Lowering for unloading
►►Undo the rotary knob. While doing so hold the prop
stand on the handle.
►►Lower the cylinder body right down to the floor.
►►Tighten the rotary knob.

REXUS operating instruction manual (Part 2) Version 2019/01 13
6.3.2 ClickFix ground stand
Functional explanation
• ClickFix ground stands are actuated via a crank handle.
• During raising/lowering, the supports automatically lock in
the end position.
• In addition, the height of the adjustable support can be
adjusted - via cotter pin.
• The ClickFix ground stand can bear forces of up to 1,000 kg
static and 500 kg dynamic.
2 31
Ground stand in driving position
1. Adjustable support (adjustable)
2. Ground stand
3. Crank handle base
Lowering for loading
Cranking down the ground stand
►►Insert the crank handle into the crank base.
►►Crank down the ground stand in a clockwise direction
until approx. 4-6 cm remains between adjustable stand
and the ground.
The ground stands lock in the vertical position.
Ground stands cranked down
Lowering for unloading
Ground stands cranked down
►►Crank the ground stands right down to the ground.
Raising to driving position
Cranking up ground stands
►►Insert the crank handle into the crank base.
►►Crank the ground stands in an anti-clockwise direction
until they lock automatically.
The ground stands are secured in driving position.
►►Safely store the crank handle.

14 Version 2019/01 REXUS operating instruction manual (Part 2)
6.4 Ramp wall
1
2
4
3
5
6
Rear view of ramp wall
1. Support surface
2. Ramp wall
3. Locking mechanism for espagnolette lock
4. Espagnolette lock
5. Gas strut
6. Hinge
1
3
4
5
6
2
Espagnolette lock closed
1. Locking bolt
2. Espagnolette
3. Key
4. Snap lock (with hole for padlock)
5. Locking hook
6. Handle
►►Unlock the handle with the key or remove the padlock.
WARNING
Fold down the ramp wall!
When unlocking and folding down the ramp wall,
feet / hands / fingers can be crushed between the
ramp wall and the ground!
►►Hold onto the side of the ramp wall with one hand.
►►Use .
Opening
Unlocking / opening the espagnolette lock
►►Push in the snap lock.
►►Pull the handle.
The lock is released.
►►Turn the handle up so that the locking hook right / left
can move out of the locking bolt.
The ramp wall is unlocked.
Closing the espagnolette lock
►►Press in the handle - so that when this folds down the
ramp wall does not fall down on the ground.

REXUS operating instruction manual (Part 2) Version 2019/01 15
The gas struts aid the operation of the ramp wall, so that it can
be operated by a single person.
Folding down the ramp wall
►►Hold the side of the ramp wall and allow the ramp wall
to descend slowly - do not let it fall.
Make sure that your feet are not near the edge of the
ramp wall.
kg
max. 1300 kg
1
Ramp wall folded down
1. Ramp wall (max. 1,300 kg load capacity)
►►The cargo bed can be loaded.
WARNING
Ramp wall overloaded!
The ramp wall may become deformed or break.
The loads / load vehicle can tip - crushing risk!
►►Drive onto the ramp wall, e.g. with the pallet truck,
evenly and slowly.
►►If necessary, before driving onto the trailer, check the
gross weight of the load vehicle with goods.
Make sure that the trailer is secured so that it cannot
roll away.
►►Make sure that road traffic safety is not impaired when
loading and unloading the trailer.
►►If necessary, use additional signalling devices,
e.g. signs, barriers.
Closing
Closing the tailgate
►►Lift up the ramp wall from the side into the vertical position.
- The gas struts help you to do this.
Unlocking the espagnolette lock
►►Unlock the espagnolette lock.
►►Fold the ramp wall up fully.
Locking the espagnolette lock
►►Press the handle so that the locking hook grips
the locking bolt.
The lock is secured with the snap lock.
The ramp wall is secured against automatic opening
while driving.
►►Additionally lock the lock with the key as protection
against unauthorised access.

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Drive onto the ramp wall (example)
Loading example 1
Loading example 2
►►Slowly and carefully drive on to the ramp wall or slowly
push the vehicle to be loaded upwards in a controlled
manner.
►►Make sure that the vehicle being loaded is in line with the
ramp wall.
6.5 Double wing door (optional)
1
2
4
3
Rear view of double wing door
1. Locking hook
2. Hinge
3. Double wing door
4. Espagnolette lock
1
2
3
4
5
Espagnolette lock closed
1. Espagnolette
2. Snap lock
3. Handle
4. Locking bolt
5. Locking hook
1
2
3
Support rope secured
1. Eyelet
2. Carabiner
3. Support rope

REXUS operating instruction manual (Part 2) Version 2019/01 17
Opening
Opening the espagnolette lock
►►Push in the snap lock.
►►Pull the handle.
The lock is released.
►►Turn the handle up, so that the locking hook at the top /
bottom can move out of the locking bolt.
The double wing door is unlocked.
NOTICE
Unsecured double wing door!
The double wing door can slam and damage the lights -
material damage!
►►Before fully opening, check that the double wing door
is secured with support rope and carabiner.
►►Swivel open the double wing door.
Double wing door open, unsecured
►►Insert the carabiner into the eyelet.
The wing door is secured against tilting.
Double wing door open, secured
Closing
Closing the double wing door
►►Swivel the double wing door closed.
- Close the left and then the right wing.
Closing the espagnolette lock
►►Press the handle so that the locking hook grips the lock-
ing bolt.
The lock is secured with the snap lock.
The double wing door is secured against unintentional opening
while driving.
Espagnolette lock closed
►►In addition, lock the lock with the key as protection
against unauthorised access.

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6.6 Sales hatch (optional)
1 2 3
45
Rexus with sales hatch
1. Rain protection cover
2. Sales hatch
3. Espagnolette lock
4. Prop stand
5. Locking hook
1
2
3
Sales hatch, open
1. Sales hatch
2. Gas strut
3. Piston rod safety device
Opening
►►Unlock the espagnolette lock.
►►Pull the sales hatch handle up
- The gas struts will support you in the process.
The sales hatch is held up by the gas struts and automatically
secured against folding shut.
Closing
►►Push in the piston rod safety device.
►►Carefully fold down the sales hatch.
►►Lock the espagnolette lock.
6.7 Access door
1
2
3
4
Access door closed
1. Access door
2. Cylinder lock
3. Rotary handle
4. Door holder
Operating the rotary handle (outside)
Unlocking opening access door
►►Shut the cylinder lock of the rotary handle.
►►Turn the rotary handle 90° in a counter-clockwise direction.
Access door open
►►Turn the access door until the door holder latches.
The access door is latched.

REXUS operating instruction manual (Part 2) Version 2019/01 19
12
Door holder latched
1. Nipple
2. Bushing
Operating the rotary knob (inside)
1
2
3
Access door open
1. Upper locking point
2. Middle locking point
3. Lower locking point
1
2
Opening the access door from the inside
1. Closing bracket
2. Rotary knob
The cylinder lock of the access door must be unlocked.
►►Rotate the rotary knob through 90° clockwise.
►►Open the access door.

20 Version 2019/01 REXUS operating instruction manual (Part 2)
7 Driving
WARNING
Unlocked ramp wall / double wing door /
sales hatch!
Unlocked ramp wall / double wing door / sales
hatch may unintentionally fold down while driv-
ing - accident risk! The goods may then fall out
- collision risk!
►►Ensure that the tailgate / double wing door / sales hatch
is locked with the rotary lever lock before driving off.
Before setting off, make sure that the maximum
permissible loads (load capacity and drawbar load) are
not exceeded.
Observe the maximum permissible towing load and
drawbar load of your towing vehicle and the trailer
coupling.
►►Where required, check the weight information for the
goods to be loaded.
►►Carry out a departure check
(see operating instruction manual, "Trailers up to 3.5 to"
(General Points - Part 1))
Take note of the safety / driving instructions for the
towing vehicle and trailer as given in the operating
instruction manual "Trailers up to 3.5 to" - General -
Part 1.
Your trailer can be licensed for a top speed of max. 100 kph.
For this, several conditions must be fulfilled.
- For information, see www.humbaur.com
►►Adapt your driving style to the road and weather conditions!
- Reduce your speed and drive particularly carefully
around bends / when turning!
►►Start braking processes smoothly (not suddenly).
Driving example
7.1 Skylight (optional)
Functional explanation
• The skylight is used to provide fresh air during the journey.
1
2
3
Skylight closed
1. Roof vent
2. Spring leaf
3. Handle
Operation
►►Press the both handles individually or one after the other
upwards.
Skylight is open.
Skylight open
►►Pull the handles downwards one after another.
Skylight is closed.