April 2006 INSTALLATION INSTRUCTIONS MODEL NO. 70680 07068 24K 5th Wheel with Heavy Duty EZ-ROLLER For use on shortbed P/U applications US Pat. No. 6247720 PARTS INCLUDE: 1. 1675-07 Head Assembly (1) 15. 1222-03 5/8-11 x 1-3/4 Hex Flange Bolt (4) 2. 4794-05 Cross Tube Assembly (1) 16. 1223-05 5/8-11 Hex Flange Locknut (4) 3. 4987-04 Yoke Assembly (1) 17. 1685-01 3/4-10 x 2-1/4 Hex Bolt (2) 4. 1673-01 Pivot Pin Assembly (1) 18. 1850-03 3/4 Flatwasher (2) 5. 3965-03 Short Latching Rod (1) 19. 1483-01 Yoke Bushing (2) 6. 3966-08 Long Latching Rod (1) 20. 1889-03 3/4-10 Nylon Lock Nut (2) 7. 3964-07 Outer Tube (1) 21. 3590-02 1/4-20 x 1-1/2 Hex Bolt (4) 8. 3096-04 Handle Assembly (1) 22. 2278-05 1/4-20 Hex Flange Locknut (4) 9. 4990-04 Left Upright Assembly (1) 23. 1308-01 Compression Spring (1) 10. 4795-07 Right Upright Assembly (1) 24. 4015-03 7/8 Flatwasher (1) 11. 3615-05 Head Handle Assembly (1) 25. 1596-05 Locking Pin Assembly (1) 12. 1557-01 Rail Hitch Pin (4) 26. 2009-04 Shim Plate (1) 13. 1335-03 Hair Pin (4) 27. 2974-01 Pivot Pin Washer (1) 14. 3498-09 Safety Pin (1) ***Be sure that the loaded trailer weight does not exceed 24,000 lbs. or the vertical load rating does not exceed 6000 lbs. ***Be sure that the weight of the loaded trailer does not exceed the truck manufacturers trailer towing or payload capacities. ***Use only a 2 king pin with this 5th wheel hitch. 1. Before beginning assembly of the EZ ROLLER, install the 70550 bed rails in your truck by following the bed rail installation instructions included with that kit. Be sure they are are parallel with each other. The diagonal dimensions X and Y should be within 1/4 of each other. See Illustration 1. With the bed rails correctly installed, the assembled EZ ROLLER will drop into the slots on the top surface of the bed rails and operate smoothly. 2. Check all of the parts from kit against the Parts Include section found on this instruction sheet, to identify the parts for easier assembly.
3. Grease the end of the the short latching rod #5 and slide into the 5 hole side of the left upright assembly #9. The latch pin should also be greased. See Illustration 2 for all locations needing to be greased. 3a. Place the latch pin into the forward locking holes in upright assembly. Place the large flatwasher #24 and the compression spring #23 on the end of the rod that extends through the inner side of the upright assembly. Slide the outer tube #7 onto the rod so that it compresses the spring and that the attachment holes in the outer tube line up with the holes in the short latching rod. Bolt parts together with the 1/4 fasteners #21 and #22, supplied. See Illustration 3. 4. Insert the long latching rod #6 into the outer tube #7. Position rod so that the correct hole is aligned with the end hole in the outer tube. See Illustration 3a. Bolt securely in place with 1/4 fasteners #21 and #22, supplied with kit. This will give the correct spacing for your 5th wheel head assembly. 5. Place the assembled upright onto the driver side of the installed base rails and pin in place with hitch pins supplied with base rail kit. See Illustration 1 and 4 for correct slot location. 6. Grease the latch pin and free end of the latching rod which is connected to the drivers side upright assembly. See Illustration 2. Slide it onto the remaining upright so that the latch pin inserts fully into the forward locking hole. Tabs on upright rail assembly should position into passenger side slots in base rail where they are pinned in place. Check to be sure unit is centered on base rails. See Illustration 4. 7. Place the cross tube assembly #2 between the left and right uprights and bolt loosely in place at same set of holes on each upright using the 5/8 fasteners supplied as shown on Illustration 4a. Height adjustments will be made later.
7a. Check operation of latching pins. Both pins must fully engage into both tube locking holes. See Illustration 5. If pins are not fully engaged, place the shim plate #27 between the cross tube and either upright as shown on Illustration 5a. Also, double check the alignment of the base rails. The locking pins MUST freely engage into the locking holes. 8. Position the head assembly #1 upside down on a clean smooth surface. Place the yoke assembly #3 into the head assembly so that holes in tabs align with holes in head side plates. Place a 3/4 flatwasher #18 and yoke bushing #19 on a 3/4 bolt #17. Grease inside and outside surfaces of bushing. Insert the bolt into hole in yoke tab and on through hole in head side plate. See Illustration 6. Be sure yoke bushing is aligned in yoke hole. Secure with a 3/4 nylon lock nut #20. Repeat process on other side of head assembly. Tighten the 3/4 fasteners to 225 to 260 ft. lbs. torque. 9. Apply grease to the large hole in the yoke and the pivot pin. See Illustrations on SERVICE AND MAINTENANCE INSTRUCTION page. 9a. Turn head and yoke assembly over and place yoke over previously installed cross tube. Align hole in yoke with hole in cross tube and insert the lubricated pivot pin #4 through hole in yoke and cross tube. Place pivot pin washer #27 on pivot pin #4 and secure with safety pin #14. 10. Check the height of the hitch head. There should be a minimum of 5-6 clearance between the bottom of the trailer overhang and the top of the truck box. More clearance may be needed if travel over uneven roads is expected. Make any adjustments as needed to obtain this clearance. 11. Tighten the 5/8 cross tube to upright attachment bolts to 160 ft. lbs. torque. 12. Attach the EZ Roller handle assembly #8 to latching rod extending out of the drivers side upright assembly, and the head handle assembly #11 to the ro d extending out of the drivers side of the head, using the remaining 1/4 fasteners #22 and #23. See Illustration 7. Your EZ Roller is now ready for operation.
CHECK MOVEMENT OF EZ ROLLER 1. Pull EZ Roller handle out and rotate counterclockwise to place the locking pin in the rear hole. Move the unit rearward the full rolling distance. The locking pin should engage and drop completely into the rear holes of each side roller rail. The handle should be completely in. 2. Pull handle out and rotate clockwise to place the locking pin in the forward hole. Move the unit forward the full rolling distance. The locking pin should engage and drop completely into the forward holes of each side roller rail. NOTE: Because the nylon buttons on the bottom of the rails may make contact with the upright assembly, the unit may not move freely when pushed by hand. It will free up as it is used with trailer attached. 3. If locking pins do not freely engage during operation, (they must fully engage in locking holes), the side rails may not be parallel. Double check that the bed rails are square and parallel as shown in Step 1. Make adjustments if needed. EZ ROLLER OPERATING INSTRUCTIONS TO MANEUVER 1. Align trailer and tow vehicle in a straight line on a level surface. 2. Pull EZ Roller handle out and rotate counterclockwise to place locking pins in rear hole. 3. Set trailer brakes and slowly drive tow vehicle forward until the EZ Roller stops with pins in rear locking position. Handle should be completely in and locking pins should be fully engaged in the EZ Roller rail locking holes. Also, visually double check that pins are engaged in holes which locks the EZ Roller in place. TO TOW 1. Align trailer and tow vehicle in a straight line on a level surface. 2. Pull the EZ Roller handle out and rotate clockwise to place locking pins in forward hole. 3. Set trailer brakes and slowly back up with tow vehicle until the EZ Roller stops with pins in forward locking position. Handle should be completely in and locking pins should be fully engaged in EZ Roller rail locking holes. 4. After visually inspecting the pins to see that they are engaged in the locking holes, you may set the trailer brakes and move the tow vehicle forward slightly to be sure locking pins are fully engaged.
TRAILER HOOK UP INSTRUCTIONS FOLLOW THESE INSTRUCTIONS FOR EACH HOOK UP 1. Before connecting your trailer to the hitch, be sure that the latch handle on the hitch head assembly is in the up horizontal position. The jaw locking mechanism should be open at this time. 2. With the hitch level, adjust the trailer height so that the king pin plate is level with or approximately 1/4 below the plate on the 5th wheel hitch. The ramps leading into the king pin box will pick up the trailer as the truck backs under the trailer king pin. 3. Lower the truck tailgate. Be sure that the trailer wheels are properly blocked, front and rear. 4. Carefully back the truck under the trailer so that the 2 king pin will engage into the slot of the hitch plate and actuate the jaw. Check the indicator located on the forward surface of the hitch head assembly. When pointer is exposed and visible, the king pin is fully seated and the jaw is closed. Inspect the jaw to be sure it is closed around the king pin and the latch handle has moved behind the jaw into the locked position. 4a. Insert the safety pin assembly through the hole in the hitch head housing and the handle. DO NOT move the truck forward until the hitch is locked and safety pin is through handle. If the safety pin cannot be inserted through the handle, check the jaw and king pin position in head. Handle must be returned fully to the lock position. 5. Connect the wiring harness from the trailer to the truck. Check trailer brakes and lights for correct operation. DO NOT raise trailer jacks at this time. 6. Apply trailer brakes alone and try to slowly pull forward with truck. This will double check that the king pin is locked into 5th wheel assembly. The trailer brakes should keep the truck from moving forward if the hitch is locked correctly. 7. Raise the trailer jacks to their retracted storage position. Remove the blocks from the front and rear of the trailer wheels. 8. Check between the bottom of the trailer overhang and the top of the truck bed for adequate clearance. Check handle to king pin box clearance during turns. Remove handle if king pin box may make contact with handle. TRAILER DISCONNECT INSTRUCTIONS 1. Block the front and rear of the trailer wheels. Disconnect the wiring harness from the truck. 2. Set the trailer jacks so that most, but not all, of the trailer load is off the hitch. 3. Remove the safety pin from the handle on the hitch head assembly. Pull the handle out and rotate down. It will stay in the unlocked position and allow the jaw to pivot open. 4. Drive the truck slowly forward and out from under the trailer.
SERVICE AND MAINTENANCE INSTRUCTIONS *Lubricate all points on 5th wheel assembly as illustrated below. *Keep internal jaw locking parts in head assembly well greased for continued smooth operation. *The latch handle should be lubricated so that it will continue to move smoothly and easily. *All remaining pivot points on hitch assembly should be greased often to prevent excessive wear. *Be sure to keep the groove in the pivot pin assembly, in the center of the cross member, packed with grease to prevent excessive wear. *Keep latching rod on Glider greased for smooth operation. For information regarding this product, or our warranty, contact your dealer or write to CUSTOMER SERVICE MANAGER P.O. Box 850, Lodi, CA 95241 70680