Only Alco-Lite Ladders are field repairable using commonly found tools — no welding needed!
CAUTION
Do not replace rung if side rail has been damaged. Contact ALCO-LITE for repair options.
Required Materials
Wood 2 X 4 wider than the inside width of the ladder
Replacement mng, bushings, and spanners
Hacksaw
Two wrenches large enough to fit 3/4″ nuts
Hammer
3/4″ threaded rod X 3′–0″ long
Two 3/4″ hex nuts (Grade 8)
Two 3/4″ flat washers
Motor oil (to be used as a lubricant)
Saw for cutting wood
Flat bladed screw driver
Directions
Lay ladder section with damaged runs on two saw horses or other suitable supports.
Clamp or secure the ladder to the support(s)
Cut out portion of damaged rung between ladder side rails. The cut should be made about 1″ from the side rail.
Insert hacksaw blade between inside rail.
After removing the bushing, carefully saw almost through the rung, being careful to stop before cutting into the side rail. Tap the rung out of the side rail.
Repeat process on the other rung end.
Measure the length the 2 X 4 is to be cut- as shown m Illustration “3”. Cut 2 X 4 to this length.
To cut rung to required length, measme through a good rung on the ladder section and add 1/4″. After cutting rung to required length, file inside of rung.
Put replacement rung through ladder side rails.
Squirt or brush oil in each end of the rung.
Make sure rung sticks out equally on each side of the ladder.
Push replacement bushings into the end of the rungs by band.
Insert steel spanners into bushing until shoulder is against bushing.
Hand tighten the nuts against the spanners.
Check to make sure the rung is still sticking out equally on each side.
Lubricate the bushings with oil. This must be done periodically throughout the tightening process.
Push the bushings into the rungs by tightening the nuts. Make sure the 2 X 4 is held in place and the rung sticks out equally on each side. Note: The bushing may not be pushed in at the same rate.
Continue tightening until both bushings are fully pushed m and flush with the end of 1he rung.
Loosen the nut and completely remove it from the threaded rod.
Pull threaded rod through the ladder and remove the spanner from inside the bushings.
Remove 2 X 4.
Wipe off excess oil.
Replace other rungs if needed.
Ladder section is ready to be reassembled and put back into service.
