Pella Window 80WW0101 User Manual

© 2012 Pella Corporation  
Part Number: 80WW0101  
WINDOW REPLACEMENT INSTRUCTIONS FOR  
CASEMENT, DOUBLE-HUNG AND CLAD FRAME WINDOWS  
INTO EXISTING CASEMENT FRAME USING FRAME SCREWS  
These instructions were tested and developed for replacing windows in wood-frame wall  
construction systems designed to manage moisture. Installation recommendations for other types  
of wall construction, wall systems or conditions, may be obtained from Pella Corporation or a  
local Pella retailer. Building designs, construction methods, building materials, and site conditions  
unique to your project may require an installation method different from these instructions and  
additional care on your part. Determining the appropriate installation method is the responsibility  
of you, your architect, or other construction professional.  
YOU WILL NEED TO SUPPLY:  
TOOLS REQUIRED:  
Tape measure  
• Cedar or Impervious shims/spacers (12 to 20)  
• Closed cell foam backer rod/sealant backer  
(12 to 30 ft.)  
• Pella® SmartFlashfoil backed butyl window  
and door flashing tape or equivalent  
• Pella Window and Door Installation Sealant or  
equivalent high quality, multi-purpose sealant  
• Level  
• Sealant gun  
• Prybar  
• Utility knife  
• Putty knife  
• Hammer  
SEALANT  
(1 tube per window)  
• Screwdrivers (Flat & Phillips)  
• Adjustable pliers  
• Side cutters  
• Roto-tool, reciprocating saw  
• Wood chisel  
• 1/8" drill bit  
• Drill  
• Low expansion, low pressure polyurethane  
insulating window and door foam sealant.  
DO NOT use high pressure or latex foams  
• #8 x 3-1/4" Finish head screws (6 to 10 per  
window)  
Installation will require two or more persons for safety reasons.  
REMEMBER TO USE APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT.  
This method of installation involves removing the sash only of the existing window. The original  
window frame will remain in place and only the existing sash, frame stops and frame hardware  
must be removed.  
CAUTION: Many windows in older homes are painted with lead-based paint. Removal of old  
windows may disturb this paint. Proper precautions must be taken to minimize exposure to dust  
and debris. Consult state or local authorities for more information.  
EXTERIOR  
EXTERIOR  
EXTERIOR  
EXTERIOR  
REMOVE EXISTING  
SASH and STOPS  
INSERT REPLACEMENT  
WINDOW  
REPLACEMENT WINDOW  
INSTALLED  
EXISTING WINDOW  
Always read the Pella® Limited Warranty before purchasing or installing Pella products. By installing this  
product, you are acknowledging that this Limited Warranty is part of the terms of the sale. Failure to  
comply with all Pella installation and maintenance instructions may void your Pella product warranty. See Limited  
Warranty for complete details at http://warranty.pella.com.  
 
3WINDOW PREPARATION  
A. Casement:  
On the room side of the window drill 1/8" diameter clearance holes through the head,  
jambs and sill of the frame. Space the holes a maximum of 6" from each end and a  
maximum of 16" on  
EVERY  
16"  
center.  
6"  
6"  
Note: On vent  
Drill 1/8"  
casements, place the  
holes so they do not  
interfere with the roto  
operator and the latch  
points on the lock side  
of the window.  
clearance hole  
6"  
6"  
EVERY  
16"  
EVERY  
16"  
Single  
Window  
3A  
Casement Sill  
6"  
6"  
B. Double-hung and Clad Frame:  
On the room side of the window, drill 1/8" diameter clearance holes through the frame at  
the locations shown. Space the holes a maximum of 6" from each end and a maximum of  
16" on center.  
Note: The lower sash must be raised to drill the holes in the sill of the double-hung  
window.  
Designer Series®  
and ProLine®  
Architect Series®  
Double-Hung  
Double-Hung Head  
Double-Hung Head  
1/2"  
Drill 1/8"  
clearance hole  
Drill 1/8"  
clearance hole  
Clad Frame Head  
1"  
Double-Hung Jamb  
Double-Hung Jamb  
Drill 1/8"  
clearance hole  
Drill 1/8"  
clearance hole  
1/4"  
Drill 1/8"  
clearance hole  
Drill 1/8"  
clearance hole  
1"  
Drill 1/8"  
clearance hole  
Drill 1/8"  
clearance hole  
1/2"  
Clad Frame Sill  
Double-Hung Sill  
Double-Hung Sill  
 
4SETTING AND FASTENING THE WINDOW  
TWO OR MORE PEOPLE ARE REQUIRED FOR THE FOLLOWING STEPS.  
Note: Because there are no stops in the opening to place the window against, be sure to hold  
the window in place when performing Steps 4A thru 4C.  
EXTERIOR  
4A  
A. Insert the replacement window in the opening by first  
placing the bottom of the window on top of the shims on  
the sill of the opening. Tip the window upright into the  
opening.  
Note: Use of a suction cup  
on the glass will assist in  
handling the window.  
4A NOTE  
INTERIOR VIEW  
Note: Each existing window frame and wall depth will  
vary in different applications; therefore there is not a  
standard measurement for the overhang of the window  
frame to the exterior or for the distance from the interior  
face of the window to interior trim. When performing  
Steps 4B thru 4C, installing the frame screws, be sure to  
keep the distance consistent all around the window.  
1
i n  
2
3
Note: On the exterior, there must be enough room for  
backer rod and 3/8" sealant bead.  
NOTE  
4B  
B. Place shims aligned with the top pre-drilled hole in  
one jamb of the window frame. Keep shims back 1/2"  
from interior face of window. Partially insert one 3-1/4"  
finish wood screw. Repeat on the other jamb.  
Note: Position the shims to ensure they allow at least  
1/2" from the exterior surface of the window to allow  
for placement of backer rod and sealant.  
C. Continue placing shims at each pre-drilled hole as needed to plumb and square the  
window. Check the window for square by making sure the diagonal measurement from  
corner to corner of the replacement window is within 1/8" in both directions. Insert a  
3-1/4" finish wood screw into each pre-drilled hole in the frame. Finish inserting the top  
screw in each jamb.  
Note: DO NOT shim above the window. DO NOT over shim.  
 
5 INTERIOR SEAL  
CAUTION: Ensure use of low pressure polyurethane window and door insulating foams  
and strictly follow the foam manufacturer’s recommendations for application. Use of high  
pressure foams or improper application of the foam may cause the window frame to bow  
and hinder operation.  
A. Apply insulating foam sealant. From the interior, insert  
the nozzle of the applicator approximately 1" deep into  
the space between the window and the rough opening  
and apply a 1" deep bead of foam. This will allow room  
for expansion of the foam and will minimize squeeze  
out. Apply sealant across interior surface of shims  
to create a continuous seal. For windows with jamb  
extensions installed, ensure the foam is placed between  
the window frame and the rough opening, not between  
the jamb extension and the rough opening. Follow foam  
manufacturer’s instructions.  
5A  
B. Check the window operation (vent units only) by opening and closing the window.  
Note: If the window does not operate correctly, check to make sure it is still plumb, level,  
square, and the jambs are not bowed. If adjustments are required, remove the foam with  
a serrated knife. Adjust the shims and reapply the insulating foam sealant.  
Interior Finish or Trim: The space between the new window and the existing window’s  
frame will need to be covered with trim. There are many ways to accomplish this and each  
case can be unique. How this is done will be the decision of the homeowner or window  
installer. A few possibilities include using cove, quarter round, or a stop moulding.  
6 EXTERIOR SEAL  
A. Insert backer rod into the space around  
6A  
the window. This should provide at least  
EXTERIOR  
3/8" clearance between the backer rod  
and the exterior face of the window.  
Note: Backer rod adds shape and depth  
for the sealant line.  
B. Place a bead of sealant at the jambs and  
6B  
head between the existing window frame  
and the replacement window frame.  
C. Begin the sill sealant bead 1/2" from one jamb, running it across the  
sill and stopping 1/2" from the opposite jamb. This 1/2" sealant gap  
on each side of the sill allows for incidental water drainage.  
D. Shape, tool, and clean excess sealant. When finished, the sealant should be the  
shape of an hourglass.  
Note: This method creates a more flexible sealant line capable of expanding  
and contracting.  
 
EXTERIOR FINISH OF EXISTING FRAME  
The exposed wood and flashing tape on the exterior stop needs to  
be covered/protected. There are many ways to accomplish this, and  
each case can be unique.  
A few possibilities include:  
a) Covering the existing trim with aluminum coil wrap/  
frame expander.  
b) Sanding, priming and painting to match existing trim.  
c) Covering the exposed wood with a high quality exterior  
grade sealant.  
Note: The contractor/installer will determine how to finish  
the exterior.  
EXTERIOR OF WINDOW  
WITH FRAME EXPANDER  
EXTERIOR FINISH OF ALUMINUM CLAD WINDOWS  
The exterior frame and sash are protected by aluminum cladding with our tough EnduraClad® or  
EnduraClad Plus baked-on factory finish that requires no painting. Clean this surface with mild  
soap and water. Stubborn strains and deposits may be removed with mineral spirits. DO NOT use  
abrasives. DO NOT scrape or use tools that might damage the surface.  
Use of inappropriate solvents, brickwash or cleaning chemicals will cause adverse reactions with  
window and door materials and voids the Limited Warranty.  
INTERIOR FINISH  
If products cannot be finished immediately, cover with clear plastic to protect from dirt, damage  
and moisture. Remove any construction residue before finishing. Sand all wood surfaces lightly  
with 180 grit or finer sandpaper. DO NOT use steel wool. BE CAREFUL NOT TO SCRATCH THE  
GLASS. Remove sanding dust.  
Pella products must be finished per the below instructions; failure to follow these instructions voids  
the Limited Warranty.  
On casement and awnings, it is optional to paint, stain or finish the vertical and horizontal sash  
edges.  
On single-hungs and double-hungs, do not paint, stain or finish the vertical sash edges; any  
finish on the vertical sash edges may cause the sash to stick. It is optional to paint, stain or finish  
the horizontal sash edges.  
On patio doors, it is optional to paint, stain or finish the vertical and horizontal panel edges.  
Note: To maintain proper product performance do not paint, finish or remove the weather-  
stripping, mohair dust pads, gaskets or vinyl parts. Air and water leakage will result if these parts  
are removed. After finishing, allow venting windows and doors to dry completely before closing  
them.  
Pella Corporation is not responsible for interior paint and stain finish imperfections for any  
product that is not factory-applied by Pella Corporation. Use of inappropriate finishes, solvents,  
brickwash, or cleaning chemicals will cause adverse reactions with the window and door  
materials and voids the Limited Warranty.  
For additional information on finishing see Pella Owner’s Manual or go to www.pella.com.  
CARE AND MAINTENANCE  
Care and maintenance information is available by contacting your local Pella  
retailer. This information is also available at www.pella.com.  
 
IMPORTANT NOTICE  
Because all construction must anticipate some water infiltration, it is important that the wall system  
be designed and constructed to properly manage moisture. Pella Corporation is not responsible  
for claims or damages caused by anticipated and unanticipated water infiltration; deficiencies in  
building design, construction and maintenance; failure to install Pella® products in accordance  
with Pella installation instructions; or the use of Pella products in wall systems which do not allow  
for proper management of moisture within the wall systems. The determination of the suitability of  
all building components, including the use of Pella products, as well as the design and installation  
of flashing and sealing systems are the responsibility of the Buyer or User, the architect,  
contractor, installer, or other construction professional and are not the responsibility of Pella.  
Pella products should not be used in barrier wall systems which do not allow for proper  
management of moisture within the wall systems, such as barrier Exterior Insulation and Finish  
Systems, (EIFS) (also known as synthetic stucco) or other non-water managed systems. Except  
in the states of California, New Mexico, Arizona, Nevada, Utah, and Colorado, Pella makes no  
warranty of any kind and assumes no responsibility for Pella windows and doors installed  
in barrier wall systems. In the states listed above, the installation of Pella products in barrier  
wall or similar systems must be in accordance with Pella installation instructions.  
Product modifications that are not approved by Pella Corporation will void the Limited Warranty.  
INSTALLING ROTO COVER AND CRANK  
Note: Finish the interior of the window and allow the window to dry before proceeding with  
these instructions. (To open the window for finishing, partially insert the lock handle into the  
jamb, unlock the unit, temporarily attach the crank handle and turn to open.)  
A. Place the cover over the  
operator stud and snap  
Pocket End  
B
into place. Position the  
pocket end of the cover  
into place.  
Note: If the cover does  
Screw Hole  
not have the screw hole,  
apply pressure on the  
pocket end of the cover  
to snap the cover into  
place and proceed to  
step C.  
Operator Stud  
A
Crank Handle  
D
Knob  
E
Operator Stud  
B. Insert the provided  
screw into the hole  
in the bottom of the  
pocket. Use a # 1 Phillips  
screwdriver to secure  
the pocket screw snug  
against the bottom of  
the pocket to avoid  
Set Screw  
C
Pocket  
scratching the crank handle knob. DO NOT over tighten.  
C. Use a medium size flat-blade screwdriver to loosen the set screw in the crank handle.  
D. Slide the crank handle onto the stud. Unlock, open window, then close and lock window.  
E. Fold the crank handle down and check alignment of knob with the pocket.  
Note: You may need to adjust the crank position on the stud until the correct alignment is  
achieved.  
F. Open the crank and tighten the set screw.  
G. After the final installation, fold the crank over and snap the knob into the pocket.  
Note: Even with the window open the crank can be folded to avoid interferring with the  
window treatments.  
 
LOCK LEVER REMOVAL AND INSERTION  
Note: You may want to remove the lock lever prior to finishing the window, or if it needs to be  
replaced with a lock lever in a different finish.  
A. Unlock and open the window.  
B. Place the lock lever in the locked position.  
Interior  
Exterior  
C. From the exterior of the window, insert a  
small flat-blade screwdriver between the  
cam and lock lever near the bottom of  
the opening between the stop and frame  
gasket.  
B
D. Push the screwdriver inwards with a small  
amount of pressure; then turn the blade  
slightly clockwise for a left hand unit,  
counter-clockwise for a right hand unit.  
DO NOT over-twist the screwdriver, this  
can damage the lock driver.  
C
Interior  
Exterior  
Note: This will release the hook in the  
lever from the cam hook.  
E. Remove the lock lever by pulling it toward  
E
the interior of the building.  
D
F. To install a lock lever, hold it in the lock  
position and insert it, from the interior, into  
the slot until it snaps into the cam.  
F
 

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