Pella Window 80WX0101 User Manual

©2012 Pella Corporation  
Part Number: 80WX0101  
WINDOW REPLACEMENT INSTRUCTIONS FOR CASEMENT,  
DOUBLE-HUNG AND CLAD FRAME WINDOWS INTO EXISTING  
DOUBLE-HUNG FRAME USING FRAME SCREWS  
These instructions were tested and developed for replacing windows in wood-frame wall  
construction systems designed to manage moisture. 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, exterior stops and frame hardware must be removed.  
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:  
Cedar or Impervious shims/spacers (12 to 20)  
TOOLS REQUIRED:  
Tape measure  
Closed cell foam backer rod/sealant backer  
(12 to 30 ft.)  
Level  
Sealant gun  
Prybar  
Pella® SmartFlash™ foil backed butyl window  
and door flashing tape or equivalent  
Utility knife  
Pella Window and Door Installation Sealant or  
equivalent high quality, multi-purpose sealant  
Putty knife  
Hammer  
(1 tube per window)  
SEALANT  
Screwdrivers (Flat & Phillips)  
Adjustable pliers  
Side Cuts  
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)  
Roto-tool, reciprocating saw  
Wood chisel  
1/8" drill bit  
Drill  
Pella replacement window sill adapter  
Installation will require two or  
more persons for safety reasons.  
REMEMBER TO USE APPROPRIATE  
PERSONAL PROTECTIVE EQUIPMENT  
EXTERIOR  
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.  
Flashing Tape  
Sill Adapter  
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.  
 
2OPENING PREPARATION  
A. Inspect the existing window frame and repair or replace  
any defective or rotted wood parts.  
EXTERIOR  
B. Clean the opening of any dirt, debris, or excess old  
paint before proceeding.  
C. Apply one piece of sill flashing tape to the sill of  
the existing window. Cut the tape the same length as  
the width of the existing window sill. Place one side of  
the tape against the vertical leg of the stool, and work  
the tape into the corner before applying to the sill.  
Press down firmly. The tape will not cover the sill depth  
completely under the new window.  
2C
Note: If needed, blocking/shims may need to be placed  
where the existing balances were located.  
TWO OR MORE PEOPLE ARE REQUIRED FOR THE FOLLOWING STEPS.  
3WINDOW PREPARATION  
Note: For Double-hung, proceed to Step B.  
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 center.  
Note: On vent casements, place the holes so they do not interfere with the roto  
operator and the latch points on the lock side of the window.  
Designer Series®  
and ProLine®  
Architect Series®  
Double-Hung  
Double-Hung Head  
Double-Hung Head  
Drill 1/8"  
clearance hole  
1/2"  
Drill 1/8"  
clearance hole  
3A  
Drill 1/8"  
clearance hole  
Casement Sill  
3B  
3B  
Clad Frame Head  
1"  
Double-Hung Jamb  
Double-Hung Jamb  
EVERY  
6"  
16"  
6"  
Drill 1/8"  
clearance hole  
6"  
6"  
3B  
Drill 1/8"  
clearance hole  
1/4"  
Drill 1/8"  
clearance hole  
Drill 1/8"  
clearance hole  
EVERY  
16"  
EVERY  
16"  
Single  
Window  
3B  
3B  
1"  
Drill 1/8"  
clearance hole  
Drill 1/8"  
clearance hole  
1/2"  
Clad Frame Sill  
6"  
6"  
Double-Hung Sill  
Double-Hung Sill  
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.  
 
4SETTING AND FASTENING THE WINDOW  
A. If the existing double-hung has a sloped sill the sill of the new window will need to  
be supported by using the Pella replacement sill adapter accessory or by using wood  
blocking as needed.  
B. If using the Pella replacement sill adapter accessory the sill adapter will need to  
be cut to the same length as the sill of the window and slid into the sill fin groove. This  
adapter may be adjusted to accommodate different sill angles by breaking off the  
grooved leg at the desired dimension. Dry fit the window to ensure the window will fit  
in the opening and that the sill adapter is trimmed properly.  
Casement Sill  
Double-Hung Sill  
4B  
4B  
Sill  
Adapter  
Sill  
Adapter  
R  
(SILL CUTAWAY VIEW)  
(SILL CUTAWAY VIEW)  
C. Apply a 3/8" bead of sealant at the point where  
the existing stool meets the existing window sill.  
Additionally, place sealant at the ends of the flashing tape,  
making sure to connect with the stool sealant.  
4D  
4C  
D. Apply a continuous 3/8" diameter bead of sealant at  
the exterior surface of the interior head and jamb stops.  
Connect this bead of sealant to the sealant line on the stool.  
TWO OR MORE PERSONS ARE REQUIRED FOR THE FOLLOWING STEPS.  
E. Insert the replacement window in the opening. Check to make sure the window rests  
against the interior blind stops and is making contact with the sealant.  
F. From the exterior, place shims near the top of one jamb, in line with the top pre-  
drilled hole in the window frame. Partially insert one 3-1/4" finish wood screw. Repeat the  
process for the other jamb.  
Note: Position 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.  
G. Continue placing shims at each pre-drilled hole as needed to plumb and square the  
window. Check window for squareness 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!  
H. Check operation before applying the insulating foam sealant in case adjustments need  
to be made.  
 
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.  
EXTERIOR  
A. Insulate between new frame and the existing frame with low  
expansion insulating foam. FROM THE EXTERIOR insert the  
nozzle of the applicator approximately 1" from the interior stop  
and apply a 1" deep bead of foam. This will allow room for the  
expansion of the foam and will minimize squeeze out. Follow  
foam manufacturer's instructions.  
Note: Masking between the window and the existing  
interior stop will help alleviate possible squeeze out  
of the expandable foam to the interior.  
5A  
B. Check the window operation by opening and closing  
the window. If bowed, remove foam with a serrated  
knife, then check operation. If still bowed, adjust shims as  
needed, then insulate as instructed in previous step.  
C. Inspect the interior and carefully trim all excess foam sealant if needed.  
6 EXTERIOR SEAL  
A. Insert backer rod into the space around the window  
at the head and jambs. This should provide at least  
3/8" clearance between the backer rod and the  
EXTERIOR  
exterior face of the window.  
6A  
6B  
Note: Backer rod adds shape and depth for the  
sealant line.  
B. Place a bead of sealant at the jambs and head  
between the existing window frame and the  
replacement window frame.  
Caution: DO NOT seal the bottom exterior  
to allow for incidental water to weep.  
C. 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 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.  
EXTERIOR OF WINDOW  
WITH FRAME EXPANDER  
Note: The contractor/installer will determine how to  
finish the exterior.  
 
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 stains 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 window and door materials  
and voids the Limited Warranty.  
For additional information on finishing see the 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 into place. Position the pocket end of the  
cover into place.  
Pocket End  
Note: If the cover does 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.  
Screw Hole  
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  
scratching the crank handle knob. DO NOT  
over tighten.  
A
B
C. Use a medium size flat-blade screwdriver to  
Crank Handle  
Operator Stud  
D
loosen the set screw in the crank handle.  
D. Slide the crank handle onto the stud. Unlock,  
open window, then close and lock window.  
Set Screw  
C
E. Fold the crank handle down and check  
Knob  
E
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  
Pocket  
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.  
C
Interior  
Exterior  
B
B. Place the lock lever in the locked  
position.  
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.  
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 units. DO NOT over-twist the  
screwdriver, this can damage the lock  
driver.  
Exterior  
E
F
Interior  
Note: This will release the hook in the  
lever from the cam hook.  
D
E. Remove the lock lever by pulling it  
toward the interior of the building.  
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.  
 

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