Pella Window 816G0101 User Manual

© 2010 Pella Corporation  
Part Number: 816G0101  
INSTALLATION INSTRUCTION - INSTRUCCIONES DE INSTALACIÓN  
FOR PELLA® PRECISION FIT®, CASEMENT, RENOVATION POCKET  
REPLACEMENT AND FIXED WINDOW REPLACEMENT  
Lea las instrucciones en español en el reverso.  
Important! e Pella Precision Fit Casement Replacement Window is designed to replace older style  
double-hung windows. e original window frame will remain in place and only the existing sash  
will be removed. e Pella Precision Fit Casement Fixed Window is a companion to the Precision Fit  
Casement and is designed to replace the fixed center window that shares a common stool and sloped  
sill with the adjacent windows and has removable interior stops. is application is typically found  
in older homes. e original window frame will remain in place and only the existing sash, glass and  
existing stops must be removed. ese instructions are not to be used with any other construction  
methods. Read these instructions thoroughly before beginning. Failure to install as recommended will  
void any warranty, express or implied. For types of installation other than shown, contact your local  
materials and site conditions unique to your project may require an installation method different  
from these instructions and additional care. Determining the appropriate installation method is the  
responsibility of you, your architect or construction professional.  
YOU WILL NEED TO SUPPLY:  
TOOLS REQUIRED:  
• Cedar or Impervious shims/spacers (12 to 20)  
• Wood blocking and bracing  
Tape measure  
• Level  
• Square  
• Closed cell foam backer rod/sealant backer (12 to 30 ft.)  
• Hammer  
• Pella® SmartFlash™ foil backed butyl window  
and door flashing tape or equivalent  
• Utility knife  
• Sealant gun  
• Screwdrivers  
(#2 Phillips and Flat blade)  
• High quality exterior grade polyurethane or silicone sealant  
(1 tube per window)  
SEALANT  
• Great Stuff ™ Window and Door Insulating Foam Sealant  
by the Dow Chemical Company or equivalent low pressure  
polyurethane window and door foam -  
• Rotary cutting tool w/cut-off wheel (if  
existing window has press fit pulleys)  
DO NOT use high pressure or latex foams  
• Drill  
• Pliers  
• Putty Knife  
• Pry bar  
T-25 TORX® Driver  
• Chisel  
Installation will require two or more  
persons for safety reasons.  
REMEMBER TO USE APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT.  
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.  
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.  
 
1
SASH REMOVAL (CONTINUED)  
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B. Cut the balance cords on the bottom sash and lift out the sash. Allow weights to fall  
to the bottom of the weight pocket.  
C. Remove the parting stops by prying them out or by pulling them out with a channel  
lock. ere may be a small wedge of wood at the bottom of the upper sash that is next  
to the parting stops. To make it easier to remove the parting stop, use a chisel to knock  
off the wedge.  
D. Lower the top sash and cut the balance cords  
allowing the balance weights to fall into the weight  
pocket. Remove the top sash.  
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E. Remove the balance cord pulleys. Unscrew and  
remove the balance cord pulleys. If the pulleys are  
press-in fit type, follow these steps:  
1. Cut off accessible portions of the collars using a rotary  
cutting tool with cut-off wheel.  
2. Bend up the remaining areas of the collars.  
3. Knock the pulleys into the balance cavity. (e pin will fall with the pulleys.)  
4. If desired, remove pulleys via bottom balance access panel.  
NOTE: If the pulleys and pins are not removed, they may interfere with the  
replacement window’s attachment screws.  
F. If desired, insulate the weight chamber by filling it  
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with low pressure window and door insulating foam.  
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2
PREPARE THE OPENING  
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A. 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. DO NOT allow the flashing tape to  
extend past the blind stops.  
2B  
B. Check to ensure the existing sill is level and not  
bowed (humped) upward. If necessary, place shims  
on the bottom of the window opening 1/2" from each  
side. Shim sill only at the jambs. Once level, attach  
shims to prevent movement.  
Note: Improper placement of shims may result in  
bowed (humped) sill.  
 
2
PREPARE THE OPENING (CONTINUED)  
C. Remove plastic wrap and card board packaging from window. DO NOT remove  
plastic shipping spacers located between the window sash and frame. e shipping  
spacers will help keep the window square during installation. DO NOT unlock or  
open window until it is fully fastened in the opening.  
Note: If screens, grilles or hardware are removed from the window at this time,  
label them and store them in a protected area.  
D. Test fit the window. e window should be  
2D
approximately 1/2” smaller than the opening  
in both width and height. Measure the distance  
between the frame and the sloped sill, this will  
Sill Adapter  
be the height to which to cut the sill adapter.  
Check to ensure the window rests against the  
exterior blind stops and will make contact with  
the sealant to be applied in steps 3 A, B, and C.  
Confirm the installation screws will fasten into  
solid wood. If not, repair the existing frame to  
ensure there is solid wood at the installation  
screw locations.  
Sealant goes here  
E. Trim the sill adapter to the proper  
height by breaking off the grooved leg at  
the desired dimension (see chart). Once  
trimmed, apply a bead of sealant to the sill  
adapter. Attach the sill adapter into the sill  
5/16” - 3/8”  
7/16” - 1/2”  
by using a board and hammer.  
9/16” - 5/8”  
Note: Scoring the leg groove multiple times  
11/16” - 3/4”  
at the desired dimension with a utility  
knife will help the leg break easier. e sill  
adapter may also be trimmed to correct  
dimension using a table saw.  
13/16” - 7/8”  
15/16” - 1”  
Score leg at desired dimension.  
Use pliers to break off leg.  
2E  
Sealant  
Sill Adapter  
3
SEALING AND FASTENING THE WINDOW  
Head blind  
stop  
A. Apply a 3/8" continuous bead of sealant to the  
interior face of the existing blind stops at the head  
and both jambs.  
Jamb  
blind  
stop  
Note: Sealant bead placement is critical to ensure  
contact with replacement window  
3A  
 
SEALING AND FASTENING  
THE WINDOW (CONTINUED)  
3
B. Place a bead of sealant where the existing stool  
Stool  
meets the existing frame sill and jambs.  
Note: Sealant bead placement is critical to ensure  
contact with replacement window  
Sill  
3B  
C. Place a bead of sealant where the jamb and sill meet.  
D. Insert the window into the opening. Set the bottom  
of the window in first and tilt the top into place. Make  
sure the window is centered in the opening and is  
pressed firmly against the exterior blind stops.  
3C  
E. Place a shim at each of the top corners slightly  
above the partially driven (factory supplied)  
attachment screws in the jambs. NOTE: If the shims  
are aligned with the attachment screws, the frame  
may bow away from the shims when driving the  
screws. Drive each top attachment screws halfway  
in to hold the window in place while shimming it  
plumb and square.  
3E  
F. Place shims approximately 5” up from the bottom of  
window to plumb and square the window. Check for  
squareness by making sure the diagonal measurement  
from corner to corner is within 1/16” in both  
directions.  
3F  
For windows over 40-1/4” tall: Place an additional  
shim slightly above the center anchor screws. is will  
prevent the screw from cracking or breaking the shim  
when driving the attachment screw.  
 
SEALING AND FASTENING  
THE WINDOW (CONTINUED)  
3
G. Finish driving all the installation screws through the wood frame jamb, ensuring  
the head of the screws is flush with the surface of the wood frame.  
DO NOT drive screws below flush with the surface of the frame.  
3G  
3G  
Improper screw depth, screw  
head driven below the surface  
of frame.  
Proper screw depth, screw  
head flush with surface of  
frame.  
H. Check window operation (vent units only). Unlock the window by lifting the lock  
handle up. Open the window by rotating the crank handle. Remove the shipping  
spacers. Open and close the window a few times to check for proper operation. Close  
and lock the window.  
Note: If there are any problems with the operation of the window, recheck the shim  
locations and adjust for plumb and square.  
4
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 insulation foam. From the interior, insert  
the nozzle of the applicator approximately 1"  
4A  
deep into the space between the window and the  
rough opening and apply a 1" deep bead of foam.  
is will allow room for expansion of the foam  
and will minimize squeeze out. Allow the foam  
to cure completely (usually 8 to 24 hours) before  
proceeding to the next step.  
Note: It may be necessary to squeeze the end of the  
tube with pliers to be able to insert into the space  
between the new and existing window frame. DO  
NOT completely fill the space from the back of the  
blind stops to the interior face of the opening.  
B. Check window operation 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 that the sides are not bowed. If adjustments are required, remove  
the foam with a serrated knife. Adjust the shims, and reapply the insulating foam  
sealant.  
C. Inspect the foam after it has cured. Fill any voids with foam prior to installing  
interior trim.  
D. Reinstall the existing interior sash stops or new trim as desired.  
 
5
EXTERIOR SEAL  
A. Place a corner bead of sealant at the jambs and head  
connecting the existing frame and the replacement  
window frame.  
5A  
Caution: DO NOT seal the bottom exterior to allow for  
incidental water to weep.  
5A  
B. Optional: Place a bead of sealant where the sill  
adapter meets the sill. If sealant is placed on the sill  
leave at least 1” of sill adapter unsealed at each end.  
is sill allow for incidental water to weep.  
1”  
5B  
Sill  
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FIXED WINDOW REPLACEMENT:  
6
FIXED SASH REMOVAL  
Note: Confirm the opening and window dimensions prior to removing the  
existing window sash.  
A. Score paint or varnish along  
interior sash stops with sharp  
INTERIOR SASH STOP  
utility knife. Carefully remove the  
interior sash stops at jambs (sides)  
and head (top) using a putty knife  
and pry bar. Set aside for reuse.  
6A  
Interior  
sash stop  
B. Remove the old sash. Remove  
other trim, stops, flashing or  
6A  
brickmould as required.  
6A  
C. Clean opening thoroughly and repair or replace any rotted or  
damaged framing if required.  
Note: e end result should be a clean flat uninterrupted surface  
on the bottom, top and sides of the opening where the new window  
will be installed.  
D. Test fit the window, make any adjustments to opening as needed.  
 
6
7
FIXED SASH REMOVAL (CONTINUED)  
E. Apply sill flashing tape. Cut a piece of flashing tape 12"  
longer than the opening width. Apply at the bottom of  
the opening as shown (2A). Do not allow the flashing  
tape to extend past the new window depth.  
Flashing  
Tape  
6E  
Note: e tape is cut 12" longer than the width so that  
it will extend 6" up each side of the opening.  
F. Check to ensure the existing sill is level. If necessary,  
place shims on the bottom of the window opening 1/2"  
from each side. Shim sill only at the jambs. Once level,  
attach shims to prevent movement.  
6F  
Note: Improper placement of shims may result in  
bowing the bottom of the window.  
PREPARE THE OPENING  
A. Remove plastic wrap and  
cardboard packaging from  
EXTERIOR  
window. Remove the wood  
spacers on the frame.  
B. Attach bracing to the top  
and bottom of the exterior  
frame to prevent the  
Bracing  
replacement window from  
falling out of the opening  
during installation.  
7B  
C. Test fit the window. e window should be  
approximately 1/2” smaller than the opening  
in both width and height. Measure the  
distance between the frame and the sloped  
sill, this will be the height to which to cut  
the sill adapter. Check to ensure the window  
rests against the bracing applied in step 7B.  
Confirm the installation screws will fasten  
into solid wood. If not, repair the existing  
frame to ensure there is solid wood at the  
installation screw locations.  
7C  
Proper Sill  
Adapter Height  
 
7
PREPARE THE OPENING (CONTINUED)  
D. Trim the sill adapter to the proper  
height by breaking off the grooved leg  
at the desired dimension (see chart).  
Once trimmed, apply a bead of sealant  
to the sill adapter. Attach the sill  
adapter into the sill by using a board  
and hammer.  
Sealant goes here  
5/16” - 3/8”  
Note: Scoring the leg groove multiple  
times at the desired dimension with  
a utility knife will help the leg break  
easier. e sill adapter may also be  
trimmed to correct dimension using  
a table saw.  
7/16” - 1/2”  
9/16” - 5/8”  
11/16” - 3/4”  
13/16” - 7/8”  
15/16” - 1”  
Score leg at desired dimension.  
Use pliers to break off leg.  
7D  
Sealant  
Sill Adapter  
SEALING AND FASTENING  
THE WINDOW  
A. Apply a 3/8" continuous bead of sealant to the interior  
face of the existing blind stops at the head and both  
jambs.  
Head blind  
stop  
8
Jamb  
blind  
stop  
Note: Sealant bead placement is critical to ensure  
contact with replacement window  
8A  
B. Place a bead of sealant where the existing stool meets  
the existing frame sill and jambs  
C. Insert window into the opening, placing the bottom of  
the window on the spacers at the bottom of the opening  
and tilting the top into place. Make sure the window  
is up against the existing stool. Center the window  
between the sides of the opening to allow clearance for  
shimming and partially drive one of the top attachment  
screws (factory provided in the unit) halfway in to hold  
the window in place while shimming it plumb and  
square.  
Stool  
Sill  
8B  
D. Place shims 1” from the bottom and top of the  
window between the window and the sides of the  
opening. Adjust the shims as needed to plumb and  
square the window in the opening. Also shim slightly  
above the partially driven (factory supplied) attachment  
screws in the jambs. If the shims are aligned with the  
attachment screws, the frame may bow away from the  
shims when driving the screws.  
8D  
Note: DO NOT shim above the window or in the space  
between the spacers at the bottom of the window. DO  
NOT over shim.  
 
SEALING AND FASTENING  
THE WINDOW (CONTINUED)  
8
9
E. Finish driving all the installation screws through the wood frame jamb, ensuring  
the head of the screws is flush with the surface of the wood frame.  
DO NOT drive screws below flush with the surface of the frame.  
8E  
8E  
Improper screw depth, screw  
head driven below the surface  
of frame.  
Proper screw depth, screw  
head flush with surface of  
frame.  
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 insulation foam. 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. is will allow  
room for expansion of the foam and will minimize  
squeeze out. If using insulating foam other than Great  
Stuff™ Window and Door Insulation Foam by the  
Dow Chemical Company, allow the foam to cure  
completely (usually 8 to 24 hours) before proceeding  
to the next step.  
9A  
Note: It may be necessary to squeeze the end of the  
tube with pliers to be able to insert into the space  
between the new and existing window frame. DO NOT completely fill the space  
from the back of the backer rod to the interior face of the opening.  
10  
EXTERIOR SEAL  
10A  
A. Insert backer rod into the space  
around the exterior of the window  
at the head and jambs, deep enough  
to provide at least a 1/2” clearance  
between the backer rod and the  
exterior face of the window.  
10A  
Note: Backer rod adds shape and  
depth for the sealant line.  
 
10  
EXTERIOR SEAL (CONTINUED)  
B. Apply a bead of high quality exterior grade sealant to  
10B  
the head and jambs.  
10B  
C. Optional: Place a bead of sealant where the sill adapter  
meets the sill. If sealant is placed on the sill leave at least  
1” of sill adapter unsealed at each end. is sill allow for  
incidental water to weep.  
1”  
10C  
Sill  
INTERIOR FINISH  
Note: e information below is effective September 15, 2007. is information may be  
different than the printed instruction.  
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  
 
EXTERIOR FINISH  
e exterior frame and sash are protected by aluminum cladding with our tough  
EnduraClad® or EnduraClad Plus baked-on factory finish that needs 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 finishes, solvents, brickwash or cleaning chemicals will cause adverse  
reactions with window and door materials and voids the Limited Warranty.  
CARE AND MAINTENANCE  
Care and maintenance information is available in the Pella Owner’s Manual. You can  
obtain an owner’s manual by contacting your local Pella retailer. is information is also  
available on 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’s installation instructions; or the use of  
Pella products in wall systems which do not allow for proper management of moisture  
within the wall systems. e determination of the suitability of all building components,  
including the use of Pella products, as well as the design and installation of allow for proper  
management of moisture within the wall systems. e 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 on 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’s installation instructions.  
Product modifications that are not approved by Pella Corporation will void the Limited  
Warranty.  
 

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