Pella 80YW0102 Guide

Part Number: 80YW0102
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, frame stops and frame hardware from the existing window. The original window frame
will remain in place. If existing window frame shows signs of water infiltration or is damaged
beyond repair, this method should not be followed and the entire existing window should
be removed. Installation recommendations for other types of wall construction, wall systems,
conditions, multiple windows or bow/bay windows, 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.
Always read the Pella®Impervia®Limited Warranty before purchasing or
installing Pella Impervia 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 Impervia
installation and maintenance instructions may void your Pella Impervia product warranty. See
Limited Warranty for complete details at http://warranty.pellaimpervia.com.
REMEMBER TO USE APPROPRIATE
PERSONAL PROTECTIVE EQUIPMENT.
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.
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YOU WILL NEED TO SUPPLY:
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Ř3HOOD®SmartFlash™foil backed butyl window
and door flashing tape or equivalent
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equivalent high quality, multi-purpose sealant
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insulating window and door foam sealant. DO
NOT use high pressure or latex foams
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TOOLS REQUIRED:
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Installation will require two or more persons for safety reasons.
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©2009 Pella Corporation
WINDOW REPLACEMENT INSTRUCTIONS FOR SINGLE-HUNG,
DOUBLE-HUNG, CASEMENT, AWNING
INTO EXISTING
DOUBLE-HUNG FRAME USING FRAME SCREWS FROM THE EXTERIOR

1REMOVE THE EXISTING SASH
Note: Remove the new window from its packaging. Inspect
and measure the new window to confirm it will fit into the
opening prior to removing the existing window. The window
needs to be 1/2" smaller in both width and height than the
pocket frame, i.e. existing sash opening.
A. Unlock the existing window. 5DLVHWKHORZHUVDVKDQG
lower the upper sash so both are in the approximate
middle of the frame.
Note: Most of the following steps may be completed
from the exterior of the house.
B. Remove the head parting stop. 5HPRYHDQ\KHDGSDUWLQJ
stop by pulling the stop down from the frame. In some
cases, the stops are nailed on and can simply be pulled
off. In other situations the stops may need to be pried or
cut out of the frame.
C. Remove the exterior jamb and head stops. This can be accomplished with a wood chisel,
circular saw, reciprocating saw, roto-tool, or equivalent. Ensure the stop is removed flush
with the existing window jamb.
Caution: Take care to prevent existing sashes from falling out when removing stops.
D. Remove the upper and lower sash. This will vary per manufacturer of existing windows.
Some will simply pull out, while others may need to be cut to be removed. Grasp the
sash and pull out of the frame. The jamb liner material may come out of the frame when
pulling the sash out.
E. Remove any and all jamb liner material. Some liners may have frame attachment
fasteners that will need to be removed before the liners can be removed.
Caution: Spring loaded balances can cause injury; use care when removing balances
from existing windows.
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2OPENING PREPARATION
A. Inspect the existing window frame and repair or replace
any defective or rotted wood parts.
B. Clean the opening of any dirt, debris, or excess old
paint before proceeding.
C. Apply one piece of 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.
Note: If needed, blocking/shims may need to be placed
where the existing balances were located.
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TWO OR MORE PEOPLE ARE REQUIRED FOR THE FOLLOWING STEPS.
3WINDOW PREPARATION (AWNING and CASEMENT ONLY)
The interior frame covers must be removed to provide access to the pre-drilled frame screw
installation holes.
CAUTION: To Avoid Interior Frame Cover Breakage - Carefully read and understand the
following steps before proceeding with cover removal.
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Note: The following interior frame cover removal steps are for Casement, Standard
Awning, Fixed Awning/Casement and Large Awning. The steps are similar for each, but
the order in which covers are removed will vary depending on the window type.
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installation of covers.

A. Prepare the Window.
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handle package.
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Construction Handle Tool may be used as a
lock handle or crank handle.
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B. Remove Interior Frame Cover #1,IDQ,QWHULRU)UDPH&RYHUKDVD4XLFN5HOHDVH
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The cover on vent units where the lock handle slot is located and the cover on the opposite
frame side.
Note: Interior Frame Covers #1 are jamb covers on Casement, Fixed Awning/Casement
and Large Awning units. On Standard Awning units, Interior Frame Covers #1 are the head
and sill covers.
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between the cover and the sash.
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and continue to insert the tool
past the spline hole up to the
point where the bend in the
tool is aligned with the edge
of the cover.
Note: When the tool is inserted with the bend aligned with the cover edge there
will be a slight gap between the tool and the face of the sash.
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cover barb from the frame
kerf behind the cover. While
keeping tension on the tool,
pull the tool away from the
frame to start releasing the
cover barbs from the
frame kerfs.
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cover begins to pull away from the frame, relocate the tool
under the cover towards the interior as shown, then pull
the tool away from the frame to continue the release of the
cover barbs from the frame.
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of the cover. Slide the tool over while pulling the cover
away from the frame. This will release the flexible barbs
on the interior side of the cover, which will aid in cover
removal. Continue sliding along the length of the cover
while pulling it away from the
frame until it is removed.
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remove the other Interior
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If installing a single Casement,
Large Awning or Fixed unit less
than 42" in width, go to Step E.
If installing a Standard Awning, multiple window combinations, or units greater than 42"
in width, go to Step C.
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C. Remove Interior Frame Cover #2.
The cover on vent units where the crank handle and roto-cover will be located.
For Standard Awning, single units greater than 42" in height and multiple window
combinations.
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closest to where the crank
handle will be located, insert
the tool between the sash and
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of insertion used for Interior
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Note: Insert the tool under
Interior Frame Cover #2 next
to the FRAME CORNER (C2).
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the cover as shown and continue to pull up to release the barbs from the kerfs.
4. When the cover has been released near the crank handle cut-out, reposition the tool
with the hook under the front edge of the cover. Slide the tool over while pulling up on
the cover. Continue along the length of the cover until it is removed.
Note: Take note of the
cover support bracket
around the roto operator
hardware, (on the sill of
casement and large awning
units and on the jamb of
standard awning units) as the
cover support bracket will be
referenced when re-installing
Interior Frame Cover #2.
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D. Remove Interior Frame Cover #3.
The cover on vent units on the opposite frame side from where the crank handle is
located.
For Standard Awning greater than 42" in width, single
units greater than 42" in height and multiple window
combinations.
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the frame and cover as shown.
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cover barbs from the frame kerfs.
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the cover and continue to pull to release the barbs from
the kerfs, removing the cover.
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TWO OR MORE PEOPLE ARE REQUIRED FOR THE FOLLOWING STEPS
4SEALING 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:
Dry fit the window, temporarily fasten or with
someone holding it in place, confirm the window
will fit. From the exterior, measure the distance
from the bottom of the window to the existing sill.
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is needed.
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mark.
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the width of the window and cut the sill adapter
to the same length. Apply the sill adapter by
sliding it into the fin groove.
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.
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.
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
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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.
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walls of the frame.
Casement
Exterior
3/16”
3/16”

Interior
4H
Double-Hung & Single-Hung - If additional installation
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through both the interior and exterior walls of the
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wall only of the frame. DO NOT penetrate the exterior
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AWNING AND CASEMENT ONLY
+ From the exterior, continue placing shims at each
pre-drilled hole as needed to plum and square the
window. Check window for squareness by making sure
the diagonal measurements from corner to corner of the
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the frame. Screws are installed from the interior. Finish
inserting the top screw in each jamb.
For Awning and Casement: See Awning/Casement Shim
and Fastener Guide.
Note: DO NOT shim above the window. DO NOT
over shim!
I. Check operation before applying the insulating foam
sealant in case adjustments need to be made.
Drive screws per the Awning/Casement Shim and Fastener Guide.
AWNING/CASEMENT SHIM and FASTENER PLACEMENT GUIDE
Number of factory drilled fastener
locations may vary depending on
size of unit(s).
= Indicates typical locations of
factory drilled anchor holes where
screws and shims are required.
= Indicates location where
installation screws are optional.
At combination
mullion joints:
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hole through the
mullion plates at
the factory drilled
anchor holes prior
to inserting screws.
<42" Frame Width
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Exterior Exterior
Double-Hung Single-Hung
3/8” 3/8”
5/32”5/32”

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Number of factory drilled fastener locations may vary depending on size of unit(s).
= Indicates typical locations of factory drilled anchor holes where screws and shims are
required.
= Indicates location where installation screws are optional.

Re-install Interior Frame Covers.
Note: Discard all Quick Release Bands before re-installing Interior Frame Covers.
K. Interior Frame Cover #3+HDGFRYHURQ&DVHPHQW)L[HGDQG
Large Awning and the jamb cover without roto cover cut-out on
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Starting on one end of the frame,
insert the cover barbs of Interior
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Align the kerfs along the length of
the cover and press until the cover
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Note: Interior Frame Cover #3
contains compression springs which
allow the cover to be compressed
when re-installing Interior Frame
Cover #1 in Step 4M.
4K NOTE
Compression Spring
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Place the cover support referenced in Step C4 inside the cover as shown. While
holding the support in place,
position the cover to align the
cover barbs with the frame
kerfs. Press the cover barbs
into the kerfs while working
toward the roto operator.
Continue to hold the support
in place to ensure proper
placement of the support over
the operator. Press the cover
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Note: The cover support
bracket may need to be repositioned over the roto operator. The correct support
position allows the cover barbs to be fully seated into the frame kerfs.
4L
Cover Support Bracket 4L
J. Insert the construction handle into the lock lever location and unlock the window.
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Open and close each sash to verify the smooth operation and alignment of sash locks
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N. Insert the roto cover, crank handle and lock handle. See steps at the end of the
instructions.

B. Check the window operationYHQWXQLWVRQO\E\RSHQLQJDQGFORVLQJWKHZLQGRZ
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.
C. Inspect the interior and carefully trim all excess foam sealant if needed.
5INTERIOR 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. Insulate between new frame and the existing frame with
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will allow room for the expansion of the foam and will
minimize squeeze out. Follow foam manufacturer’s
instructions. If over filled with foam, the foam must
be trimmed back to allow room for backer rod and
sealant.
Note: It may be necessary to squeeze the end of
the tube with pliers to be able to insert into the
space between the window frame and the rough
opening.
Note: Masking between the window and the existing interior stop will
help alleviate possible squeeze out of the expandable foam to the interior.
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D. Insert jamb hole plugsSURYLGHGLQWRHDFKVFUHZKROH
for single-hung and double-hung units.
Jamb
plug
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6EXTERIOR SEAL
A. Insert backer rod into the space around the window
at the head and jambs. This should provide at
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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 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.
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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.
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frame expander.
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grade sealant.
Note: The contractor/installer will determine how to
finish the exterior.
EXTERIOR FINISH OF EXISTING FRAME
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INSTALLING ROTO COVER AND CRANK
A. Place the cover over the operator stud and snap
into place.
B. Apply pressure to the pocket end of the cover and
snap into place.
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loosen the set screw in the crank handle.
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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 interfering with the
window treatments.

LOCK LEVER REMOVAL AND INSERTION
Note: You may want to remove the
lock lever if it needs to be replaced
with a different finish.
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B. Place the lock lever in the
locked position.
C. From the exterior of the window,
look through the opening behind
the lock lever to locate the point
where the lock lever and lock cam
meet.
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flat-blade screwdriver straight into
the opening and center the blade
tip at the point the cam and lever
meet.
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E. Push the screwdriver against the
lock cam and rotate the bottom of
the blade toward the lock lever.
This will push the lock cam away
from the lock lever hook so the
lever can be removed.
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straight out toward the interior of
the building.
G. To install a lock lever, from the interior hold it in the locked position and
insert into the slot until it snaps onto the cam.
Note: The lock cam must be in the locked position before the lock lever can
be inserted.
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Part Number: 80YW0102
FINISH
The interior and exterior frame and sash are protected by a powder coat 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 spirts. DO NOT use abrasives. DO NOT scrape or use tools
that might damage the surface.
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window and door materials and voids the Limited Warranty.
CARE AND MAINTENANCE
Care and maintenance information is available by contacting your local Pella retailer. This
information is also available at www.pellaimpervia.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
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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
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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
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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.