Eagle Double-Hung Replacement Sash Kit Installation Instructions

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1 Eagle Double-Hung Replacement These instructions are for installation in typical wood frame wall construction. These instructions may not be applicable for all installations due to building design, construction materials or methods used and/or building or site conditions. Consult a contractor or architect for recommendations. These instructions are for Eagle double-hung windows only. Installation instructions for other types of windows are available online at EagleWindow.com. Please read the following instructions thoroughly before starting. PARTS INCLUDED (1) Top Sash (1) Bottom Sash (2) Jamb Liner and Balance Systems (1) Head Stop (1) Sill Dam (1) Full Insect Screen U-channel (3) #6 x 1-1/4" Painted Phillips Flat Head Screws (3) #6 x 1-1/4" SS Phillips Pan Head Screws (16) #8 x 1" Phillips Pan Head Screws KEY Top Sash Bottom Sash Jamb Liner and Balance System Head Stop Sill Dam Full Insect Screen U-channel (optional) 5 View TOOLS REQUIRED Safety Glasses Tape Measure Utility Knife Putty Knife Plastic Scraper Hammer Trim Nailer Nail Punch Cordless Drill Caulk Gun #2 Phillips Bit 3/32" Drill Bit Flat-head Screwdriver Pencil SUPPLIES REQUIRED Shims Sealant 1-1/2" Finish Nails

2 GENERAL WARNINGS AND CAUTIONS Read and follow these warnings and cautions during installation. Safety should always come first. Windows and doors can be heavy. Use safe lifting techniques and a reasonable number of people with enough strength to lift, carry and install window and door products to avoid injury and/or product damage. Use caution when working at elevated heights and around unit openings. Follow manufacturers instructions for ladders and/or scaffolding. Failure to do so may result in injury or death. Follow manufacturers instructions for hand or power tools. Always wear safety glasses. Failure to do so may result in injury and/or product damage. Follow instructions of foam, sealant and flashing manufacturer regarding material application and compatibility with this product. Metal fasteners and other hardware components may corrode when exposed to preservative treated and fire-retardant treated lumber. Obtain and use the appropriate metal fasteners and hardware as called out by the installation guide to fasten unit to any rough opening made from pressure treated and fire-retardant treated lumber. Failure to use the appropriate materials for the installation may cause a failure resulting in injury, property or product damage. GLASS Leave protective film in place until after construction is finished. Leave (NFRC) performance label in place until final inspection or for homeowner s use/records. Suction grips will not hold if placed over seam of film to lift or move unit. Unit will fall causing damage or injury. Sealants will damage exterior coating on glass. Film seam Suction cups Page 2

3 FINISHING - Finish wood surfaces immediately after installation. Unfinished wood will deteriorate, discolor, and/or may bow and split. - Do not stain or paint weather strip, vinyl, glass or hardware. Product damage may occur. Film is not a substitute for masking. Finish all hidden wood surfaces. Read and follow finishing product instructions and warnings on finish material. FILM REMOVAL Starting from a seam or corner of the film (using a plastic scraper if needed), remove the protective film from the glass surface. Remove protective film within nine months of installation and when temperature is above 32 F. Dispose of film immediately after removing. Film may pose suffocation hazard to children. Static created when removing film can ignite flammable materials or cause a shock, and can pass through the other side of the glass. See warning label on glass. Page 3

4 CLEANING Clean glass using liquid glass cleaner. Clean exterior frame, sash, and insect screens using mild detergent and water with a soft cloth and brush. For hard to clean areas use a nonabrasive cleaner, alcohol-and-water or ammoniaand-water. - Abrasive cleaners will damage glass surface. - Metal razor blades can damage glass surface and exterior coating. - Acid solutions used for cleaning masonry or concrete will damage glass, fasteners, hardware, and metal flashing. Protect unit and follow cleaning product instructions carefully. If acid contacts unit, wash all surfaces with water immediately. MAINTENANCE Do not apply any type of film to insulating glass. Thermal stress and glass damage can result. Shading devices (insulated coverings, shutters, etc.) may also cause thermal stress and condensation damage. For more information, contact your Eagle dealer. Do not install air conditioner in window. Injury and/or product or property damage may occur. Page 4

5 REMOVING EXISTING SASH STEP 1 STEP 2 STEP 3 sash stop Putty knife Existing window Tape measure Check measurements of both the existing window and the replacement sash before starting to confirm the correct unit size. Utility knife Cleanly score paint or varnish along the interior sash stop with a sharp utility knife. Do not damage the stops as they may be reused. sash stop Gently remove interior sash stops at jambs and head using a stiff putty knife (and pry bar if required). Set aside to reuse. STEP 4 STEP 5 STEP 6 Balance cord Parting stop Utility knife Utility knife Putty knife Top sash Bottom sash blind stop Balance cord Cut the balance cords on the bottom sash, if present. Remove the bottom sash and dispose of properly. Weights can fall to the bottom of the weight chamber. Remove the parting stops and dispose of properly. Lower the top sash. Cut the balance cords, if present, and allow the balance weights to fall to the bottom of the weight chamber. Remove the top sash and dispose of properly. Be careful not to damage the exterior blind stop. Page 5

6 REMOVING EXISTING SASH (CONT D) STEP 7 STEP 8 Cord pulley Weight pocket cover Weights Remove the cord pulleys, if present, and dispose of properly. Remove weight pocket covers if present, but do not dispose. Remove the weights, if present, and dispose of properly. PREPARE THE OPENING STEP 1 STEP 2 STEP 3 Inspect the existing window frame for damage. Deteriorated or rotted wood members including the exterior blind stops, must be repaired prior to sash kit window installation. Pulley void Weight chamber Clean the opening, removing excess paint, dirt and debris. Fiberglass batt insulation Weight pocket covers Insulate the weight chamber with fiberglass batt insulation. Reapply the weight pocket covers, if present. Fill pulley voids with a wood insert to make sure installation screws will have a solid surface to anchor to. Page 6

7 PREPARE THE OPENING (CONT D) STEP 4 Tape measure Check and make sure the window opening is square. Diagonal measurements must be within 1/8". INSTALLING THE WINDOW 1 STEP 1 STEP Remove the packaging materials from your replacement sash kit components and dispose of properly. Metal fasteners and other hardware components may corrode when exposed to preservative treated and fire-retardant treated lumber. Obtain and use the appropriate metal fasteners and hardware as called out by the installation guide to fasten unit to any rough opening made from pressure treated and fire-retardant treated lumber. Failure to use the appropriate materials for the installation may cause a failure resulting in injury, property or product damage. 1 Jamb Liner Clip (1) 2 Foam Backing (1) 3 Spring Cover (1) 4 S-Clip (2 or 4) 5 Block and Tackle Balance* (2 or 4) 6 Dust Pad (1) 7 Pivot Shoe (2) 8 Sash Stop (1) 9 Jamb Liner Foam Plug (2) 10 Jamb Liner (1) 11 Sill Dam Pad (1) 11 Remove the jamb liner clip (back half of vinyl jamb liner) from each of the jamb liner assemblies. Refer to the jamb liner and balance assembly detail (as illustrated). Leave the remainder of the jamb liner assembly intact * assembly is shown with double block and tackle. Double balances will only be seen in larger sash. 5 7 Page 7

8 INSTALLING THE WINDOW (CONT D) STEP 3 Side jamb pocket 1-1/2" 7/8" blind stop 7/8" clip Evenly spaced blind stop 1-1/2" Jamb Clip Detail clip Pre-drilled holes Sill dam pad Sill #8 x1 PPH Screws clip Sill dam pad Side Jamb Detail Position the jamb liner clips into each of the side jamb pockets, placing the outside edge against the exterior blind stop and tight against the sill. Pre-drill 6-8 holes into the jamb liner clip with a 1/8" drill. Then fasten the jamb liner clips through the pre-drilled holes using the #8 x 1 Phillips pan head screws provided. STEP 4 STEP 5 clip assembly Foam backing clip clip Foam backing Foam backing Side Jamb Detail clip Foam backing Side Jamb Detail Place the foam backing back into the jamb liner clips. Trim any excess foam at the top. Snap the remaining jamb liner assembly including the balances onto the jamb liner clips. Make sure that all balances and pads are in place. Refer back to the exploded jamb liner assembly detail in Step 2. Page 8

9 INSTALLING THE WINDOW (CONT D) STEP 6 Top sash pivot shoe Jamb liner Bottom sash pivot shoe U of pivot shoe Flat-head screwdriver The pivot shoes are shipped in a lock position. Firmly gripping a flat-head screwdriver, insert the tip into the top sash (exterior) pivot shoe and rotate to the unlocked position. Carefully pull down on the pivot shoe until it is 2/3 of the way down the jamb liner. Turn the screwdriver 90 degrees to lock the pivot shoe in place. Then insert the flat-head screwdriver into the bottom sash (interior) pivot shoe and carefully pull down 2" below the top sash pivot shoe. Turn the screwdriver 90 degrees to lock this pivot shoe in place as well. Repeat this same procedure on the opposite side jamb liner. Pivot shoes are under high tension. Use flathead screwdriver with long handle so that both hands can be used to set balance tension. Sudden release of pivot shoe could damage unit. Locked Unlocked STEP 7 Top sash slot nearest outside slot nearest outside Install the top sash exterior side up first. Keep the left side of the sash slightly lower than the right side. Insert the left pivot pin of the sash into the jamb liner slot nearest the outside making sure it is above the pivot shoe. Lower the left corner of the sash until the pivot pin rests in the U of the pivot shoe. Place the right pivot pin of the sash into the jamb liner slot nearest the outside making sure it is above the pivot shoe. Lower the right corner of the sash until the pivot pin seats into the pivot shoe. Windows and doors can be heavy. Use safe lifting techniques and a reasonable number of people with enough strength to lift, carry and install window and door products to avoid injury and/or product damage. Top sash (Reversed angle of left jamb) Page 9

10 INSTALLING THE WINDOW (CONT D) STEP 7 (cont d) Jamb liner Top sash Top sash While making sure the pins stay seated in the jamb liners, tilt the sash upward. Depress the jamb liners on each side and snap top sash into place. Slide the sash up and down to make sure the pivot pins are properly secured in the pivot shoes and that the sash operates smoothly. Bottom sash Jamb liner Bottom sash Bottom sash Follow the same procedures as above with bottom sash only using the pivot shoes located in the interior slot of the jamb liners. Page 10

11 INSTALLING THE WINDOW (CONT D) STEP 8 Head stop 1-1/2" Finish nails Head stop #6 x 1-1/4" Painted Phillips flat head screws Sill dam A) Place the head stop between the jamb liners, aligning the slot of the part with the inside slot of the jamb liner. Push the head stop up tight against the head jamb. Secure the head stop with 1-1/2" finish nails. Raised bottom sash Sill Dam Sealant Detail Sill dam Sill dam Sealant Head and Sill Detail B) Raise the Bottom Sash. Place the sill dam between the jamb liners in the same fashion as the head stop. Push the sill dam down tightly against the sill. Level the sill dam on the sill and shim as required. Then remove the sill dam and apply a bead of sealant to the bottom of the sill dam towards the exterior. Place the sill dam back into place and verify that it is still level. Secure the sill dam to the sill with the #6 x 1-1/4" Phillips flat head painted screws provided. It is advised to drill a pilot hole into the sill to keep the screws and sill dam from moving during fastening. Then apply a bead of sealant along the outside edge of the sill dam where it meets the sill. Page 11

12 INSTALLING THE WINDOW (CONT D) STEP 9 1-1/2" Finish nails Existing interior stop Existing interior stop Reapply the existing interior stops or new if desired with 1-1/2" finish nails. Existing interior stops Side Jamb Detail Head and Sill Detail Page 12

13 INSTALLING OPTIONAL SCREEN STEP 1 STEP 2 brickmold casing Insect screen frame Pencil mark Pencil Loop latch Full insect screen U-channel #6 x 1-1/4" Stainless steel Phillips pan head screws Full insect screen U-channel Full insect screen Head and Sill Detail Ball head screw Drill three 3/32 holes, 2" from each end and one centered in the full insect screen U-channel. Secure the U-channel to top of the exterior brickmold casing (as illustrated) using three #6 x 1-1/4" stainless steel Phillips pan head screws. blind stop Side Jamb Detail Insert the insect screen into the U-channel and position tight against the exterior blind stops. Rotate the loop latches down 90 degrees. Place a pencil in latches and make a pencil mark on the sill to mark the location of the ball head screws. Using a nail punch and hammer, make a starter hole at each mark and then drill 3/32" holes. Lightly pound the ball head screws (furnished with screws) into these holes on the sill. Swing the loop latch down over the ball head screws to lock the insect screen in place. Page 13

14 NOTES See the Caring for Eagle Windows and Doors guide for additional care and maintenance information. Methods and procedures for installation of siding and other cladding materials, trim, moldings and other finish materials around door openings are not specified in these instructions. Such materials should be installed in conformity with the manufacturer s specifications and/or industry standards for such materials. If masonry cladding is used, the soldier course of masonry must be one-half inch away from the bottom of the sill on all doors. Because all construction must anticipate some water infiltration, it is important that the wall system be designed and constructed to properly manage moisture. Eagle Window & Door is not responsible for claims or damages caused by unanticipated water infiltration, deficiencies in building design, construction and maintenance, failure to install Eagle products in accordance with these instructions, or the use of Eagle products in systems which do not allow for proper management of moisture within the wall system. The determination of the suitability of all building components, including the use of Eagle products, as well as the design and installation of flashing and sealing systems, are the responsibility of you, your architect, or a construction professional. Moisture problems, including unacceptable water infiltration, have been associated with barrier systems such as EIFS (also known as synthetic stucco). Eagle products should not be used in barrier EIFS systems unless Eagle s current, recommended installation procedures for installation of windows and doors into EIFS are used. Any other use of Eagle products with barrier EIFS systems will void the warranty. Contact your sealant supplier to choose a sealant that is compatible with, and that will adhere adequately to, all building materials used in the door area. Important: Perimeter sealant must be Grade NS Class 24 per ASTM C920 and compatible with the window/door product, nail fin and the finished exterior of the building. Use of improper sealant could result in sealant failure, resulting in air and water infiltration. Eagle makes no warranty, expressed or implied, that the methods and procedures described in these instructions are suitable for any particular purpose or installation. These instructions do not add to or modify the terms, conditions or limitations of Eagle s manufacturer s warranty. A drip cap is required on all windows and doors. Failure to utilize and incorporate a drip cap could void the Eagle Window & Door warranty. Refer to the Eagle warranty for additional information. These installation procedures have been tested by an independent laboratory under ideal installation conditions using the ANSI/AAMA/NWWDA 101/I.S test method for installation, and meet DP45 performance levels for installation only. Eagle and all other marks denoted are trademarks of Eagle Window & Door Manufacturing, Inc Eagle Window & Door Manufacturing, Inc. All rights reserved. Page 14

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