fixed upper sash replacement guide - andersen windows · weight of window/door unit(s) and...

Weight of window/door unit(s) and accessories will vary. Use a reasonable number of people with sufficient strength to lift, carry, and install window and door unit(s) and accessories. Always use appropriate lifting techniques.

Using ladders and/or scaffolding and working at elevated levels may be hazardous. Follow equipment manufacturer's instructions for safe operation. Use extreme caution when working around window and door openings. Falling from opening may result in injury or death.

Improper use of hand/power tools could result in injury and/or product damage. Follow manufacturer's instructions for safe operation of equipment. Always wear safety glasses.

Read all instructions carefully before attempting this procedure. If you have any questions about your ability to complete this procedure, call Andersen at 1-888-888-7020 for further direction. Andersen WindowCare® service center hours are Monday through Friday, 7 a.m. to 7 p.m. Central Time and Saturday 8 a.m. to 4 p.m. Central Time. Thank you for choosing Andersen® products.

“Andersen” is a registered trademark of Andersen Corporation. All other marks where denoted are marks of Andersen Corporation. ©2007 Andersen Corporation. All rights reserved. Instruction Guide 105898 F Revised 06/29/07

Fixed Upper Sash Replacement Guidefor Andersen® 400 Series Woodwright® Springline™ Single-Hung Windows Manufactured Between September 2005 and October 2006

Tools and Supplies• Safety Glasses• Silicone Sealant• 1/8" Hex Wrench• Phillips Screwdriver• Small Pry Bar• 1/16" Dowels• Filament or Duct Tape• Gloves• Caulk Gun• Putty Knife• Hammer• Utility Knife• Painter’s Tape

Parts Included(1) Instruction Guide(1) Exterior Sash Assembly(1) Interior Wood Sash Assembly(1) Interior Sash Stop(1) Upper Sash Interlock(1) Interior Grille Bar (optional)(2) Foam Weatherseal(12) #8 x 1-1/2" Screws(6) #8 x 3/8" Screws

Interior Sash Stop

Interior Wood Sash Assembly

Exterior Sash Assembly

Interior View

Upper Sash Interlock

1

Support Sash during removal and reinstallation. Failure to support Sash may result in injury, product, and/or property damage.

• Remove insect screen if present.• Tape broken glass with filament or duct tape to reduce

glass fragmentation.• Remove interior removable grille bars if present.• Position Lower Sash about 4" from sill.• Slide Wash Assists down both side jambs to release Tilt

Latches.• Tilt Lower Sash in, toward interior to 90° and support on

chair or object.

Interior View

Lower Sash at 90˚

Wash Assist

4"

Filament or Duct Tape

• Thinners• Cleaners• Mineral spirits• Foam Insulation can• Solvent soaked rags

• If suction cups are used while moving or installing unit, make sure that cups are not applied on the seam of the protective film.

• If suction cup is applied on the seam, the suction cup will lose adhesion, causing unit to slip or drop and potentially causing damage or injury.

• Do not allow sealants to contact exterior glass surface. Glass surface or exterior coating damage will result.

• If protective film is present, leave in place until unit is installed and job site construction is completed to protect glass surface.

Glass• Tempered safety glass is not standard and must be special

ordered. Check local building codes for required safety glass locations.

• Do not remove product performance label before final inspection.

Protective Film Seam

Suction Cup

1. Position Lower Sash

REMOVE FROM AREA:

Peeling off protective film may result in a static charge that could cause a shock or spark.

Static charge and spark can pass through to the OTHER SIDE of glass.

Solvents, cleaners and foam insulation must be dry and all flammables must be properly stored before removing protective film.

Misting glass with water may reduce static charge and spark.

For best results, protective film should be removed within 9 months of installation in temperatures above 32° F.

2

Balance Cord Lock must be engaged (locked) before disengaging Sash from frame and/or before detaching Balance Cord Clips from jambs. Balance Cords must remain locked when Sash is not engaged with frame and/or Balance Cord Clips are not attached to jambs. Failure to keep Balance Cord locked in these situations may cause sudden release of Balance Cord which could potentially cause injury and/or product damage.

Support bottom of Sash while detaching balance Cord Clips to prevent it from falling onto sill. Failure to do so may result in injury and/or product damage.

• Engage (lock) Balance Cord Lock in Balance on both sides of Lower Sash by turning hex screw 1/2 turn clockwise using 1/8" hex wrench. Positive stop will be felt.

• Remove hex head screws securing Balance Cord Clips to frame using 1/8" hex wrench. Retain screws for reuse. Sash will move freely in Jamb Liner after screws are removed.

Balance Cord Clip

Balance

1/8" Hex Wrench

Balance Cord Lock (hex screw)

Lower Sash Support on a chair/object

Interior View

3. Remove Lower Sash

2. Lock Balance Cord Locks and Remove Balance Cord Clips

• Hold Lower Sash at 90˚, lift one side until Brake Levers are clear of frame, and remove. Set Sash aside in a safe location.

Use extreme care when working around window opening. Never leave a window opening unattended, especially when children are present. Falling from window opening may result in injury or death.

Brake Lever

Interior View

3

If there are no permanently applied Grille Bars proceed to Step 5.

• Remove permanently applied interior Grille Bars from Upper Sash by forcing thin putty knife between glass and Grille Bars to cut tape. Pry up to lift bars.

• Work putty knife along the Grille Bar removing the entire Grille Bar. Remove all interior Grille Bars from Upper Sash. Be careful while working around broken glass.

4. Remove Permanently Applied Grille Bars from Upper Sash

• Insert small pry bar between Upper Sash Interlock and interior of Upper Sash at one end. Push Upper Sash Interlock down and work small pry bar between Sash and Interlock.

• Work small pry bar along bottom of Sash, loosening Interlock. Be careful not to damage Jamb Liner.

• Discard old Upper Sash Interlock.

5. Remove Upper Sash Interlock

Interior View

Putty Knife Grille Bars

Interior View

Small Pry Bar


Upper Sash

Wear gloves, safety glasses, goggles, or eye shields when handling glass. Failure to do so may result in injury.

Jamb Liner

4

• From interior, remove #8 x 1-1/2" screws from perimeter of Exterior Sash Assembly using a Phillips screwdriver. Support Exterior Sash Assembly at all times.

• Pull Exterior Sash Assembly down 1" to 2" then pull bottom towards interior and remove from frame.

• Discard old Exterior Sash Assembly.

Outer Frame Member

Exterior

#8 x 1-1/2" Screw


Jamb Liner

• Remove Lock Keeper(s) from Upper Sash using Phillips screwdriver. Keep Lock Keeper(s) and screws for new Upper Sash.

• Insert a putty knife between glass and Interior Wood Sash Assembly. Pry Interior Wood Sash Assembly away from glass.

• Discard old Interior Wood Sash Assembly.

Interior View

Phillips Screwdriver Putty Knife


Lock Keeper

6. Remove Interior Sash Stop

8. Remove Exterior Sash Assembly

7. Remove Interior Wood Sash Assembly

Interior

• Insert a putty knife between head jamb and Interior Sash Stop. Pry Interior Sash Stop away from head jamb. Work putty knife around head jamb removing Interior Sash Stop.

• Discard old Interior Sash Stop if damaged.

Putty Knife

Putty Knife

Interior Wood Sash Stop

Head Jamb

Interior View

InteriorExterior

Support Sash Assembly while removing screws to prevent it from falling out. Failure to do so may result in injury and/or product damage.

5

9. Install New Exterior Sash Assembly

InteriorExterior

Weatherseal

Head Jamb

Weight of Sash will vary. Use a reasonable number of people with sufficient strength to lift, carry and install Sash. Always use appropriate lifting techniques.

• Lift Exterior Sash Assembly into position. Place top of Exterior Sash Assembly against top inside of Outer Frame Member. Hold bottom of Sash Assembly away from Outer Frame Member.

• Slowly push bottom of Sash against Outer Frame Member and up, against head jamb. Hold Exterior Sash Assembly tight against Outer Frame Member and top frame and center between side Jamb Liners.

Interior View


Outer Frame Member

• Examine weatherseal on head jamb. Replace if necessary. Match existing weatherseal length and location.

Outer Frame Member

Exterior

#8 x 1-1/2" Screw

• Install #8 x 1-1/2" screw in bottom corner of Sash in predrilled hole on 45˚ angle, while holding Exterior Sash Assembly in position.

• Fasten other bottom corner of Exterior Sash Assembly. Keep Exterior Sash Assembly centered within the frame. Fasten top of Exterior Sash Assembly though predrilled holes on 45˚ angle.

• Install remaining #8 x 1-1/2" screws around perimeter of Exterior Sash Assembly in remaining predrilled holes.

Jamb LinerInterior


Interior View

#8 x 1-1/2" Screws


Predrilled Holes

45˚

6

10. Prepare Interior Wood Sash Assembly

• Remove red tape backer from VHB tape on interior side of Exterior Sash Assembly.

• Place 1/16" dowel across the VHB tape and hold in place by taping the dowel to glass with painter’s tape. Place dowels every 12" around Exterior Sash Assembly.

• Apply two 1/4" beads of silicone sealant around perimeter of Interior Wood Sash Assembly. See drawing for locations of silicone sealant beads.

VHB TapeTape Backer

Exterior Sash Assembly Interior View

Interior ViewVHB Tape

Painter’s Tape 1/16" Dowel

Interior Wood Sash Profile

1/4" Bead Silicone Sealant

Caulk Gun


Glass

VHB Tape

1/16" Dowel

Exterior

Interior

Follow silicone sealant manufacturer’s instructions regarding surface cleaning and preparation, application, and temperature when applying silicone sealant. Failure to do so may result in water infiltration.

Interior Side Down

7

11. Install Interior Wood Sash Assembly

• Place Interior Wood Sash Assembly over Exterior Sash Assembly aligning all edges.

• While holding Interior Wood Sash Assembly in place, start at bottom corner, remove painter’s tape from dowel and slide dowel out from under Interior Wood Sash Assembly. Make sure Interior Wood Sash Assembly stays aligned with Exterior Sash Assembly.

• Push corner of Interior Wood Sash Assembly against Exterior Sash Assembly until it contacts VHB tape.

• Follow the same procedure removing remaining dowels working around the Sash.

• Push Interior Wood Sash Assembly firmly against Exterior Sash Assembly, contacting VHB tape.

• Install Interior Sash Stop around inside of curved head jamb against Interior Sash Assembly. Attach with 1-1/4" finish nails, 2" from each end of Interior Sash Stop and every 6" between.

• Install previously removed Lock Keeper onto Interior Wood Sash Assembly using a Phillips screwdriver. Use predrilled holes.

Interior View


Dowel

Interior View


Phillips Screwdriver

Lock Keeper

Lock Keeper Screw

Dowel


VHB Tape


Exterior

Interior

2"

6"


Interior Sash Stop

1-1/4" Finish Nail

1-1/4" Finish Nail

Exterior Interior


Curved Head Jamb

8

• Start to remove tape backer from VHB tape on back of Grille Bars approximately 2" from each end. Pull backer past edge of Grille Bar. Start all ends of tape backers.

• Place Grille Bar onto interior Upper Sash glass. Align Interior Grille Bar with Exterior Grille Bar.

Use position of Exterior Grille Bar for orientation and location of Interior Grille Bar.

13. Reapply Grille Bars to Glass

12. Install Upper Sash Interlock

If there are no permanently applied Grille Bars proceed to Step 14.

Interior Exterior Cross Section Detail

Interior View

VHB Tape

Tape Backer

Grille Bar

Silicone Sealant

Tape Backer

Grille Bar

• While applying just enough force to keep Grille Bar from moving, start slowly pulling an end of tape backer away from tape. Pull backer perpendicular to grille bar. Push Grille Bar against glass about 4" behind tape backer as it is being removed from tape.

• Pull tape backers away from remaining tape following same procedure.

• Push Grille Bar firmly against glass to adhere tape to glass.


#8 x 3/8" Screw

Upper Sash Interlock Profile

1/4" Bead Silicone Sealant

Interior View


Upper Sash

• Apply two 1/4" beads of silicone sealant to new Upper Sash Interlock in locations shown.

• Push Upper Sash Interlock into position on bottom of Upper Sash. Make sure Upper Sash Interlock is tight to bottom of Sash.

• Install #8 x 3/8" screws into predrilled holes in Upper Sash Interlock.

Follow silicone sealant manufacturer’s instructions regarding surface cleaning and preparation, application, and temperature when applying silicone sealant. Failure to do so may result in water infiltration.

9

Balance Cord must be extended at least 6" from Balance before reinstalling sash.

Balance Cords are under high tension. Sudden release of Balance Cord may cause injury and/or product damage. Make sure Brake Levers are locked.

• Check that each Balance Cord is extended at least 6" from each Balance on lower Sash. Balance Cords must be extended at least 6" from Balance before reinstalling Sash.

• If Balance Cords are extended at least 6", proceed to Step 15.

• If Balance Cord is not extended at least 6", grasp Balance Cord firmly and disengage (unlock) by turning hex screw 1/2 turn counterclockwise with 1/8" hex wrench and turning Brake Lever parallel to Balance over the top of pulley. Balance is loaded at this point.

• Maintain a firm grasp on Balance Cord and pull out at least 6" from balance. Then, immediately lock Balance Cord by turning Brake Lever toward exterior side of Sash, perpendicular to exterior surface of Sash, and by turning hex screw 1/2 turn clockwise with 1/8" hex wrench. Balance Cord is not loaded at this point.

• Repeat for opposite Balance Cord if not extended at least 6" from Balance.

Interior Side Up

Brake Lever(perpendicular to sash/locked)

Brake Lever(parallel to sash/unlocked)

Balance Cord(6" Minimum)

14. Prepare Balance Cord for Lower Sash Reinstallation

If Balance Cords is wrapped around Brake Lever, Sash will not operate properly and may result in injury and/or product damage.

10

15. Reinstall Lower Sash

• Place Lower Sash on work surface exterior side up.

• Check that Brake Levers are positioned perpendicular to Sash, pointing to the exterior side of the Sash, in the locked position. Reposition if necessary.

• If Balance Cords are not extended at least 6", follow instructions in Step 14.

• Lay Balance Cords on exterior surface of Sash.

• Check that Wash Assists are at top of frame.• Lift Sash into opening at 90˚ and place Brake

Levers into inner channel on Side Jamb.

• Fasten Balance Cord Clips at original locations in inner frame channel on Side Jamb using previously removed screws. Keep Sash supported perpendicular to opening while fastening Balance Cord Clips.

• Disengage (unlock) Balance Cord Lock on each Balance (both sides of sash) by using 1/8" hex wrench to turn hex screw 1/2 turn counterclockwise, while supporting Sash.

• Slide Tilt Latches to open position and return Lower Sash to closed position.

• Check Tilt Latch engagement in Jamb Channel by gently pushing Sash back and forth.

• Push Lower Sash down into closed position.

Exterior Side Up

Brake Lever(perpendicular to sash/locked)

Wash AssistBrake Lever

Interior View

Wash Assist Balance Cord Clip

Side Jamb

Tilt Latch

1/8" Hex Wrench

Balance Cord Lock (hex screw)

Lower Sash Support on a chair/object

Interior View

Interior

Exterior

Side Jamb

Inner Channel

11

Finishing, Cleaning, and Maintenance Instructions

FINISHINGRead and follow finishing manufacturer’s instructions and warnings on each container of finishing material for priming, painting, staining, and varnishing.

CLEANINGClean exterior frame and door panel using a mild detergent-and-water solution and a soft cloth or brush. DO NOT use abrasive cleaners or solutions containing corrosive solvents. For persistent dirt or grime, use a nonabrasive cleanser or a mixture of water and alcohol or ammonia.

MAINTENANCEImmediately sand and refinish any wood that becomes stained or mildewed to prevent further discoloration and/or damage. For further information, contact your local Andersen Dealer. Dealers can be found in the Yellow Pages under Windows.

• DO NOT expose unfinished wood to high moisture conditions, excessive heat or humidity. Finish wood surfaces immediately after installation. Unfinished wood surfaces will discolor, deteriorate, and/or may bow and split.

• DO NOT stain or paint weatherstrip, silicone beads, vinyl, glass, or hardware.

• Acid solutions used to wash masonry/concrete will damage glass, fasteners, hardware, and metal flashing. Follow the acid solution manufacturer’s instructions carefully. Protect and/or cover Andersen® products during the cleaning process to prevent acid contact. If acid does come in contact with unit, immediately wash all surfaces with clean water.

Finish interior wood surfaces, including hidden surface (as shown by arrow) at check rail immediately after installation.

Lower Check Rail

12

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