40684 Talbot Line, St. Thomas, Ont., N5P 3T2 Phone: (519) 637-7899

Toll Free: (800) 265-5701 Fax: (519) 637-3403

Web Site: www.northstarwindows.com

NORTH STAR

4-PANEL PATIO DOOR

ASSEMBLY INSTRUCTIONS

(JN/P-Dr04/4PanAssy – 06/28/05)

FOUR PANEL PATIO DOOR HARDWARE LIST

645.2090ROLLER ASSEMBLY

645.3010ROLLER SHIMS

645.3030HEAD GASKET (LH & RH)

645.3020SILL GASKET (LH & RH)

645.3000OPERATING PANEL SEAL

645.5435 INTERLOCK END CAP L

950.1090HOLE PLUG 3/8"

645.5430INTERLOCK END CAP R

645. 5640SILL INTERLOCK DUST PLUG 1" x 3"

575.1036HEAD INTERLOCK DUST PLUG 1/2" x 1-1/2"

645.2085HEAD DUST PLUG

645.5200INTERIOR HANDLE, SCREWS & LEVER

645.5220EXTERIOR HANDLE

645.5260SINGLE POINT LOCK & KEEPER

16 580.1386 #8 x 2-1/2" R. H. W. ZINC

2 580.6115 #10 x 3/4" F. H. ZINC

10 580.1090 #6 x 3/4" F. H. WHITE

2 580.1310 #8 x 1/2" P. H CAMTAP ZINC

2 580.0930 #5 x 1/2" F. H. ZINC

QTY. DESCRIPTION

QTY. DESCRIPTION

QTY. DESCRIPTION

2

2

1

4

8

2

2

1

1

1

7

2

2

2

1 575.1035 MULLION DUST PLUG (TOP) 1-1/4" x 1-1/4"

4 580.6125 #10 x 1-1/2 P. H. CAMTAP ZINC

2 545.5460 SASH BUMPER (HEAD)

12/21/04

2 645. 5550 SASH BUMPER (SILL)

DETAIL A

DETAIL A

DETAIL B

DETAIL B

A

B

STEP 1SLIDE FIXED SASH SUPPORTS

INTO SILL AS INDICATED

STEP 2REMOVE PROTECTIVE FILM FROM HEAD

GASKETS AND APPLY TO BOTH SIDE JAMBS.

APPLY SILICONE TO THE LEG LOCATION

SHOWN ON EACH SIDE JAMB AND FASTEN

USING #8 x 2-1/2” R. S. W. SCREWS.

STEP 3REMOVE PROTECTIVE FILM FROM

SILL GASKETS AND APPLY TO BOTH

SIDE JAMBS AND FASTEN TO SILL

USING #8 x 2-1/2” R. S. W. SCREWS.

4-PANEL PATIO DOOR ASSEMBLY INSTRUCTIONS

FIXED SASH SUPPORTS

SILICONE

P. 111/01/04

DETAIL B

DETAIL B

DETAIL A

DETAIL A

B

A

IF ASSEMBLED AT JOB SITE, TEMPORARILY

PIN FRAME IN OPENING.

EXTERIOR

VIEW

INTERIOR

VIEW

STEP 4FOR PANEL ORIENTATION READ LABEL ON

EDGE OF PANEL, ENSURING GLASS STOPS

ARE TO UNIT INTERIOR.

INSERT FIXED PANELS AS INDICATED AND

PLACE ON FIXED PANEL SUPPORTS AND

SLIDE INTO SIDE JAMB POCKETS.

STEP 5APPLY SILICONE ON BOTTOM AND SIDES OF 1" x 3"

SILL INTERLOCK DUST PLUG AND PLACE ON SILL,

FLUSH WITH FIXED PANEL SUPPORT AS INDICATED IN

DETAIL A. FASTEN WITH #6 x 3/4" F. H. SCREW. REPEAT

STEP FOR OPPOSITE PANEL.

USING RUBBER MALLET INSTALL INTERLOCKS BEFORE

SECURING FIXED PANELS WITH 4 - #6 x 3/4" F. H.

SCREWS PER PANEL THRU FRAME WEATHER STRIP

GROOVE AS INDICATED.

MAKE SURE HEAD JAMB IS TIGHT AGAINST THE TOP

OF THE INTERLOCK, THAT THE FIXED PANELS AND

FRAME ARE SQUARE BEFORE FASTENING.

COMPLETE ANCHORING OF UNIT FRAME ENSURING

UNIT IS SQUARE, PLUMB AND LEVEL.

P. 2

PANEL ORIENTATION LABEL

11/01/04

DETAIL B

DETAIL B DETAIL A

DETAIL A

BA

STEP 8PEEL AND STICK ROLLER SUPPORT FOAM PADS INSIDE OF BOTTOM RAIL AND INSERT ROLLER ASSEMBLIES (NO SCREWS REQUIRED). APPLY BEAD OF SILICONE FULL LENGTH TO UNDERSIDE EXTERIOR EDGE WHERE WEATHER STRIP ADAPTOR SNAP IN LEG CONTACTS SASH. SILICONEBOTTOM RAIL ACROSS ENDS TO COMPLETELY SEAL OFF EACH END BETWEEN SASH AND WEATHER STRIP ADAPTER. NEXT SNAP SASH WEATHER STRIP ADAPTOR INTO PLACE TO SECURE ROLLER ASSEMBLIES AND FASTEN WITH #5 x 1/2" F. H. SCREW AT MIDPOINT OUTSIDE EDGE ON 45 DEGREE ANGLE, AS SHOWN. (NOT IN ROLLER TRACK PATH) THE WEATHER STRIP ADAPTOR FOR THE LEFT OPERATING PANEL (VIEWED FROM EXTERIOR) IS 1/4" LONGER THEN THE PANEL WIDTH TO ACCOMMODATE MULLION.

P. 3

STEP 6APPLY 1/2 x 1-1/2" INTERLOCK SEAL ON UNDERSIDE OF HEAD JAMB AS INDICATED.REPEAT THIS STEP ON OPPOSITE FIXED PANEL.

STEP 9INSTALL OPERATING PANEL WITH THE LONGER WEATHER STRIPADAPTOR ON THE RIGHT SIDE (VIEWED FROM INTERIOR) THEN INSTALL OTHER PANEL ON THE LEFT.

12/21/04

#5 x 1/2" F. H. SCREW

SILICONE

STEP 7APPLY SILICONE ON BOTTOM AND SIDES OF 1" x 3"DUST PLUG AND PLACE ON SILL FLUSH WITH FIXEDPANEL SUPPORT AS INDICATED IN DETAIL A. FASTENWITH # 6 x 3/4" F. H. SCREW THRU CENTER OF PLUG.REPEAT STEPS FOR OPPOSITE FIXED PANEL.

DETAIL B

DETAIL B

DETAIL C

DETAIL C

B

C

P. 4

STEP 12PLACE SMALL BEAD OF SILICONE IN BOTTOM INTERLOCK OPENING. INSERT END CAP AS SHOWN. INSTALL INTERLOCK ON OPERATING PANEL AS INDICATED, ENSURE INTERLOCK IS FLUSH WITH BOTTOM OF WEATHER-STRIP ADAPTOR. REPEAT STEPS FOR OPPOSITE OPERATING PANEL(1 RIGHT AND 1 LEFT END CAP IS PROVIDED)

STEP 10INSERT LOCK WITH LATCH ENGAGEMENT UPWARD AND FASTEN WITH 2 #10 x 3/4" F. H. SCREWS. INSERT THUMB LEVER AS INDICATED, AND INSTALL HANDLES ENSURING SCREWS ARE ON THE INTERIOR OF DOOR PANEL.(STANDARD SINGLE POINT HARDWARE SHOWN)

LATCH ADJUSTMENT SCREW

STEP 11INSTALL INTERIOR AND EXTERIOR HANDLE AS SHOWN (NO LOCK REQUIRED ON THIS PANEL).

11/01/04

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DETAIL A

DETAIL A

A

P. 6

STEP 19SLIDE OPERATING PANELS TO THE CLOSED POSITION.INSERT DUST PLUG INTO HEAD JAMB POCKET WITH SCREW HOLE TOWARDS INTERIOR AND SLIDEINTO POSITION SO WOOL PILE IS FLUSH WITH EDGE.OF DOOR PANEL. FASTEN WITH (1) #8 x 1/2" P. H. SCREW.

STEP 20INSERT SCREEN PANEL INTO HEAD TRACK, AND BOTTOM ONTO SCREEN SILL TRACK. (LEFT HAND SCREEN PANEL HAS THE VERTICAL SCREEN CHANNEL ADAPTOR)

DUST PLUG (2 REQUIRED, 1 FOR EACH SLIDING PANEL)

11/01/04

DETAIL B

DETAIL B

DETAIL A

DETAIL A

DETAIL C

DETAIL C

B

A

C

STEP 23SECURE SCREEN BY ADJUSTING TOP AND BOTTOM ROLLERS WITH ADJUSTMENT SCREWS FOR SMOOTH OPERATION.

STEP 21INSERT RIGHT AND LEFT OPERATING PANELSTOPS IN HEAD JAMB POCKET AND THENRIGHT AND LEFT SIDE JAMB POCKET COVERSAS INDICATED. INSERT EXTERIOR HEAD JAMBPOCKET COVER BETWEEN FIXED PANELS.

P. 711/01/04

STEP 22INSTALL SCREEN LATCH KEEPER USING 2 #5 x 3/4" P. H. SCREWS ON MARKED LOCATIONS.

STEP 24INSERT SASH BUMPER (SILL) AS SHOWN FOR BOTH OPERATING PANELS

DETAIL A

DETAIL A

DETAIL B

DETAIL B

AB

PRIOR TO INSTALLING NAILING FIN

APPLY 1/8" BEAD OF SILICONE AT

THIS LOCATION. FULL LENGTH OF

HEAD & SIDE JAMBS

APPLY SILICONE TO END JOINT

ON EACH NAILING FIN.

NAILING FIN INSTALLATION INSTRUCTIONS

APPLY SILICONE ON JOINT

11/11/04

P. 1

PATIO DOOR INSTALLATION INSTRUCTIONS

STEP 1A LEVEL BASE AND SQUARE OPENING IS CRITICAL FOR THE PERFORMANCE OF THE DOOR. APPLY TWO BEADS OF SILICONE ON BASE, 1" IN FROM INTERIOR AND EXTERIOR EDGE OF SILL BEFORE INSTALLING DOOR.

STEP 2PLACE DOOR FRAME INTO OPENING AS SHOWN, ENSURING SILICONE FORMS A GOOD SEAL BETWEEN FLOOR AND DOOR SILL. (DOOR MAY ALSO BE INSTALLED FULLY ASSEMBLED)

11/11/04

DETAIL A

DETAIL A

DETAIL B

DETAIL B

A

B

P. 2

STEP 3SHIM SIDE JAMBS IN THREE PLACES AS SHOWN AND FASTEN TOP AND BOTTOM W ITH #10 x 2-1/2" P. H. SCREWS IN V GROOVE AS SHOWN IN DETAIL "B". PLACE MIDDLE SHIM IN LINE W ITH MARKED LOCATIONS FOR LOCK KEEPER. FASTEN SIDE JAMB AND KEEPER USING #10 x 2-1/2" P. H. SCREWS AS SHOWN IN DETAIL "A". FASTEN HEAD JAMB AFTER FIXED PANEL AND INTERLOCK ARE INSTALLED. (REFERTO DOOR ASSEMBLY INSTRUCTIONS FOR DETAILS)

STEP 4TRIM EXCESS WOOD SHIMS AND LOOSELY FILL CAVITY BETWEEN JAMBS AND OPENING W ITH FIBER INSULATION. APPLY A QUALITY EXTERIOR GRADE CAULKING TO THE EXTERIOR FRAME CAVITY BETWEEN DOOR FRAME AND OPENING

SINGLE POINT LOCK KEEPER

11/11/04