RYTEC Bantam Operating instructions

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Bantam®
(Manual Operat ion)
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Installation &
Owner ’ s Manual
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[ R e v i s i o n: May 25, 2000, R0815007, ©Rytec Co r po r a t ion 20 00]

WARRANTY
The Bantam Dock Door purchased by you ("Buyer") should not be installed or operated before you read
the product manuals explaining the proper methods of installing, operating and maintaining the equip-
ment.
Rytec Corporation ("Seller") warrants that the Bantam Dock Door ("Product") sold by it to the Buyer will
be free from defects in materials and workmanship under normal use for a period of twelve months from
the date of shipment of the Product from Seller's plant. Electrical components are warranted for a
period of ninety (90) days from date of shipment. In addition, the Seller offers an extended two (2) year
warranty on the 2-ply Rilon door panel material.This extended warranty covers parts only. If within the
applicable period any Products shall be proved to Seller's satisfaction to be defective, such Product shall
be repaired or replaced at Seller's option. Such repair or replacement shall be Seller's sole obligation and
Buyer's exclusive remedy hereunder and shall be conditioned upon Seller's receiving written notice of
any alleged defect within ten (10) days after its discovery and, at Seller's option, return of such
Product to Seller, f.o.b. its factory.THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER
REPRESENTATION AND WARRANTIES, EXPRESS OR IMPLIED, AND SELLER EXPRESSLY DIS-
CLAIMS AND EXCLUDES ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR
PURPOSE.
PARTS AND ASSEMBLIES sold separately by Rytec Corporation that fail due to defects in material or
workmanship within NINETY (90) days from the date of shipment or installation will be replaced under
warranty provided installation has been carried out in accordance with Rytec procedures. This warranty
is limited to providing a replacement part only, not including freight, special charges or cost of
installation.
Any description of the Product, whether in writing or made orally by the Seller or Seller's agents,
specifications, samples, models, bulletins, drawings, diagrams, engineering or similar materials used in
connection with Buyer's order are for the sole purpose of identifying the Product and shall not be
construed as an express warranty. Any suggestions by Seller or Seller's agents regarding use, application
or suitability of the Product shall not be construed as an express warranty unless confirmed to be such in
writing by Seller.
Seller's liability with respect to the Product sold to Buyer shall be limited to the warranty provided herein.
SELLER SHALL NOT BE SUBJECT TO ANY OTHER OBLIGATIONS OR LIABILITIES, WHETHER
ARISING OUT OF BREACH OF CONTRACT, WARRANTY, TORT (INCLUDING NEGLIGENCE AND
STRICT LIABILITY) OR OTHER THEORIES OF LAW, WITH RESPECT TO PRODUCTS SOLD OR
SERVICES RENDERED BY SELLER, OR ANY UNDERTAKING, ACTS OR OMISSIONS RELATING
THERETO. Without limiting the generality of the foregoing, Seller specifically disclaims any liability for
property or personal injury damages, penalties, special or punitive damages, damages for lost profits or
revenue, services, down time, shut down or slow down costs, or for any other types of economic loss, and
for claims of Buyer's customers or any third party for any such damages. SELLER SHALL NOT BE
LIABLE FOR AND DISCLAIMS ALL CONSEQUENTIAL, INCIDENTAL AND CONTINGENT DAMAGES
WHATSOEVER.
This warranty shall be void in its entirety if failure of any product shall be caused by any installation,
operation or maintenance of the Product which does not conform with the requirements set forth by Seller
in the applicable product manuals or is the result of any cause other than a defect in the material or
workmanship of the Product.
11/21/96

TABLE OF CONTENTS
PAGE
INTRODUCTION .....................................................................................1
HOW TO USE MANUAL .......................................................................... 1
INSTALLATION
TOOLS AND EQUIPMENT REQUIRED ................................................... 2
BASIC JOB REQUIREMENTS ................................................................. 2
GENERAL ARRANGEMENT OF DOOR PARTS..................................... 2
ANCHORING METHODS .......................................................................... 3
Concrete or Brick Wall................................................................................3
Wood or Brick Wall......................................................................................3
Insulated Walls ............................................................................................3
LOCATING THE CENTERLINE OF THE DOOR OPENING .................... 4
LOCATING SIDE COLUMNS .................................................................... 4
INSTALL SIDE COLUMNS........................................................................ 5
INSTALL HEADER ASSEMBLY
Doors without Hood Assembly .................................................................$
Doors with Hood Assembly.......................................................................6
INSTALL HEAD ASSEMBLY..................................................................... 8
INSTALL CHAIN AND CHAIN KEEPER
Chain Installation........................................................................................9
Chain Keeper Installation ..........................................................................10
INSTALL BOTTOM BAR............................................................................ 11
INSTALL ANCHOR HOLE PLUGS AND CAULKING
Anchor Hole Plug Installation ...................................................................11
Caulking .......................................................................................................11
INSTALL HOOD ......................................................................................... 11
FINAL CHECKS......................................................................................... 12
OPERATION
GENERAL ARRANGEMENT OF DOOR PARTS..................................... 13
OPEN/CLOSE DOOR................................................................................ 13
To Open the Door........................................................................................13
To Close the Door .......................................................................................13

PAGE
DRIVE SYSTEM OPERATION .................................................................. 14
BOTTOM BAR
Breakaway Feature—Impact ......................................................................15
Breakaway Feature—Repair ......................................................................15
PLANNED MAINTENANCE
RECOMMENDED SCHEDULE ................................................................. 16
WEEKLY INSPECTION
Visual Damage Inspection .........................................................................16
Check Door Operation................................................................................16
BI-ANNUAL INSPECTION
Mounting Hardware Inspection.................................................................18
Chain.............................................................................................................18
Fabric Inspection ........................................................................................18
Weather Seal Inspection
HEADER ASSEMBLY...........................................................................19
SIDE COLUMNS ..................................................................................19
Bottom Bar Inspection ...............................................................................20
Lubrication...................................................................................................20
Governor Inspection...................................................................................21
REPLACEMENT PROCEDURES
WEATHER SEAL
Header Assembly ........................................................................................22
Side Columns ..............................................................................................23
PARTS LIST
PARTS ORDERING INFORMATION
How To Order Parts .....................................................................................25
Return of Repair Parts................................................................................25
Additional Information ...............................................................................25
DOOR FRAME/HOOD ASSEMBLY .......................................................... 26
DOOR AND REDUCER ............................................................................. 28
BOTTOM BAR ASSEMBLY....................................................................... 30

1
HOWTO USE MANUAL
Throughout this manual, the following key words are
used to alert the reader of potential hazardous
situations, or situations where additional information
for successfully performing the procedure is
presented:
WARNING is used to indicate the potential
for personal injury, if the procedure is not
performed as described.
CAUTION is used to indicate the potential
for damage to the product or property dam-
age, if the procedure is not followed as de-
scribed.
IMPORTANT: IMPORTANT is used to relay in-
formation CRITICAL to the suc-
cessful completion of the
procedure.
NOTE: NOTE is used to provide additional infor-
mationtoaidintheperformanceofthepro-
cedure, or operation of the door, but not
necessarily safety related.
INTRODUCTION
The Rytec®Bantam®dock door is a manually-
operated, low maintenance industrial door.The
information contained in this manual will allow you to
install, operate and maintain the door in a manner
which will insure maximum life and trouble-free
operation.
If you have any questions that have not been covered
in this manual, contact your local Rytec representative
or the Rytec Customer Support Department at 1-800-
628-1909.
The installation of your Rytec Bantam dock door is not
difficult providing the following procedures are adhered
to. Any unauthorized changes in procedure, or failure
to follow the steps as indicated, will automatically void
our warranty.Any changes in the working parts,
assemblies, or specifications as written, that have not
been authorized by Rytec Corporation, will also cancel
our warranty.The responsibility for the successful
operation and performance of this door then becomes
yours.
DO NOT INSTALL, OPERATE OR PERFORM
MAINTENANCE ON THIS DOOR UNTIL YOU HAVE
READ AND UNDERSTOOD THE INSTRUCTIONS
CONTAINED IN THIS MANUAL. If you have any
questions, call your Rytec representative or the Rytec
Customer Support Department at 1-800-628-1909.
Always refer to the door serial number when calling
the representative or Rytec Customer Support
Department.The serial number plate is located at the
top of the right side column.
INTRODUCTION

2
INSTALLATION
TOOLS AND EQUIPMENT REQUIRED
1. Socket and wrench set
2. 1/2-inch diameter concrete anchor bolts
(See ANCHORING METHODS on page 3.)
3. 1/2-inch diameter threaded rod.
(See ANCHORING METHODS on page 3.)
4. Two ladders (taller than the door opening height)
5. Forklift
6. Carpenters or spirit level (4-foot long minimum)
7. Carpenters square
8. Hammer drill
9. 1/2-inch diameter masonry drill bits
10. 3—4 foot bar clamps
11. Hammer and mallets
12. Crowbar or prybar
13. Assorted hand tools (pliers, tape measure, etc.)
14. Assorted shim stock
15. Water level, line level or transit
BASIC JOB REQUIREMENTS
1. A forklift must be supplied by the customer, dealer
or installer.
2. Two installers are required.
3. The customer must guarantee 100% access to the
door opening during the installation. No traffic
should be allowed through the door during the
installation.
GENERAL ARRANGEMENT OF DOOR PARTS
GENERAL ARRANGEMENT OF DOOR PARTS
Figure 1 shows the location of major components of
your Bantam dock door.This illustration should be
used as reference only and should not be used as part
of the installation instructions.
Right Side
Column
Bottom Bar
Assembly
Latches
Left Side
Column
Chain Keeper
Chain
Governor Fabric Roll
Reducer
A8500001
Figure 1

3
ANCHORING METHODS
Correct anchoring of the side columns to the wall is
important for smooth and safe door operation.The wall
material should be strong enough to support the door
and anchors. Figures 2–6 show the most common
anchoring methods; use the method that best fits your
application. All anchoring hardware and material are
the responsibility of the door owner and/or installer.
If you have any questions, call your Rytec
representative or the Rytec Customer Support
Department at 1-800-628-1909.
NOTE: Use 1/2-inch diameter expansion shell
stud-type anchors for concrete walls, or
1/2-inch diameter threaded through bolts
for brick walls or other applications where
expansion bolts are not applicable.
Concrete or BrickWall (Figure 2)
Concrete or
Brick Wall
Side Column
Expansion
Anchor
A0500005
Figure 2
Wood or BrickWall (Figure 3)
Wood or Brick Wall
Side Column
Through Bolt
or Threaded Rod
A0500007
Figure 3
Insulated Walls (Figures 4–6)
Side Column
Through Bolt
or Threaded Rod
Insulated Wall
Crush Plate
(1/2 in. x 6 in. x 8 in.)
A0500006
Figure 4
Insulated Wall
Aluminum-Clad 2 x 4 (Back Side)
Through Bolt
or Threaded Rod
Side Column
A0500008
Figure 5
Insulated Wall
Through Bolt
or Threaded Rod
Aluminum-Clad 2 x 4
(Both Sides —Full Length)
Side Column
A0500009
Figure 6
ANCHORING METHODS

4
LOCATING THE CENTERLINE OF THE DOOR
OPENING
NOTE: Accuratemeasurementiscriticaltocorrect
door installation. Verify all measurements
before installing components.
Measure the door opening width in inches.Divide the
width by two to obtain the centerline dimension. Mark
the floor at the centerline. (See Figure 7.)
Centerline
Door Opening
1/2 Door
Opening
Width
A0500001 Opening Width
Figure 7
LOCATING SIDE COLUMNS
1. A door production layout drawing is attached to the
small parts carton, located in the shipping crate.
This drawing identifies the production width of your
door.
2. Using the production width from the layout draw-
ing, measure out from the door opening centerline,
1/2 of the production width and mark the floor on
each side of the centerline.
3. Using a carpenters square, mark a line on the
floor at each end of the production width line.The
line should extend at least one foot out from the
wall. (See Figure 8.)
This door is equipped with a breakaway
bottom bar assembly. In order for the as-
sembly to work properly, the door opening
width must not be smaller than the produc-
tion door width. If the door opening width
is smaller than the production width,do not
proceed with the installation. Contact your
Rytec representative or Rytec Customer
Support Department at 1-800-628-1909.
1/2 Production
Width
Mark on Floor
(Each Side of Opening)
Centerline
Door Opening
A0500002
Figure 8
4. Check the floor on each side of the door opening
for level.If one side of the opening is higher than
the other, shimming under the side column will be
required.
Figures 9 and 10 show two recommended methods
that can be used to assure a level side column
installation.
NOTE: Contact the Rytec Customer Support De-
partment if the floor is more than 1 inch out
of level.
Line Level
This Dimension Must Be
Equal on Both Sides of
Door Opening
Shim Plate
(If Required)
A0500003
Figure 9
LOCATING SIDE COLUMNS

5
It is critical that the side columns are
mounted level and square to the wall and
floor, both vertically and horizontally.
A 4-foot level and carpenters square are
recommended for this procedure. The
use of bar clamps to hold the side columns
to the wall during installation is recom-
mended, as these hold the columns se-
curely in place, while allowing slight
movement of the columns during the in-
stallation of the head assembly.
NOTE: All anchoring hardware and material is the
responsibility of the door owner and/or in-
staller.
3. When the side column has been positioned
properly, anchor the column to the wall using
appropriate anchors. (See ANCHORING METH-
ODS on page 3.) Anchor holes have been pro-
vided in the side columns.(See Figure 11.)
DO NOT tighten anchors at this time.
NOTE: Use 1/2-inch diameter expansion shell
stud-type anchors for concrete walls, or
1/2-inch diameter threaded through bolts
for brick walls or other applications where
expansion bolts are not applicable.
4. Mount the opposite side column to the wall using
the same procedure as outlined for the other side
column.
Water Level
This Dimension Must Be
Equal on Both Sides of
Door Opening Shim Plate
(If Required)
A0500004
Figure 10
INSTALL SIDE COLUMNS
NOTE: Some applications may require the use of
pullouts to gain clearance of existing ob-
structions. All measurements are taken to
the side columns, not to pullouts.
1. Remove the side columns from the shipping crate.
2. Place each side column on the floor, against the
wall aligning it with the production width line
marked on the floor.The side column is located to
the outside of the door production width line.
(See Figure 11.)
Production Width Line
Anchor Holes
(2 Anchors Required)
Anchors Supplied by
Door Owner/Installer
Seal Inside
Anchor Holes
(2 Anchors
Required)
Side Column Must Be
Located to Outside of Line
LEFT COLUMN SHOWN
A8500002
Figure 11
INSTALL SIDE COLUMNS

6
INSTALL HEADER ASSEMBLY
Doors without Hood Assembly
1. Attach header extrusion support brackets to the
header extrusion using four (two per side) 3/8-16 x
1-1/4-inch serrated-flange hex screws.
(See Figure 12.) Brackets and mounting hardware
are shipped in the small parts carton.
Header
Extrusion
Serrated-Flange
Hex Screw (2 Per Side)
Support Bracket
(Mount toTop of
Header Extrusion)
Serrated-Flange
Hex Nut (2 Per Side)
A8500004
Figure 12
2. Install the header extrusion and support bracket
with bracket to the inside of the side columns
using four (two per side) 3/8-16 x 1-1/4-inch
serrated-flange hex screws and serrated-flange
hex nuts. (See Figure 13.)
LEFT SIDE SHOWN
Side Column Serrated-
Flange
Hex Nut
(2 Per Side)
Support Bracket
(Mount to Inside
of Side Columns)
Serrated-Flange
Hex Screw
(2 Per Side)
A8500005
Figure 13
3. Check to see that the side columns are plumb and
square.
4. Tighten all anchors holding the side columns to
the wall.
5. Remove bar clamps, if used to hold side columns
to wall.
Doors with Hood Assembly
NOTE: The reducer location is determined at the
timethedoorisordered and manufactured.
DO NOT attempt to change the location of
the reducer without contacting your
local Rytec representative or the Rytec
Customer Support Department at
1-800-628-1909.
1. Determine the drive and non-drive sides of the
head/fabric roll assembly.This is important for
correct installation of support brackets.When the
head/fabric roll assembly is properly installed, the
panel/bottom bar should be coming off the back of
the drum.(See Figure 14.)
RYTECRYTEC RYTEC
Reducer
(Drive) Side
Non-Drive Side
Bottom Bar
Assembly
A8500040
Figure 14
INSTALL HEADER ASSEMBLY