CALF SHELTER 6, 12, 15, 18, & 24 MODELS ASSEMBLY MANUAL Read this manual before using product. Failure to follow instructions and safety precautions can result in serious injury, death, or property damage. Keep manual for future reference. Part Number: BNS-11104 R0 Revised: 3/11/09
This product has been designed and constructed according to general engineering standards a. Other local regulations may apply and must be followed by the operator. We strongly recommend that all personnel associated with this equipment be trained in the correct operational and safety procedures required for this product. Periodic reviews of this manual with all employees should be standard practice. For your convenience, we include this sign-off sheet so you can record your periodic reviews. Date Employee Signature Employer Signature a. Standards include organizations such as the American Society of Agricultural and Biological Engineers, American National Standards Institute, Canadian Standards Association, International Organization for Standardization, and/or others.
APPLEGATE CALF SHELTER 6, 12, 15, 18, & 24 MODELS TABLE OF CONTENTS 1. Introduction... 5 2. Safety First... 7 2.1. General Safety... 8 2.2. Assembly Safety... 9 3. Assembly... 11 3.1. Pre-Assembly... 11 3.1.1. Placement... 11 3.1.2. Before You Begin... 11 3.1.3. Tools Required... 12 3.2. Calf Shelter Layout & Specifications... 13 3.3. Calf Shelter Assembly... 15 4. Appendix... 21 4.1. Parts List... 21 BNS-11104 R0 3
APPLEGATE CALF SHELTER 6, 12, 15, 18, & 24 MODELS 4 BNS-11104 R0
APPLEGATE - CALF SHELTER 6, 12, 15, 18, & 24 MODELS 1. Introduction 1. INTRODUCTION Note: Portable calf shelters are very popular with cow/calf ranchers who need additional shelter for young calves during chilly wet weather. Protecting your animals makes them more comfortable, resulting in less feed and fewer veterinarian visits. Shelters provide better rates of gain and feed-to-gain rations compared to animals without shelters. This leads to lower production costs, which in turn will lead to an increase in profits. Isolating young dairy calves for the first 8 to 12 weeks of life has been shown to minimize the transfer of pathogens and consequent disease and death. Calf hutches are effective in reducing this risk and their use is highly recommended for young, pre-weaned dairy calves. Applegate Calf Shelters are specifically designed with the comfort and protection of your animals in mind. These calf shelters will outlast wooden shelters by many years. Our shelters give your calves a place in the pasture where they can escape from poor weather conditions such as heavy rainfall, blazing sun, harsh winds, and extreme cold weather. The open front helps brighten the interior for calves and is more inviting...mom is always close by. Your insurance agent will love this calf shelter. The shelters are portable and most people put them up onto wood skids or drill stem pipe skids and drag them from the ends. Skids are not supplied with the shelters. BNS-11104 R0 5
1. INTRODUCTION APPLEGATE - CALF SHELTER 6, 12, 15, 18, & 24 MODELS 6 BNS-11104 R0
APPLEGATE - CALF SHELTER 6, 12, 15, 18, & 24 MODELS 2. Safety First 2. SAFETY FIRST The Safety Alert symbol to the left identifies important safety messages on the product and in the manual. When you see this symbol, be alert to the possibility of personal injury or death. Follow the instructions in the safety messages. Why is SAFETY important to you? Three big reasons: Accidents disable and kill. Accidents cost. Accidents can be avoided. SIGNAL WORDS Note the use of the signal words DANGER, WARNING, CAUTION, and NOTICE with the safety messages. The appropriate signal word for each message has been selected using the definitions below as a guideline. The Safety Alert symbol means ATTENTION, BE ALERT!, YOUR SAFETY IS INVOLVED. DANGER Indicates an imminently hazardous situation that, if not avoided, will result in serious injury or death. WARNING Indicates a hazardous situation that, if not avoided, could result in serious injury or death. CAUTION Indicates a hazardous situation that, if not avoided, may result in minor or moderate injury. NOTICE Indicates a potentially hazardous situation that, if not avoided, may result in property damage. BNS-11104 R0 7
2. SAFETY FIRST APPLEGATE - CALF SHELTER 2.1. GENERAL SAFETY 6, 12, 15, 18, & 24 MODELS 2.1. GENERAL SAFETY Important: The general safety section includes instructions that apply to all safety practices. Any instructions specific to a certain safety practice (e.g., assembly safety), can be found in the appropriate section. Always read the complete instructional sections and not just these safety summaries before doing anything with the equipment. YOU are responsible for the SAFE use and maintenance of your equipment. YOU must ensure that you and anyone else who is going to work around the equipment be familiar with all procedures and related SAFETY information contained in this manual. Remember, YOU are the key to safety. Good safety practices not only protect you, but also the people around you. Make these practices a working part of your safety program. The most important safety device on this equipment is a SAFE user or operator. It is the user/operator's responsibility to read and understand ALL safety instructions, safety decals, and manuals and follow them before assembly, operating, or maintaining the equipment. All accidents can be avoided. A person who has not read and understood all safety instructions is not qualified to operate or use the equipment. Untrained users/operators expose themselves and bystanders to possible serious injury or death. Equipment owners must give instructions to employees before allowing them to operate or use the product. Review safety information initially and annually with all personnel who will be using the product. Use this equipment for its intended purposes only. Do not modify the equipment in any way. Unauthorized modification may impair the function and/or safety, and could affect the life of the equipment. Any modification to the equipment voids the warranty. Do not allow children, spectators, or bystanders within the work area. Have a first-aid kit available for use should the need arise, and know how to use it. Provide a fire extinguisher for use in case of an accident. Store in a highly visible place. Wear appropriate protective gear. This list includes, but is not limited to: a hard hat gloves protective shoes with slip-resistant soles protective goggles hearing protection 8 BNS-11104 R0
APPLEGATE - CALF SHELTER 2. SAFETY FIRST 6, 12, 15, 18, & 24 MODELS 2.2. ASSEMBLY SAFETY Before servicing, adjusting, or repairing powered equipment, unplug, place all controls in neutral or off position, stop the engine or motor, remove ignition key or lock out power source, and wait for all moving parts to stop. Follow good shop practices: keep service area clean and dry be sure electrical outlets and tools are properly grounded use adequate light for the job at hand Think SAFETY! Work SAFELY! 2.2. ASSEMBLY SAFETY Have 2 people handle the heavy, bulky components. Stay away from overhead power lines and other obstructions during assembly. Contact with power lines can cause electrocution. Tighten all fasteners to their specified torque before using the equipment. Do not work in high winds. BNS-11104 R0 9
2. SAFETY FIRST APPLEGATE - CALF SHELTER 2.2. ASSEMBLY SAFETY 6, 12, 15, 18, & 24 MODELS 10 BNS-11104 R0
APPLEGATE - CALF SHELTER 3. ASSEMBLY 6, 12, 15, 18, & 24 MODELS 3.1. PRE-ASSEMBLY 3. Assembly WARNING Before continuing, please reread the safety information relevant to this section at the beginning of this manual. Failure to follow the safety instructions can result in serious injury, death, or property damage. 3.1. PRE-ASSEMBLY 3.1.1. PLACEMENT Locate the calf hutch on a well drained knoll with the open end facing south to benefit from spring sunshine. Set the hutches in rows running east-west, with enough space between them so that each hutch can be moved sideways to new ground whenever calves are changed. Some ranchers may want a scaled-down version so it can be skidded onto a flat-bed trailer or truck platform for transportation to remote sites. If the site is exposed to strong winds, the shed should be anchored at four corners to prevent wind damage. Bed the floor liberally with straw, wood chips, or other dry bedding material. When the manure pack needs cleaning out, pry the skids carefully out of the manure pack, then tow the shed backwards off the bedded area to a new site. Clean and spread the manure after the shed has been moved. 3.1.2. BEFORE YOU BEGIN 1. Inspect parts thoroughly to ensure all parts are included in the kit. 2. Find a level area to assemble the shelter. 3. Separate hardware and layout into groups for easier identification during assembly. 4. You will require two or more people to assemble the shelter. BNS-11104 R0 11
3. ASSEMBLY APPLEGATE - CALF SHELTER 3.1. PRE-ASSEMBLY 6, 12, 15, 18, & 24 MODELS 3.1.3. TOOLS REQUIRED flat blade screwdriver two 3/8 aligning punches or centering punches cutting pliers pry bar 9/16 and 7/16 wrench and socket with ratchet 5/16 drill bits and drill rubber mallet 12 BNS-11104 R0
APPLEGATE - CALF SHELTER 3. ASSEMBLY 6, 12, 15, 18, & 24 MODELS 3.2. CALF SHELTER LAYOUT & SPECIFICATIONS 3.2. CALF SHELTER LAYOUT & SPECIFICATIONS Item No. Description Item No. Description 1 Short Roof Section 11 Vertical Calf Bar 2 Long Roof Section 12 Horizontal Calf Bar 3 Sidewall Type 1 13 Bar Bracket 4 Sidewall Type 2 14 Post 5 Sidewall Type 3 15 Post Bracket 6 Exterior Flashing 16 Post Brace 7 Interior Flashing 17 Side Channel 8 Beam Section 60 18 Rear Corner Brace 9 Beam Splice Plate 19 Front Corner Brace 10 Beam Bracket 20 Rear Angle Figure 3.1 BNS-11104 R0 13
3. ASSEMBLY APPLEGATE - CALF SHELTER 3.2. CALF SHELTER LAYOUT & SPECIFICATIONS 6, 12, 15, 18, & 24 MODELS Figure 3.2 Calf Shelters - Specifications Model Length Depth Height Weight CS6 6' 8' 5' 331 lb CS12 12' 8' 5' 458 lb CS15 15' 8' 5' 518 lb CS18 18' 8' 5' 576 lb CS24 24' 8' 5' 964 lb 14 BNS-11104 R0
APPLEGATE - CALF SHELTER 3. ASSEMBLY 6, 12, 15, 18, & 24 MODELS 3.3. CALF SHELTER ASSEMBLY Figure 3.3 3.3. CALF SHELTER ASSEMBLY 1. Bolt the post bracket (15) and the post brace (16) to the post (14). Bolt the front corner brace (19) to the post (14) but do not tighten these bolts at this time. (See Figure 3.4.) Figure 3.4 BNS-11104 R0 15
3. ASSEMBLY APPLEGATE - CALF SHELTER 3.3. CALF SHELTER ASSEMBLY 6, 12, 15, 18, & 24 MODELS 2. Bolt together the beam sections (8) using the splice plates (9) and 3/8 x 3/4 bolts. (See Figure 3.5.) Figure 3.5 3. Use the illustrations in Figure 3.6 to determine the overall length that the angle will be. These lengths will also apply to the overall beam length. Bolt together the rear angle pieces (20, see Figure 3.1) using 3/8 x 3/4 bolts with the head of the bolts on the inside. Figure 3.6 16 BNS-11104 R0
APPLEGATE - CALF SHELTER 3. ASSEMBLY 6, 12, 15, 18, & 24 MODELS 3.3. CALF SHELTER ASSEMBLY 4. Bolt the side channels (17) to the rear angle (20) using the rear corner brace (18) and 3/8 x 3/4 bolts. (See Figure 3.7.) 5. Bolt together the side channels (17) to the post (14) using the front corner brace (19) and 3/8 x 3/4 bolts. (See Figure 3.1 and 3.7.) Tighten all the bolts at this time. Figure 3.7 Important: Posts and side channels must form a 90 angle. 6. Bolt the beam (9) to the posts (14) using the post braces (16) and 3/8 x 3/4 bolts. Tighten all the bolts. (See Figure 3.8.) BNS-11104 R0 17
3. ASSEMBLY APPLEGATE - CALF SHELTER 3.3. CALF SHELTER ASSEMBLY 6, 12, 15, 18, & 24 MODELS Figure 3.8 Important: 7. If you re using a skid (not included), lift the frame up and place the skid under the frame at this time. Make sure the frame is square and level. 8. Bolt the ends of the roof sheets (1,2) together in complete arches as shown in Figure 3.9 using 3/8 x 3/4 bolts with the heads on the outside. Tighten these bolts as you go. Attach the assembled arch onto the frame. Alternate the short roof sheet position for optimal strength. The calf hutches feature an adjustable calf bar for the safety and well-being of your calves or foals, and is packaged in a crate for easy shipping. The shelter is completely knock-down and bolt together, a design which makes on-site assembly problem free. Note: The calf bars (11,12) can be installed with the bar brackets (13) and 3/8 x 3/4 bolts now or after the side walls are attached. 18 BNS-11104 R0
APPLEGATE - CALF SHELTER 3. ASSEMBLY 6, 12, 15, 18, & 24 MODELS 3.3. CALF SHELTER ASSEMBLY Figure 3.9 9. Bolt the interior flashing (7) and the exterior flashing (6) to the roof starting from the bottom. Do not tighten these bolts at this time. (See Figure 3.10.) Figure 3.10 10. Beginning at the back and working forward, bolt on the sidewall sheets (3,4,5) between the exterior and interior flashings using 3/8 x 3/4 bolts (see Figure 3.11 and 3.2). There are left and right sidewalls, so ensure that the bolt holes in the sidewalls are flush with the side channels. BNS-11104 R0 19
3. ASSEMBLY APPLEGATE - CALF SHELTER 3.3. CALF SHELTER ASSEMBLY 6, 12, 15, 18, & 24 MODELS Figure 3.11 11. After the sidewalls are attached, tighten the bolts for the flashing. 12. Install the corner brackets (10) using 3/8 x 3/4 bolts. Drill and place 1/4 x 1-1/4 bolts approximately every 20 along the flashing to secure the interior, exterior, and sidewall sheets. Figure 3.12 20 BNS-11104 R0
APPLEGATE - CALF SHELTER 4. APPENDIX 6, 12, 15, 18, & 24 MODELS 4.1. PARTS LIST 4. Appendix 4.1. PARTS LIST Table 4.1 6 Calf Shelter Part No. Part Name Qty. 202-2534 8' CRATE 1 BTS-10900 SHORT ROOF SECTION 2 BTS-10902 LONG ROOF SECTION 2 BTS-10904 SIDEWALL TYPE 1 LEFT 1 BTS-10906 SIDEWALL TYPE 2 LEFT 1 BTS-10908 SIDEWALL TYPE 3 LEFT 1 BTS-10909 SIDEWALL TYPE 1 RIGHT 1 BTS-10910 SIDEWALL TYPE 2 RIGHT 1 BTS-10911 SIDEWALL TYPE 3 RIGHT 1 BTS-10912 EXTERIOR FLASHING 6 BTS-10913 INTERIOR FLASHING 6 BRS-10914 BEAM SECTION 72 1 BRS-10915 BEAM BRACKET 2 BTS-10916 HORIZONTAL CALF BAR (65-3/4") 1 BTS-50800 BAR BRACKET 2 BRS-10919 POST 2 BTS-10920 POST BRACKET 4 BTS-10921 POST BRACE 2 BTS-10922 SIDE CHANNEL 2 BTS-10923 REAR CORNER BRACE 2 BTS-10924 FRONT CORNER BRACE 2 BTS-10918 REAR ANGLE 72 1 BTS-70900 6' CALF SHELTER BOLT BAG 1 313-2299 3/8" x 3/4" BIN BOLT 218 313-2300 3/8" x 1-1/8" BIN BOLT 26 313-2304 3/8" x 2-1/2" BOLT 4 309-1769 3/8" FLANGE NUT 274 306-1878 1/4" x 3/4" SELF-TAPPING SCREW 12 313-2310 1/4" x 1-1/4" BIN BOLT 20 309-1704 1/4" FLANGE NUT 20 BNS-11104 R0 21
4. APPENDIX APPLEGATE - CALF SHELTER 4.1. PARTS LIST 6, 12, 15, 18, & 24 MODELS Table 4.2 12 Calf Shelter Part No. Part Name Qty 202-2534 8' CRATE 1 BTS-10900 SHORT ROOF SECTION 4 BTS-10902 LONG ROOF SECTION 4 BTS-10904 SIDEWALL TYPE 1 LEFT 1 BTS-10906 SIDEWALL TYPE 2 LEFT 1 BTS-10908 SIDEWALL TYPE 3 LEFT 1 BTS-10909 SIDEWALL TYPE 1 RIGHT 1 BTS-10910 SIDEWALL TYPE 2 RIGHT 1 BTS-10911 SIDEWALL TYPE 3 RIGHT 1 BTS-10912 EXTERIOR FLASHING 6 BTS-10913 INTERIOR FLASHING 6 BRS-10914 BEAM SECTION 72 2 BTS-10925 BEAM SPLICE PLATE 1 BRS-10915 BEAM BRACKET 2 BTS-10926 VERTICAL CALF BAR (53") 1 BTS-10916 HORIZONTAL CALF BAR (65-3/4") 2 BTS-50800 BAR BRACKET 5 BTS-10947 TOP BAR BRACKET 1 BRS-10919 POST 2 BTS-10920 POST BRACKET 4 BTS-10921 POST BRACE 2 BTS-10922 SIDE CHANNEL 2 BTS-10923 REAR CORNER BRACE 2 BTS-10924 FRONT CORNER BRACE 2 BTS-10928 REAR ANGLE 78 2 BTS-70901 12' CALF SHELTER BOLT BAG 313-2299 3/8" x 3/4" BIN BOLT 331 313-2300 3/8" x 1-1/8" BIN BOLT 26 313-2304 3/8" x 2-1/2" BOLT 14 309-1769 3/8" FLANGE NUT 397 306-1878 1/4" x 3/4" SELF-TAPPING SCREW 12 313-2310 1/4" x 1-1/4" BIN BOLT 20 309-1704 1/4" FLANGE NUT 20 22 BNS-11104 R0
APPLEGATE - CALF SHELTER 4. APPENDIX 6, 12, 15, 18, & 24 MODELS 4.1. PARTS LIST Table 4.3 15 Calf Shelter Part No. Part Name Qty 202-2534 8' CRATE 1 BTS-10900 SHORT ROOF SECTION 5 BTS-10902 LONG ROOF SECTION 5 BTS-10904 SIDEWALL TYPE 1 LEFT 1 BTS-10906 SIDEWALL TYPE 2 LEFT 1 BTS-10908 SIDEWALL TYPE 3 LEFT 1 BTS-10909 SIDEWALL TYPE 1 RIGHT 1 BTS-10910 SIDEWALL TYPE 2 RIGHT 1 BTS-10911 SIDEWALL TYPE 3 RIGHT 1 BTS-10912 EXTERIOR FLASHING 6 BTS-10913 INTERIOR FLASHING 6 BRS-10929 BEAM SECTION 60 3 BTS-10925 BEAM SPLICE PLATE 2 BRS-10915 BEAM BRACKET 2 BTS-10926 VERTICAL CALF BAR (53") 1 BTS-10931 HORIZONTAL CALF BAR (85.5") 2 BTS-50800 BAR BRACKET 6 BTS-10947 TOP BAR BRACKET 1 BRS-10919 POST 2 BTS-10920 POST BRACKET 4 BTS-10921 POST BRACE 2 BTS-10922 SIDE CHANNEL 2 BTS-10923 REAR CORNER BRACE 2 BTS-10924 FRONT CORNER BRACE 2 BTS-10930 REAR ANGLE 66 3 BTS-70902 15' CALF SHELTER BOLT BAG 313-2299 3/8" x 3/4" BIN BOLT 393 313-2300 3/8" x 1-1/8" BIN BOLT 26 313-2304 3/8" x 2-1/2" BOLT 14 309-1769 3/8" FLANGE NUT 459 306-1878 1/4" x 3/4" SELF-TAPPING SCREW 12 313-2310 1/4" x 1-1/4" BIN BOLT 20 309-1704 1/4" FLANGE NUT 20 BNS-11104 R0 23
4. APPENDIX APPLEGATE - CALF SHELTER 4.1. PARTS LIST 6, 12, 15, 18, & 24 MODELS Table 4.4 18 Calf Shelter Part No. Part Name Qty 202-2534 8' CRATE 1 BTS-10900 SHORT ROOF SECTION 6 BTS-10902 LONG ROOF SECTION 6 BTS-10904 SIDEWALL TYPE 1 LEFT 1 BTS-10906 SIDEWALL TYPE 2 LEFT 1 BTS-10908 SIDEWALL TYPE 3 LEFT 1 BTS-10909 SIDEWALL TYPE 1 RIGHT 1 BTS-10910 SIDEWALL TYPE 2 RIGHT 1 BTS-10911 SIDEWALL TYPE 3 RIGHT 1 BTS-10912 EXTERIOR FLASHING 6 BTS-10913 INTERIOR FLASHING 6 BRS-10914 BEAM SECTION 72 3 BTS-10925 BEAM SPLICE PLATE 2 BRS-10915 BEAM BRACKET 2 BTS-10926 VERTICAL CALF BAR (53") 2 BTS-10916 HORIZONTAL CALF BAR (65-3/4") 3 BTS-50800 BAR BRACKET 8 BTS-10947 TOP BAR BRACKET 2 BRS-10919 POST 2 BTS-10920 POST BRACKET 4 BTS-10921 POST BRACE 2 BTS-10922 SIDE CHANNEL 2 BTS-10923 REAR CORNER BRACE 2 BTS-10924 FRONT CORNER BRACE 2 BTS-10928 REAR ANGLE 78 3 BTS-70903 18' CALF SHELTER BOLT BAG 1 313-2299 3/8" x 3/4" BIN BOLT 443 313-2300 3/8" x 1-1/8" BIN BOLT 26 313-2304 3/8" x 2-1/2" BOLT 24 309-1769 3/8" FLANGE NUT 519 306-1878 1/4" x 3/4" SELF-TAPPING SCREW 12 313-2310 1/4" x 1-1/4" BIN BOLT 20 309-1704 1/4" FLANGE NUT 20 24 BNS-11104 R0
APPLEGATE - CALF SHELTER 4. APPENDIX 6, 12, 15, 18, & 24 MODELS 4.1. PARTS LIST Table 4.5 24 Calf Shelter Part No. Part Name Qty 202-2534 8' CRATE 1 BTS-10900 SHORT ROOF SECTION 8 BTS-10902 LONG ROOF SECTION 8 BTS-10904 SIDEWALL TYPE 1 LEFT 1 BTS-10906 SIDEWALL TYPE 2 LEFT 1 BTS-10908 SIDEWALL TYPE 3 LEFT 1 BTS-10909 SIDEWALL TYPE 1 RIGHT 1 BTS-10910 SIDEWALL TYPE 2 RIGHT 1 BTS-10911 SIDEWALL TYPE 3 RIGHT 1 BTS-10912 EXTERIOR FLASHING 6 BTS-10913 INTERIOR FLASHING 6 BRS-10914 BEAM SECTION 72 4 BTS-10925 BEAM SPLICE PLATE 3 BRS-10915 BEAM BRACKET 2 BTS-10926 VERTICAL CALF BAR (53") 3 BTS-10916 HORIZONTAL CALF BAR (65-3/4") 4 BTS-50800 BAR BRACKET 11 BTS-10947 TOP BAR BRACKET 3 BRS-10919 POST 2 BTS-10920 POST BRACKET 4 BTS-10921 POST BRACE 2 BTS-10922 SIDE CHANNEL 2 BTS-10923 REAR CORNER BRACE 2 BTS-10924 FRONT CORNER BRACE 2 BTS-10928 REAR ANGLE 78 4 BTS-70904 24' CALF SHELTER BOLT BAG 1 313-2299 3/8" x 3/4" BIN BOLT 555 313-2300 3/8" x 1-1/8" BIN BOLT 26 313-2304 3/8" x 2-1/2" BOLT 34 309-1769 3/8" FLANGE NUT 641 306-1878 1/4" x 3/4" SELF-TAPPING SCREW 12 313-2310 1/4" x 1-1/4" BIN BOLT 20 309-1704 1/4" FLANGE NUT 20 BNS-11104 R0 25
4. APPENDIX APPLEGATE - CALF SHELTER 4.1. PARTS LIST 6, 12, 15, 18, & 24 MODELS 26 BNS-11104 R0
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Applegate Livestock Equipment Inc. Is a Division of Ag Growth International Inc. Group P.O Box 151 902 South St. Rd. 32 Union City, IN 47390 phone: 800-354-9502 fax: 765-964-3529 website: www.applegatelivestockequipment.com Ag Growth Industries Limited Partnership 2009 28