Calmer BT Chopper Upgrade Kit User manual

Farmer Invented. Farmer Tested. Farmer Proven.®
RESIDUE MANAGEMENT UPGRADE KIT
INSTALLATION MANUAL
CASE-IH* 3000 & NEW HOLLAND* 98D SERIES
CORN HEADS
www.CalmerCornHeads.com
Weekdays 8-5 p.m. - Office [phone]
After Hours/Weekends - Marion’s Cell [phone]
*Trademarks are not owned by, affiliated with, or under license to Calmer Corn Heads, Inc.
and used solely for the utility of Calmer Corn Head products mentioned herein.

Introduction 2
Warranty 2
Safety Section 2
Before Operation 3
Components List 4
Step 1 – Disassembly of Current Components 5
Step 2 – Replacing Stalk Roll Drive Coupler 6
Step 3 – Modifying Stalk Rolls 7
Step 4 – Installing Calmer BT Chopper®Stalk Rolls 8
Step 5 – Installing/Adjusting Calmer Stripper Plates 11
Step 6 – Installing 7-Tooth Drive and 9-Tooth Idler 12
Sprockets and Gathering Chains
Helpful Corn Head Settings and Adjustments 15
Installing Calmer’s Down Corn Plastic Gathering 17
Chain Paddles
Maintenance Record 18
TABLE OF CONTENTS
1 www.CalmerCornHeads.com

INTRODUCTION
Thank you for purchasing Calmer’s BT Chopper®Upgrade Kit for your corn head. We hope you will
get many years of productive use from it. The purpose of this upgrade kit is to improve your corn
head’s performance and accelerate corn residue decomposition. All product users must read and
understand this manual prior to equipment operation. This manual is considered part of your machine
and should remain with the machine at all times. Do not allow anyone to operate or maintain this
equipment who has not fully read and comprehended this manual. Failure to follow the recommended
procedures may result in personal injury or death or equipment damage.
Information in this manual is designed to help owners and operators to obtain the best results and
safe operation from their investment. The life of these products depends largely on the care it is given
and we suggest that the manual should be read and understood and referred to frequently. If for any
reasons you do not understand the instructions and safety requirements, please contact us at any time.
The intent of this manual is to provide guidelines to cover general use and to assist in avoiding ac-
cidents and injuries.
There may be times when circumstances occur that are not covered in the manual. At those times it is
best to use common sense and contact our factory.
The requirements of safety cannot be emphasized enough in this publication. We urge you to make
safety your top priority when using and maintaining this equipment.
WARRANTY
Calmer Corn Heads, Inc. has been in business since 2004 and has an excellent reputation for
quality and workmanship. Please contact us (the manufacturer) if you feel a component has not lasted
to your expectation. These concerns will be handled on a case-by-case basis. Please contact our
factory directly at [phone] for replacement parts.
SAFETY
Read and understand this manual and all safety signs before maintaining and operating. Review the
safety instructions and precautions annually.
TAKE NOTE! THIS SAFETY ALERT SYMBOL FOUND THROUGHOUT THIS
MANUAL IS USED TO CALL YOUR ATTENTION TO INSTRUCTIONS INVOLVING
YOUR PERSONAL SAFETY AND THE SAFETY OF OTHERS. FAILURE TO FOLLOW THESE
INSTRUCTIONS CAN RESULT IN INJURY OR DEATH.
[phone] 2

THIS SYMBOL MEANS: ATTENTION!
BECOME ALERT! YOUR SAFETY IS INVOLVED!
Note the use of the signal words DANGER, WARNING and CAUTION with the safety messages. The
appropriate signal word for each has been selected using the following guidelines:
DANGER: Indicates an imminently hazardous situation that, if not avoided, will result in
death or serious injury. This signal word is to be limited to the most extreme situations
typically for machine components which, for functional purposes, cannot be guarded.
WARNING: Indicates a potentially hazardous situation that, if not avoided, could result
in death or serious injury, and includes hazards that are exposed when guards are removed.
CAUTION: Indicates a potentially hazardous situation that, if not avoided, may result in
minor or moderate injury.
NOTICE is used to address safety practices not related to personal safety.
This equipment is dangerous to children and persons unfamiliar with its operation. The operator
should be a responsible adult familiar with farm machinery and trained in this equipment’s
operations. Do not allow persons to operate or assemble this unit until they have
read this manual and have developed a thorough understanding of the safety
precautions of how it works.
SAFETY SIGNS
Sharp Objects signs are placed on the exterior of all stalk roll boxes. See
the sign, right, for reference and understand the associated cutting dangers
with the enclosed product.
BEFORE OPERATION
• Carefully study and understand this manual.
• Do not wear loose-fitting clothing which may catch on moving parts.
• Always wear protective clothing and substantial shoes.
• Always wear provided cut-resistant gloves when installing stalk rolls
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(2) STALK ROLL
COUPLERS

THE COMPLETE CALMER RESIDUE MANAGEMENT DELUXE
UPGRADE KIT INCLUDES PER ROW:
Your reference for Right and Left is as you are sitting in the combine cab looking at the corn.
Case-IH 3000/New Holland
98d Upgrade Kit
CD
AB
E
F
[phone] 4
(2) LOWER
IDLER SPRING
WASHERS
(20) 3/8” x 1 3/4” -16
SOCKET HEAD
CAP SCREWS
(4) 1/2” x 1 1/2”
ROLL PINS
(1) TRANSITION PLATE
(2) CUT-RESISTANT
GLOVES
(6) STAINLESS
STEEL WASHERS
A
B
C
(2) BT Chopper®Stalk Rolls
(1) Left Stripper Plate
(1) Right Stripper Plate
D
E
F
(2) 9-Tooth Idler Sprockets
(2) 7-Tooth Drive Sprockets
(2) 48-Pitch Chrome-Pin
Gathering Chains
(2) STALK ROLL
COUPLERS

DANGER: Ensure the corn head is secured properly, combine lift cylinder stops
are in place, equipment is turned-o, and the parking brake is engaged before
attempting any adjustments. Be sure to follow all manufacturer’s safety
procedures when setting-up and working on the corn head.
1. Attach the corn head to your combine in accordance with the instructions in the manufacturer’s
owner’s manual. It is critical to lock the lift cylinder in the raised position before
making any further adjustments.
2. Raise and secure or remove the corn head dividers and hoods.
3. Remove chain guides.
4. Remove idler blocks.
5. Remove stripper plates.
6. Remove stripper transition plate (at gear box).
7. Remove all weed knives.
8. Remove stalk roll blades.
CAUTION: Inspect all parts to be reassembled and replace excessively worn
components as necessary.
CAUTION: Inspect all stalk roll shafts, bearings, and/or stub shafts. If bearings
and/or shafts are bad, replace as necessary. Ensure stalk roll shafts are parallel
with each other. If they are not parallel, re-shim nose bearing support according
to manufacturer’s specications. Failure to do so with void warranty!
Disassembly of Current Components
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STEP 1

[phone] 6
STEP 2
Replacing Stalk Roll Drive Coupler
1. Remove bearing support bolts. See below.
2. Slide stalk roll shaft away from gearbox to remove shaft.
3. Remove stalk roll drive coupler.
4. Install new coupler.
5. Install roll pins to attach drive coupler to stalk roll shaft.
6. Perform spiral modification (see page 7).
7. DO NOT install BT Choppers Stalk Rolls at this time.
8. Install stalk roll shaft into row unit. Ensure stalk roll spirals are intermeshing
(not opposed).
9. Install bearing support bolts and tighten making sure stalk roll bearing runs true with
stalk roll drive shaft.

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1. To ensure cornstalks flow easily with Calmer BT Chopper’s®“open-window” design, modify the
spiral by removing (2) short sections of the helicoid on each stalk roll. This step is strongly suggested.
2. Clean stalk roll shafts. All material between the old blades and spiral must be
removed.
BEFORE AFTER
Modifying Stalk Roll Spirals
STEP 3

[phone] 8
STEP 4
Installing Calmer BT Chopper®Stalk Rolls
DANGER: BT Choppers®are extremely sharp! Make sure that you are wearing
the gloves provided with your order and that you handle the stalk rolls with
extreme care!
CAUTION: Stalk rolls may fall o during assembly. Follow the outlined
procedure below and stay out from underneath the unbolted/unsupported stalk
roll shells at all times! DO NOT TRY AND CATCH A FALLING STALK ROLL SHELL!
NOTICE: Corn head angle must be adjusted to 23-25 degrees in standing corn
and 20 degrees in down/lodged corn for maximum performance and to avoid
excessive wear on components! Failure to do so will void warranty!
Notice: The shells are designed to be installed so the seams of both rolls are both horizontal or
both vertical, depending on the rotation of the rolls. Stalk rolls are improperly installed if one is
horizontal and one is vertical.
Rolls are marked on the left (L) and right (R) spirals and must be installed
as a set, from the same box, as packaged from Calmer Corn Heads.
Important: Stalk rolls are to be installed from your perspective while
sitting in the combine cab, looking at the corn head.

1. Remove and discard 4 shipping bolts from each roll. Do not reuse these
bolts!
2. From the top of the corn head, install 1 left half shell on the left stalk roll
shaft and 1 right half shell on the right stalk roll shaft.
Note: If persuasion is necessary, tap the rolls only between the blades and bolts
over the bosses as shown using a suitable punch. See image A.
3. Rotate the half shells horizontal as shown. See image B.
4. Clean oil from 1 1/2” socket head cap screws, then apply lock tight
medium-strength thread locker.
5. From the bottom side of the corn head, install the right shell. See image C.
Ensure both shells are aligned and using a 1 1/2” socket head cap screw in the
middle hole, hand tighten to secure the shell. If bolts do not start easily,
slide the shell front or back to align the holes.
6. Install the left shell following the same steps, then slide/pry the shells tight
against the spiral.
7. Clean oil from remaining 1 1/2” socket head cap screws, then apply lock
tight medium-strength thread locker. Hand tighten all screws.
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A
B
FRONT
REAR
C

[phone] 10
9. Ensure the shells are against the spiral, then torque the bolts to 55 ft. lbs., alternating
from top to bottom of the corn head and middle to ends of the stalk rolls in
order, as shown.
*Tightening order: 1A, 1B, 2A, 2B, 3A, 3B, 4A, 4B, 5A, 5B
Weed knives for 30 corn heads can be set to 1/8” clearance. NOTICE: To achieve 1/8” clearance,
you may need to trim the rear tab of the weed knives, closest to the gear box bolts.
Weed knives for 20 corn heads will need modified to achieve 1/8” clearance.
5B
3B
1B
2A
4A
5B
3B
1B
2A
4A
5A
3A
1A
2B
4B
5A
3A
1A
2B
4B
TOP OF ROW UNIT BOTTOM OF ROW UNIT

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1. Install Calmer transition plate. OEM transition plate can no longer be used!
2. Install Calmer Stripper Plates
Recommended Stripper Plate Adjustments: Begin with normal settings of 1 1/8” gap at the
front and 1 3/16” gap at the rear, then adjust accordingly to ensure plates are 1/16” wider than the
diameter of the 3rd cornstalk node above the brace root. Ensure stripper plate gap is centered over the
stalk rolls.
Hydraulic Plates: Below are instructions for setting your Calmer Hydraulic Stripper Plates:
Position stripper plates so the center gap between the edge of the stripper plates is located over the
center of the stripping tunnel.
For Hydraulic Plates Only: Once the stripper plates are at the desired gap, mark the gauge on the
frame or write down the value given in the cab’s “A” post display for future reference. This is the ideal
spot for the hydraulic stripper plates to match your initial settings.
Note: To minimize the amount of trash and stalk intake, the stripper plates must be open 1/16” wider
than the diameter of the 3rd cornstalk node above the brace root.
Installing/Adjusting Calmer Stripper Plates
STEP 5
CALMER TRANSITION PLATE

[phone] 12
STEP 6
Installing Calmer 7-Tooth Drive and 9-Tooth
Idler Sprockets and Gathering Chains
1. Inspect chain guides & idler blocks for wear.
Important: You must use stainless steel washers with Calmer’s 9-Tooth Idler.
Some modication may be required when installing. (See below)
2. Disassemble the old idler sprocket.
Gathering Chain Tighteners
Gathering chain tighteners occasionally lock up. This is caused when the spring vibrates and au-
gers itself into the hole between the bolt and the flat strap. This can be fixed by removing the idler
bolt and adding a second washer (enclosed) at thebottom of the pipe spacer, which is identical to
the washer at the top of the pipe spacer (See photo below). Apply anti-seize or lubricant to the bolt
threads for future adjustments.
3. Inspect to see if plow bolt shoulder extends above the idler strap.
• If the plow bolt shoulder extends above the idler strap then you must smooth-out the shoulder
with a grinder until flush with the idler strap.
• If the plow bold shoulder is flush or does not extend above the
idler strap, no further modification is required.
Install enclosed washer
here leaving about 2
spring wire widths
LOWER IDLER SPRING
WASHER/CHAIN
TIGHTENER WASHER
GATHERING
CHAIN
TIGHTENER

4. Reassemble the 9-tooth idler sprocket by
inserting the plow bolt through the idler strap.
5. Reinstall factory washer on plow bolt then 6. Install the 9-tooth idler sprocket with the
install 2 stainless-steel washers (provided), teeth beveled on 3 sides facing up.
below the sprocket.
7. Place 1 stainless-steel washer (provided) on 8. Reinstall 5/8” lock washer and nut (some
the plow bolt, on top of the idler sprocket. heads have regular 5/8” washer and a
lock nut) and torque to 100 ft. lbs. (Slight
resistance when turning sprocket by hand
is normal)
9. Oil the gathering chain drive shaft.
10. Place the gathering chain around the idler sprocket.
11. Insert the 7-tooth sprocket in the chain at the drive end.
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Teeth beveled
on 3 sides face up

[phone] 14
12. Lug Timing
For Standing Corn: Time the gathering chain lugs so the lugs are staggered.
For Down Corn: With 9-tooth idlers, time the lugs so they are almost horizontally opposed
from each other. Adding plastic paddles will also help in harvesting down corn. (See page 16)
These oversized down corn plastic gathering chain paddles are available for
purchase from Calmer Corn Heads.
13. Reinstall bolt and washer into top of gathering shaft to secure 7-tooth sprocket.
14. Tighten the gathering chain tightener until there is a 3/16” clearance
and washer. Apply anti-seize or lubricant to threads for future adjustments.
15. Test for proper installation of components. To ensure proper installation of components, using
the feeder house reverser, operate corn head for 10 seconds. Next, operate corn head
normally at idle then gradually increase to full speed.

HELPFUL CORN HEAD SETTINGS & ADJUSTMENTS
Marion’s Recommended Sieve Adjustments for Corn: I personally disagree with the
suggested sieve settings in many owner’s manuals. Below is what I’ve found to be most successful
throughout my years of farming.
Bottom Shoe Sieve: Run Wide Open (Try this one round to gauge effectiveness)
Top Chaer Sieve: Close until sample in the grain tank is clean
Reason: When harvesting corn, the bottom sieve is not needed. There is no part of the kernel that
needs to be re-threshed! Therefore, the bottom sieve should be wide open. This allows the kernels to
fall directly into the clean grain auger.
Results of my Recommended Sieve Settings:
1. More capacity
2. More air to top sieve
3. Less separator loss
4. Less cracks in dry corn
5. Less grinding in wet corn
6. Less plugging of return elevator in wet corn
Corn Head Angle: A properly adjusted corn head angle is critical to its performance. For
optimum performance and to retain Calmer’s warranty on parts, the corn head angle MUST be set
between 23-25 degrees in standing corn and 20 degrees in down/lodged corn.
Setting Your Corn Head Angle: Place the combine on a level surface then lower the corn
head until the row unit frame is 2-inches off the ground. Place a magnetic protractor directly on the
stripper plate and read the angle. If the angle is too steep, pull the top of the corn head toward the
combine, push the bottom out, or a combination of both.
Setting Gathering Chain Speed to Match Ground Speed: Begin calibration with initial
gathering chain speed of 55 RPMs. If butt shelling is a problem, slow down the corn head speed until
it starts to bulldoze cornstalks, then speed back up until bulldozing stops. Note: If RPMs are too fast,
trash intake and butt shelling increase. If RPMs are too slow, you may experience poor stalk chop,
row unit bulldozing and ear loss.
15 www.CalmerCornHeads.com

HELPFUL CORN HEAD SETTINGS & ADJUSTMENTS
[phone] 16
Reducing Ear Toss:
1. For minimal ear toss, the feeder house chain must be running at maximum speed. Adjust the
corn head speed to conditions in the transmission or in the oil bath.
2. Cross auger should be horizontally adjusted rearward, as close to the feeder house chain and
rear stripper/stripping tunnel as possible. This will improve the transfer of material from cross
auger to the feeder house chain, ultimately reducing ear toss. (Note: Adding half and/or full
links to lengthen the feeder house chain will move it closer to the auger.)
Cross Auger Flighting: Cross auger should be vertically adjusted to have 1 3/4” clearance
between the auger flighting and tray at the tightest point. This significantly reduces ear slicing which
is a cause of cracked kernels in the grain tank. When you turn on the end rows, there should be a
layer of ears between flighting and the tray.
Gear Box Lubricant: See manufacturer’s owner’s manual for proper lubricant specifications.
One and three
quarter inch clearing

INSTALLING CALMER’S DOWN CORN
PLASTIC GATHERING CHAIN PADDLES
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Follow the instructions for assembly of plastic gathering chain paddles and attach to every other lug on
each gathering chain. (One orange paddle is used on the row left of the feeder house in front on the
buddy seat for calibrating corn head speeds.)
1. Install and hammer the two provided carriage bolts into each paddle, ensuring the bolt shoulders are
seated in the paddles. Repeat for remaining paddles and bolts, while being careful to not damage
threads.
2. Install paddles on every other lug of the gathering chain, ensuring the bevel is closet to the chain. (See
graphic above for reference) Use a standard 7/16” socket to install and tighten lock nuts.
3. Repeat steps for remaining rows.
Closest
to chain
CLOSEST
TO CHAIN

INSTALLING CALMER’S DOWN CORN
PLASTIC GATHERING CHAIN PADDLES
[phone] 18
MAINTENANCE RECORD
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June 2020
TO OBTAIN WARRANTY SERVICE
PLEASE CALL 1-309-629-9000
P.O. Box 9 | Alpha, IL 61413 | [phone] | fax [phone]
www.CalmerCornHeads.com
The replacement parts comprising and the methods associated with Calmer’s Residue Man-
agement Program are covered by the following patents issued by the United States Patent
and Trademark Office: 7,886,510, 8,171,708, 8,220,237, 8,464,505, 8,857,139, 8,863,487,
9,554,511, 9,560,804, 9,668,414, 10,039,232, 10,045,483
Calmer Corn Heads Residue Management Upgrade Kit Limited Warranty
Calmer warrants our parts 100%. This warranty is good throughout the first season after purchase of the part.
What this means is that if the part breaks within the first season of use, we will replace the part with a new one without
charge to you. Calmer pays for the shipping both ways as well. In the alternative, if you wish, we will refund to you all of
the money you paid to Calmer for the part. If the Calmer part does not work in a manner that you expected, we prom-
ise that we will work with you to adjust settings and to see if we can obtain satisfactory performance. In the end, if the
Calmer part does not work on your farm to your complete satisfaction, we will refund your purchase price. Disclaimers:
Calmer is not responsible for and does not warrant as to consequential damages or any other types of damages that may
be claimed as a result of part breakage or unsatisfactory performance. In other words, except as stated herein all other
warranties or liabilities, expressed or implied, oral or statutory, including any warranty of merchantability or fitness for a
particular purpose are expressly denied.
“The information in this book reects some of the data
I’ve collected throughout my 30+ years of conducting
on-farm research. I hope you found it useful and are
encouraged enough to do your own on-farm research.
After all, we can’t improve what we don’t measure!”
MARION CALMER
CEO – Calmer Corn Heads, Inc.
President – Calmer’s Independent Ag Research Center
Owner/Operator – Calmer Farms