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