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Farmer Invented, Farmer Tested, and Farmer Proven...

Residue Management Improvement Parts


for 40 and 90 series Corn Heads

problem

solution

Better Than
A Chopping
Corn Head!

problem

kits and components for


JD 40 and 90 series corn heads

solution

www.calmercornheads.com

309.629.9000

MEET MARION CALMER - INVENTOR


Marion Calmer is a Farmer from Western Illinois. He can be seen speaking
at many conferences and in many publications. He is a Farmer helping other
Farmers increase their profit potential.
He started his farming operation of just 40 acres of corn and 10 gilts in 1975.
He has been on the cover of many farm magazines. During his farming
career, he has spent several hours modifying and inventing farm machinery.
This machinery includes;
1995-Worlds first 15 inch corn head. 2007-Worlds first chopping stalk roll.
2012-Worlds first 12 inch corn head. 2013-Worlds first 32 row 15 inch corn head.
These inventions have lead to 10 patents and numerous awards. They are;
-Winner of the Farm Industry News 2014 FinOvation Reader Award

-Top attraction at the 2013 Farm Progress Show.
-Member of the 2014 Farm Bill Advisory Board serving under Congress
Woman Cheri Bustos.
-Voted as one of the 40 No-Till legends.
-No-Till Farmer Residue Management Product of the Year (2009, 2010, 2011).
-Outstanding presentation awards at the National No-Till Conference.

Marion Calmer in his 15 row corn
-Agricultures 25 most influential people award.
-Outstanding Agri-Business Club Alumni Award-Selected Public Image of Agriculture award out of 200,000 Farmers in U.S.

1920 - Woodhull, IL

2013 - Woodhull, IL

Water Reservoir

Water Reservoir

Marion Calmers Grandfather Ansker Calmer and his brother Barney


w/the first corn sheller on a solid rubber tired Model T truck

Marion Calmer and his brother Donavin in front of the first


Calmer 32 row 15 inch corn head

Calmer Corn Heads is known for specializing in the manufacturing of narrow row corn heads, and the award winning Calmer
BT Chopper and upgrade Kit. Marion Calmer believes that with proper machinery, row width, and research, Farmers can
not only increase yields, but simultaneously reduce weed pressure and erosion to see their true profit potential grow.

First Calmer Test Corn Heads 1995

Marion Calmer on the Current Calmer IH vs JD test head

My biggest success thus far has come from testing and production of
the Calmer BT Chopper. Its ability to simultaneously chop and shear
the stalk without loosing grasp and control of the plant is amazing!
Marion Calmer, Calmer Corn Heads - Alpha, IL

www.calmercornheads.com

FARMER INVENTED, FARMER TESTED, AND FARMER PROVEN...

CALMER Residue Management Improvement Parts


Will Help Reduce Your Excessive
3 easy step
Residue, Trash, and Butt Shelling
s
Problems!

STEP 1
INSTALL

CALMER BT CHOPPER STALK ROLLS AND WEED KNIVES


The most important component
in upgrading a corn head is the
quality and performance of the
stalk rolls. Calmer BT Chopper
stalk rolls have a revolving
window in combination with 10
razor sharp knives that will turn
your BT stalks into small chopped,
cut, shredded, and sheared
residue that will decompose
more quickly. This will enable
you to manage your residue
more easily with your tillage, and
planting operations.

The Calmer
Weed Knives
are made
special to run
with the Calmer
BT Chopper
stalk rolls

STEP 2
INSTALL

CALMER 6-TOOTH GATHERING CHAIN DRIVE SPROCKETS


AND 9-TOOTH IDLER SPROCKETS

6 Tooth

STEP 3
INSTALL

Standard
48 Pitch
Gathering
Chain

9 Tooth

By slowing down just the gathering


chain 25% with the patented smaller
6-Tooth Driver, trash intake can be
reduced by as much as 60%. The
larger patented 9-Tooth idler pushes the gathering chain lugs further
into the center line of the row unit,
therefore improving its grabbing
ability when harvesting down corn.

CALMER BEVELED STRIPPER PLATES

Manual Adjust

Hydraulic Adjust

The patented Hard


Surfaced Beveled
Edge Stripper Plates
emulate the butt of the
ear of corn. This contour
helps to reduce
butt shelling and
simultaneously allows
husks and leaves to pass
through the stripper plate
gap onto the ground, not
into the combine.

Call Calmers to order today (309) 629-9000

Symptom --CORN STALKS STILL STANDING AFTER HARVEST

problem

-- NO FEEDING CHAMBER
worn spiral

Steel Flutes
Block Entry

NO Entry Window

First 2inches of
flutes are
worn out

Remaining 14-inches are in


like new condition

6 fluted Knife Rolls after 2000 acres of use

These overlapping flutes spin at 950 RPMs creating a


wall of rotating steel restricting entry of the corn stalk.
By examining a used 6 fluted stalk roll we can see the
first 2-inches of the flutes are worn out. The balance
of the flutes indicate minimal wear (see photos above).
Stripper plate wear also confirms this theory.

No Stalk Engagement

The Evidence

Intermeshing stalk rolls with 6 flutes have continuous


overlap in the entry area. When rotating at normal
speeds, these intermeshing flutes prevent the corn
stalk from engaging easily with the flutes (see all photos).
This hesitation allows stalks, and ears to pass below
the corn head without being processed. This makes
the field look like it was plucked, not picked. (see photo

right)

No Cut!
No Chop!
No Shear!

The Result

No residue to soil contact

We put a corn stalk in front of the knife chamber.


The corn stalk can not engage with flutes and bends
over. This is what happens when we try to pick corn
with out a revolving window. (see photo at right).

Corn
stalks
CANNOT
travel
easily
into knife
chamber

The corn has been plucked off


We have 2 different fields. On one field we used the Calmer update.
We saw great trash reduction w/the slow down kit, and nice even
stands behind the BT Choppers. In the other field we used stock
parts, and we saw less even stands. We also had more trash to deal
with, and even after planting you could still see all the trash.
Lyle Schilpp - Harmon, IL

www.calmercornheads.com

FARMER INVENTED, FARMER TESTED, AND FARMER PROVEN...

solution

patented
open window

-- OPEN WINDOW CREATES A FEEDING CHAMBER


Install Calmer Patented BT Chopper Stalk Rolls

STEP 1

4 Open
Window

10 razor sharp knives


process stalks

During rotation the shortened flutes are timed to create


2- large, 4 inch patented open windows

The Evidence
The windows allow the corn stalks to feed easily
from the spiral area into the 17 1/2 inch knife
chamber. The entire corn stalk is processed.
This makes for longer stalk roll life, reduction of
low ear snap, and less bulldozing of stalks at the
end rows. The bottom line is profit for you! This
guarantees 100% traction the first time a blade
touches the stalk.

The Result
Residue to soil contact is instantly achieved

Corn stalks
CAN travel
easily into this
roll with an
open window

Going down the field, the stalk stays vertical, and


engages with the Calmer BT Chopper. The corn
stalks are received in the feeding chamber, and
engage with the 10 razor sharp blades. This is the
benefit of the feeding chamber.

Calmer BT Chopper exploded stalk stubs are


easier on tires and decompose more quickly

I did a round for the neighbor with my updated corn head, and he saw
first hand why I use the Calmer BT Choppers. My neighbors wife
says she wont have to run the shredder now. He called right away
and ordered.
Mark Hoffman - Whitewater, WI

Call Calmers to order today (309) 629-9000

Symptom --LONG UNPROCESSED STALKS ARE SLOW TO DECOMPOSE

problem

-- NON- AGGRESSIVE FLUTES RESULT IN LONG STALKS


THAT LIMIT RESIDUE TO SOIL CONTACT

Corn stalk did not travel into the knife


chamber
KNIFE-TO-KNIFE
STALK ROLLS

= 92%

Residue Cover
on 06/25/2014

Residue from factory rolls are


hard to plant into

Tall stalks left in the field that will be very


slow to decompose
CALMER BT
CHOPPER
STALK ROLLS

= 78%

Residue Cover
on 06/25/2014

Calmer BT Chopper residue is


easier to plant into
We Harvest green stalks, and the chopper rolls work great on them.
No more shredder is needed. My son said it was some of the best
money we spent.
Paul Isringhausen - Jerseyville, IL

www.calmercornheads.com

FARMER INVENTED, FARMER TESTED, AND FARMER PROVEN...

solution

-- 10 OVERLAPPING RAZOR SHARP FLUTES CHOP AND


SHEAR ALLOWING RESIDUE TO SOIL CONTACT

STEP 1

Install Calmer Patented BT Chopper Stalk Rolls


The spirals and
open windows have
been removed

{
{

Zone-A
Zone-B

(Zone-A)

The knives maintain


grasp and control of
the stalk

(Zone-B)
The overlapping
knives chop and
shear

Chopped and sheared stalks


expose the pith of the corn stalk
for the earthworms

The top pair of knives maintain grasp and control.


This prevents the upper portion of the stalk from
floating in the row unit, and eventually ending up in
the combine. The other center pair of knives cut,
chop, shred, and shear.

Less blowing of leaves and husks

The corn stalk stubble acts like a snow fence and


prevents blowing of the leaves and husks on dry
windy days. This is great for corn on corn.

Calmer BT Chopper
Chop and Shear Area

Pith exposed for rapid decomposition

I have been using the complete Calmer Kit for years with no trash in the
combine. I use the BT Choppers to combine corn for a variety of tillage
practices, and the Farm Managers are very pleased with how the residue
looks. Last year was a dry Winter, and the residue still decomposed nicely.
I have found that the BT Choppers do a fine job of sizing up stalks to be
baled for bedding or feed.
Mike Shaw - Ogden, IA

Call Calmers to order today (309) 629-9000

Symptom --LARGE PILE OF FLUFF ON DRY AFTERNOON

problem

-- EXCESSIVE GATHERING CHAIN SPEED

Kill Stop Examination


The genetic enhancements of
todays corn hybrids are taller
and dryer at harvest time. Prior
to 2008 corn heads utilized
gear boxes with speed ratios
from the 1960s that used fast
gathering chain speeds. Using
these fast gathering chain, and
slow stalk roll speeds to harvest tall dry corn plants cause
the gathering chain lug to break
or shear off the top half of the
plant before the stalk rolls have
a chance to pull it below the
stripper plates. The gathering
chain lug then takes the broken
portion of the plant, and pushes
it into the cross auger. When
the cross auger conveys these
broken portions of the corn
plant to the center of the corn
head, they collide and create a
LARGE PILE OF FLUFF.

Top Half of Plant

(see photo at right)

The Evidence

Photo provided by Eric Hayenga


Taken in Groton, SD - November 2000

The first indication that the gathering chain was running too fast was confirmed during kill stops. Examinations of
the large pile of fluff indicated it was composed mostly of the top portion of the corn plant broken or sheared off by
the gathering chain lug. (see photo above)
The second indication that the gathering chain was running too fast was corn stalks hair pinning at the top of the
stripping tunnel on a wet or damp day. This happens because the gathering chain lug forces the top portion of the
corn plant over the row unit frame.

Ive been using Calmers Trash Reduction system since 2004. It


definitely reduces trash. No reason for gathering chains to go zingn
around at high speeds.
Allen Berry, farmer/crop consultant--Nauvoo, Illinois

www.calmercornheads.com

FARMER INVENTED, FARMER TESTED, AND FARMER PROVEN...

ssoolluuttiioonn

-- SLOW DOWN GATHERING CHAIN SPEED 25%

STEP 2

Install Calmers Patented 6-Tooth


Gathering Chain Drive Sprocket
to slow down JUST the gathering
chain. This sprocket is 25 percent
smaller than the factory 8-tooth sprocket. The smaller sprocket allows the stalk rolls to
make additional revolutions so that more of the plant disappears below the stripper plate
before the gathering chain lug can break it off. We suggest that you have the oil bath in
overdrive, (the big sprocket on the back (driver), and the little sprocket on front (driven)).
We also suggest that the Factory 8 tooth idler sprocket on the chain tightener be
replaced with the Calmers Patented 9-Tooth Idler Sprocket for 3 reasons;
1- It takes up excessive slack created by the 6-tooth driver, so a standard 48 roller
chain can be used.
2-The bigger diameter reduces wear on the idler block
3-The bigger diameter increases the chain lug grabbing ability in down corn.

6
Tooth
Driver

9-Tooth
Idler

Standard
48 Pitch
Gathering
Chain

The Evidence
Factory 8-Tooth
Sprocket used
on this half of
the corn head
has more trash

Calmer 6-Tooth
Sprocket used on
this half of the corn
head is cleaner

Yellow ears, and no top half of plants

The Test Results

We converted half of our test corn head to the Calmer 6-Tooth Drive Sprockets leaving the other half with the factory
8-tooth sprockets. We did multiple kill stops at
TOTAL
Ozs. of
Time Ozs. of Trash Ozs. of Trash
normal ground speeds and bagged loose trash on
w/8-tooth
w/6-Tooth
Trash Reduced Trash Reduced
both halves, weighed it, and compared the
1:45
6
13
7
54%
difference. Reduction of trash intake was visibly
noticeable from the windshield of the combine
2:00
4
18
14
78%
and also confirmed by weight comparison test
data.
5:00
15
32
17
53%
In multiple kill stops on a dry afternoon, the Calmer
6-tooth sprockets reduced trash intake and stalk
5:30
15
37
22
60%
breakage by as much as 78-percent in 15% moisture
corn. Harvesting speeds increased from 3 to 6 mph.

TOTAL

40

100

60

60% average

Ive been running Calmers Trash Reduction Kits since 2004, and have
never had to stop for trash. Never having to stop once in all that time,
I feel, has increased my productivity 25%-30% due to the combine not
having to sort through all that trash. Its incredible running 6 mph while
picking 200 bu corn!
Mendell Elson -- Miami, MO

Call Calmers to order today (309) 629-9000

Symptom --HIGH LEAF INTAKE, BUTT SHELLING, AND UNHUSKED EARS

problem

-- STRAIGHT STRIPPER PLATES


The original straight stripper plates are not formed to match the natural shape
of the bottom side of the corn leaf. During ear separation, the plant leaves
engage with these straight stripper plates causing them to be unnecessarily
torn from the stalk.
Straight stripper plates do not emulate the rounded butt of the ear, and do not
allow the ear shank to get close enough to the stalk rolls to pinch the shank.
This allows the husk to stay attached to the ear, sending the husk into the
combine, creating more material for the combine to handle.

The Evidence
The corn stalk leaves and ear husks are mixed in with yellow
ears during kill stop examinations. (see photo below)

Too much yellow (leaves, husks, and stalk) out of the straw
chopper is evidence that the corn head is picking dirty

Factory straight stripper plates butt shell

Over the past 6 years Ive been upgrading to the newest Calmer
Trash Reduction Kit parts, and each year it just keeps getting
better. The Calmer BT Chopper really make the stalks
disappear, making planting easier.

Jeff Newman -- Woodhull, IL

www.calmercornheads.com

FARMER INVENTED, FARMER TESTED, AND FARMER PROVEN...

solution

--BEVELED STRIPPER PLATES

STEP 3

Install Calmers Patented Beveled Stripper Plates. These beveled


stripper plates are straight in the front retrieving area to reduce ear
wedging, and beveled in the stripping area to allow the stalk rolls to
engage more ear shanks, husks, and leaves. These beveled stripper
plates have a weld hardened surface for extended life. (see photos
right and below)
Opening Stripper Plates can reduce trash intake, but can also increase header loss. Normal settings are 1 1/8-inch at the bottom and
1 3/16-inch at the top.

The Test Results

To test this theory, we converted half of our corn head to


the beveled stripper plate design. The other half remained with factory straight stripper plates. The stripper
gaps were set the same on both sides of the corn head
at testing. We did multiple kill stops at normal ground
speeds on dry afternoons and bagged any loose trash
on both sides, weighed it, and compared the difference.

Time

Calmers Beveled Stripper Plates emulate the


rounded butt of the ear. This does a better job of
displacing the energy which reduces butt shelling

Ounces of Trash Ounces of Trash with Ounces of Trash


with
Beveled Stripper
Reduced
Straight Stripper
Plates

Percentage of Trash
Reduced

1:15

53

32

21

40%

2:00

40

35

13%

2:10

40

40

0%

2:30

62

36

26

42%

3:00

71

43

28

40%

3:30

50

35

15

30%

4:30

59

38

21

36%

33% average

Calmers beveled stripper plates push more


kernels toward the cob, reducing butt shelling

The reduction in trash intake was visibly noticeable from


the combine windshield, and also confirmed by weight
comparison test data.

In multiple kill stops, on dry afternoons, trash intake was


reduced by 33-percent.

Harvesting speeds increased significantly.

There was no noticeable change in header loss.

Optimum stripper gap was 1 1/8-inch at the bottom and 1


3/16-inch at the top in 200bu corn.

We plant wheat into corn stalks and we only disc 1 time. We


cant believe how the chopper grinds up the stalks. The ride
is a lot faster now.
Larry Hocking and Family - Mount Carmel, IL

Call Calmers to order today (309) 629-9000

10

RETURN ON INVESTMENT-

--IN REVIEW--

By installing the CALMER RESIDUE MANAGEMENT


IMPROVEMENT KIT today, you can increase your
harvest speed by 2 mph, and enjoy a projected savings
on 1000 acres of corn;

Farmers who have been using the Calmer kit


and components claim to experience a yield
increase the following year.
Example of our thinking;

Corn Following Corn


+11 to +19 bu/AC x $5 = $55-$95/AC
1000ac corn following corn = 1000 x $55 = $55,000
Labor and parts to improve an 893
= <$15,000>

CORN HEAD
STEP 1
INSTALL

- CALMER BT CHOPPERS and Weed Knives


CALMER Patented Revolving Open
Window BT Chopping Knife Rolls.
Cutting edge technology with 2 open
windows enabling the entire stalk roll to
be utilized. Stalk rolls that chop, cut,
shred, and shear into confetti like
pieces.

First Year Profit = $40,000

$40,000 = 267% ROI

Soybean Following Corn


+2 to +3 bu/AC x 10 = $20-$30/AC
1000ac corn following corn = 1000 x $20 = $20,000
Labor and parts to improve an 893

= <$15,000>

First Year Profit = $5,000

$5,000 = 33% ROI


Contact us for a free estimate on
upgrading your corn head today!

The bottom line is profit for the Farmer.

patented

open
window

Calmer weed knives are made special to


fit the outside dimension of The BT Chopper

We are able to pick 2000-2500 bu/hour once we switched over


to the Calmer Kit.
Kenneth Miller -- Kennedyville, MD

11

www.calmercornheads.com

FARMER INVENTED, FARMER TESTED, AND FARMER PROVEN...

RESIDUE MANAGEMENT IMPROVEMENT PARTS


STEP 3
STEP 2
INSTALL

INSTALL

- CALMER Sprockets & Chains -

- CALMER Stripper Plates -

CALMERs Patented 6-Tooth Gathering


Chain Drive Sprockets along with the
9-Tooth Idler Sprockets use the 48 pitch

CALMERs Patented Multi-Zone Beveled


Stripper Plates.

gathering chains. This slow down kit


allows the stalk rolls to make additional revolutions, making more of the plant disappear
below the stripper plate before the gathering
chain lug can break it off.

6-Tooth sprockets
fit both 40 and 90
series JD heads

These beveled stripper plates are straight in


the front to reduce ear wedging, and to scoop
up low hanging ears in down corn. The beveled
portion is kinder to the ear to help reduce butt
shelling. The bevel also allows the stalk rolls
to engage more ear shanks, putting husks and
leaves on the ground, therefore reducing trash
through the combine.

Hard Surfaced and Beveled


Manual Adjust

Hydraulic Adjust

Standard
48 Pitch
Gathering
Chain

9-Tooth Idler
Sprocket

Calmers 6-Tooth Gathering


Chain Drive Sprockets are
heat treated for longer life,
and have a deeper skirting
to keep weeds and debris
from wrapping.

Multi-Zone Beveled Stripper


Plates help reduce butt shelling.
Available as Hydraulic or Manual
Trash Reduction Kits.

With Calmers Trash Reduction Kits, Harvesting in frozen fields were


no problem. The stalk splinter and shatter in both directions. There
were no problems with dozing at the end of the field, and the down corn
was easy to pick. No popping ears! We should have upgraded our 893
sooner.
Jan Vosburg -- Climax, Michigan

Call Calmers to order today (309) 629-9000

12

Down Corn - Marion Calmers Top 19 Ideas for Harvesting Down Corn
1.

Install auto header height on your corn head. We prefer Headsight sensor system over the Deere or Case
sensor systems. Headsight is more sensitive and it is spring loaded so you can back up with out tearing it off. (Headsight: (574)-546-5022)

2.

Flatten the corn head angle. We prefer to make gravity less of an enemy. When the corn is lodged in a direction other than with the row install (wedge kits) or pull the top beam of the corn head toward the combine. Park the
combine on a level surface and lower the header until the lowest point of the row unit is 2 above the ground. Place a
protractor on the stripper plate and read the angle. I like 20 degrees for down corn and 25 degrees for standing corn.

3.

Steepen the corn head angle. If the corn is lodged with the row a steeper angle allows the gathering chain
lugs to get closer to the ground for retrieving stalks laying parallel to the row units.
4. Install Calmer gathering chain slow down kit. The 6-Tooth Driver and 9-Tooth Idler to give more overlap and
better pulling ability.
5.

Synchronize gathering chain speed to ground speed. We prefer to have the gathering chain lugs moving

toward the header at the same speed as the corn stalks do. (Mark a lug with orange or yellow paint to count the RPMs)
40 RPMs of the gathering chain= 3 mph in ground speed

27 RPMs of the gathering chain= 2 mph in ground speed


We install 6 tooth gathering chain drive sprockets on John Deere Corn Heads and 7 tooth gathering chain drive sprockets on
2200 CASE and NH heads in both standing and down corn. This slows down just the gathering chains, but keeps the stalk rolls
running at full speed. There are already enough broken stalks in the field, so I dont want the gathering chains making any more
of them. If the down corn is root lodged I dont want the gathering chain lug pulling the root balls out of the ground and into the

6. Raise the cross auger. We prefer to set the clearance between the tray and auger flighting at 1 inch for standing corn and 2 inches for down corn. This allows the dislodged material floating above the poly deck covers to be
sucked under the auger and transported to the feeder house.
7.

Open stripper plates. This reduces the energy required to move dislodged material through the row unit.

8.

Use more taper from bottom to top on strippers. Example: 1 3/8 inch bottom and 1 inch top (near the gear

9.

Center the stripping tunnel above the stalk roll tunnel. Hydraulic plates can shift the stripping tunnel to one

200 bu corn standing 1 1/8 inch

200 bu corn lodged 1 inch.

box.)

side causing restriction and breakage of the stalks.

10. Synchronize gathering chain lugs to be opposed from one another. This increases aggressiveness of gathering. Not recommended in rocky conditions.

11. Add plastic paddles on every other gathering chain lug. This increases the conveying capacity of a chain.
12. Install a corn reel. This provides more energy for transporting dislodged material from divider snouts to cross
auger.

13. Take off any end risers or tall corn extensions. This reduces the angle of incline which improves flow.
14. Remove rubber ear savers. This reduces the energy required to flow material to the row unit.
15. Add weight to poly divider snouts to help them stay under the canopy. Some brands of poly divider snouts want
to Hop up and out of the canopy.

16. Grind the wear shoe tips of the dividers or shim to give more pitch to help them stay under the canopy.
Be careful not to make them too aggressive so they self engage and fold underneath the head.

17. Use stalk rolls with revolving windows. This allows easy feeding of stalks from spirals to flutes.
18. Start harvesting on the down wind side of the field. If the corn rows run North and South, and the corn is
blown down to the East, start on the East side and work your way to the West. This will significantly reduce end
divider plugging and bunching.
19. Turn the gathering chains around. This will increase aggressiveness.

I picked 1600 acres of down corn that you could not even see the rows
in. I installed the Calmer rolls on my custom built corn head, no auto
steer, just head control. My agronomy guys were so impressed on how
my field looked, how little corn was on the ground, and how the stalks
were chewed up.
Mike Reed -- Iowa Falls, IA

13

www.calmercornheads.com

FARMER INVENTED, FARMER TESTED, AND FARMER PROVEN...

solution

-- CALMER BT CHOPPER INSTALLED ON YOUR CORN HEAD


IS BETTER THAN A CHOPPING CORN HEAD

The factory chopper blades removed on the right 1/2, and Calmer BT Chopper installed for test purposes

-Easy to Upgrade Your Own Corn Head


-Less Cost
-Less Maintenance
-Less Moving Parts
-Less Weight
-Small Confetti Like Residue
-Decomposes More Quickly
-Exploded Stalk Stubble Helps Keep Residue From Blowing
-Easier To Work Into Soil
-Easier On Tires
-Easier To Plant Into

Residue from a chopping head windrows

Calmer BT Chopper residue is spread evenly

The information you have just read is my train of thought on the benefits of the Residue Management
Improvement Parts and how the Calmer BT Chopper is the most advanced chopping system in the
industry. These parts are Farmer Invented, Farmer Tested, and Farmer Proven to get you the results
you really need, while making you money in the process.
Aerial seeded cover crop wheat program in their area. The wheat was
flown on a week ago, and the residue from the Calmer BT Chopper is
covering the seeded area perfectly as I pick corn. No need for a vertical
tillage tool because it is covering it, so I am done. There are only cobs
and no fodder in the combine. The grainery noticed the clean grain with
no trash.
Tim Bishop -- Chesapeake Bay, MD

Call Calmers to order today (309) 629-9000

14

Profitable corn head adjustments and modifications


We suggest staying on the (fast) sprocket for feeder chain speed when harvesting
1. Must have heavy duty reverser (8 row or above you know because it has a finned aluminum cooler
(recommended by John Deere)).
2. Only use full synthetic oil in the reverser
3. There are 2 grease fittings on the reverser. These need to be placed at the 12 oclock and 2
oclock positions. Put 12 pumps of grease in the 12 oclock and only 2 pumps of grease in the 2
oclock. Never over grease !!!
4. Once you start up the machine (at idle) you need to run variable speed up and down (2x) to lubricate
prior to Harvest.
OIL BATH SETTINGS- The 40/90 corn head should have the
oil bath in overdrive, the (big sprocket on the back (driver), and
the little sprocket on the front (driven))

Please refer to the following;

40/90 CORN HEAD GEAR RATIOS;


69389312931290-

30 Driver; 25 Driven
30 Driver; 25 Driven
22 Driver; 18 Driven
22 Driver; 18 Driven

Check lube level in gear boxes. Use JD corn head grease to re-fill. The grease level should be above
the spur gear seen through the top inspection plug (1 to 1 1/2 inch below inspection hole). Use a flashlight.
The boxes should not be full of grease. There has to be air for expansion and contraction of lube.

Marion Calmer recommends that you;

Calibrate Corn Head Speed to Achieve Proper Gathering Chain Speed


1- To calibrate RPMs, all Calmer orders come with an orange colored paddle
to bolt on a center gathering chain lug.
2- Raise the corn head, put combine in park, engage threshing motor to full
speed. Count revolutions for 1 minute.
3- Use the Chart below to convert gathering chain RPMs to equivalent ground speed;

bolt on center
gathering chain lug

27 RPMs
40 RPMs
54 RPMs
67 RPMs

=
=
=
=

2 MPH
3 MPH
4 MPH
5 MPH

I ended up with a split field...My combine broke down so my neighbor


finished up combining for me... I could definately see the difference.
Vaughn Jensen -- Emmett, ID

15

www.calmercornheads.com

FARMER INVENTED, FARMER TESTED, AND FARMER PROVEN...


To Reduce Ear Toss - Move cross auger back as close as possible to feeder chain drum. Run feeder
chain on fast speed for both corn and beans. Add half and full links to feeder chain. This reduces the dead air
space between feeder chain, and cross auger flighting. This reduces the height of the pile of ears between the
cross auger and the feeder house, therefore reducing back feeding and ear toss.
Opening stripper plates can reduce trash intake, but can also increase header loss. Beginning settings
are 1 1/8-inch at the bottom and 1 3/16-inch at the top, then adjust accordingly.

Gathering Chain Tightener

Used Gathering Chain Tighteners occasionally lock up. This


is caused when the spring vibrates and augers itself into the hole
between the bolt and the flat strap. This can be fixed by adding
a second washer at the bottom of the pipe spacer identical to the
washer that is currently at the top of the pipe spacer. Apply Anti
Seize Lubricant to the bolt threads for future adjustment.
Corn head angle is very important! The
angle needs to be between 23 and 25-degrees for
optimum performance in both standing and lodged
corn. Put 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 on the stripper plate and read the angle. If the angle is too steep,
pull the top of the corn head toward the combine
or push the bottom out, or a combination of both.

Use A Protractor To Achieve The Correct Corn Head Angle

Use reverse flighting. Some older 12-row, 30-inch


corn heads used rubber flaps and no flighting. The
performance of the older auger is poor. Other John
Deere split cross augers had no reverse flighting near
the bearing hanger. The short section of reverse
flighting can be purchase from John Deere (RH part
#H206301, LH part #H206302) and welded on.

Reverse Flighting

Plastic Gathering
Chain Paddles:
Attached to the
gathering chain lugs
will improve
gathering and
conveying
performance
in
Plastic Gathering Chain Paddles
down corn.

Adjust Auger
to 1 3/4 inch
clearance
between
flighting and tray
to reduce
ear slicing.
flighting and tray

Without all the trash, my combine has a larger grain capacity. Im


very happy with the Calmer Trash Reduction Kits on my 893. The
stalks on the ground were no problem at planting time!

Jeff Reiter -- Cascade, Iowa

Call Calmers to order today (309) 629-9000

16

Calmers Trade Show, Conference, and Seminar Schedule


Visit us at a Trade Show, Conference, or Seminar
FARMFEST

------------Redwood Cnty, Minnestota

AUGUST

5-7, 2014

DAKOTAFEST SHOW
Mitchell, South Dakota

------------

AUGUST 19-21, 2014

FARM PROGRESS SHOW



Boone, Iowa

--------------

AUGUST 26-28, 2014

HUSKER HARVEST SHOW


-------------
Grand Island, Nebraska

SEPTEMBER 9-11, 2014


BIG IRON FARM SHOW



-------------
West Fargo, North Dakota

SEPTEMBER 9-11, 2014

FARM SCIENCE REVIEW


London, Ohio
PEORIA FARM SHOW
Peoria, Illinois

QUAD CITIES FARM SHOW



Rock Island, Illinois

-----

JANUARY 14-17, 2015


----
---------

JANUARY 18-20, 2015

SIOUX FALLS FARM SHOW ---------------


Sioux Falls, South Dakota

JANUARY 28-30, 2015

-------------

---------------

FEBRUARY 3-5, 2015

NATIONAL FARM MACHINERY SHOW ---Louisville, Kentucky


January 27-29, 2015

COMMODITY CLASSIC
Phoenix, Arizona

DECEMBER 9-11, 2014

CUSTOM HARVESTER

-------------Grand Island, Nebraska

IOWA POWER FARM SHOW


Des Moines, Iowa

SEPTEMBER 16-18, 2014

------------- DECEMBER 2-4, 2014

NATIONAL NO-TILL CONFERENCE


Cincinnati, Ohio

--------------

NEBRASKA POWER FARM SHOW


Lincoln, Nebraska

FEBRUARY 11-14, 2015


FEBRUARY
26-28, 2015

CALMER SEMINARS
December 17
January 7
or

February 18
I saw the Calmer BT Choppers at a Farm Show, and decided to
give them a try. Harvest was great, and I actually experienced
better performance and residue results than Calmer had
advertised!

John Fricke -- Grafton, ND

17

www.calmercornheads.com

FARMER INVENTED, FARMER TESTED, AND FARMER PROVEN...

Specializing in New Narrow Row Corn Heads

Patented single chain design to get between narrow


rows. Large paddles on every other lug and an ear
guide for better grabbing ability and conveying.

Patented Calmer BT Chopper Residue Management


Improvement Kit is standard on all newly built
Calmer Corn Heads making them a superior corn head

Calmer 30 row 12 inch Corn Head at Farm Progress 2013 - A Worlds First!

Calmer 32 row 15 inch Corn Head - A Worlds First!


Calmer Corn Heads may, at any time and without prior notice, modify the content and operation of its website or this brochure, remove or modify the specific patents and/or patent list
demonstrated in this brochure or on its web site www.CalmerCornHeads.com. A partial list of United States (US) patents that Calmer Corn Heads either owns or licenses for its products
includes: 5,704,202; D494,605; 7,104,038; 7,373,767; 7,886,510; 8,171,708; 8,220,237; and 8,464,505. Other US and foreign patents are pending on the Companys products and technologies. All product names, whether or not appearing in large print or with the trademark symbol, are trademarks of Calmer Corn Heads, its affiliates, related companies or its licensors
or joint venture partners, unless otherwise noted. All other trademarks, service marks, and logos (hereinafter Marks) used in this brochure are the Marks of their respective owners. The
following is a partial list of registered trademarks: BT Chopper, Calmer BT Chopper and Calmer BT Crusher. Calmer and the Calmer Corn Heads logos are the exclusive trademark of
Calmer Corn Heads. Nothing contained herein shall be construed as conferring any license or right under any patent, trademark or copyright of Calmer Corn Heads, Inc. or any third
party. All images and text are the exclusive property of Calmer Corn Heads, Inc. Copyright 2014.

Call Calmers to order today (309) 629-9000

18

Farmer Invented, Farmer Tested, and Farmer Proven...

P.O. Box 9 | Alpha, IL 61413


(309) 629-9000 | fax (309) 629-9001
www.calmercornheads.com

Print Date July 2014