Capstan Synchro User manual

TM
Synchro™
Spray Application
Operator Manual
113100-596 Rev. B | Revised 01/2024 | ©2023 Capstan Ag Systems, Inc.

Thank you for your business!
At CapstanAG, our goal is to redene the way people do their chemical application. Our PWM control systems
have been setting the bar for maximum productivity for more than 20 years. Our focus on performance, support,
and education have dramatically changed the landscape of agricultural chemical application.
CapstanAG specializes in creating proprietary systems for the agricultural industry, primarily focusing on
chemical and fertilizer applications. Our inventive process involves research, engineering, design, and lab and
eld testing.
Service Contact Information
If a problem occurs with your system that cannot be corrected with the information in this manual, please
contact your dealer for service and technical assistance. If further assistance is needed, contact CapstanAG.
System Purchased: _____________________________________
Dealer: _______________________________________________
Contact: ______________________________________________
Phone: _______________________________________________
Address: ______________________________________________
City,State/Province, Zip: __________________________________
Factory Service/Repairs
CapstanAG
4225 S.W. Kirklawn Ave. | Topeka, KS 66609
Hours: 8:00 a.m. to 4:00 p.m. CST
Toll-free number: [phone] | Fax: [phone]
CapstanAG.com | CapstanAG.ca
[email protected]
©2023 Capstan Ag Systems, Inc. All rights reserved. No part of this publication may be reproduced, stored in
a retrieval system, or transmited, in any form or by means electronic, mechanical, photocopying, or otherwise,
without prior written permission of Capstan Ag Systems, Inc.

2024 Capstan Ag Systems, Inc. 113100-596, Rev. B 01/02/24 iii
Contents
Contents
Chapter 1: Safety ................................................................................................................................. 7
Signal Words ................................................................................................................................................8
Safety Signs .................................................................................................................................................8
Pressurized Fluid Lines ................................................................................................................................9
Personal Protective Equipment ....................................................................................................................9
Battery Safety ...............................................................................................................................................9
Chemical Safety ...........................................................................................................................................9
Emergency Safety ........................................................................................................................................9
Chapter 2: Warranty ........................................................................................................................11
Limited Warranty.........................................................................................................................................12
What does the Limited Warranty cover? ..............................................................................................12
What is the period of coverage? ..........................................................................................................13
How do you get service? ......................................................................................................................13
How does state law relate to this Limited Warranty? ...........................................................................13
Chapter 3: Introduction .............................................................................................................. 15
This Manual ................................................................................................................................................16
System Identication ..................................................................................................................................17
Chapter 4: Installation ................................................................................................................. 19
Clean the Existing System ..........................................................................................................................20
Before Installation .......................................................................................................................................20
Nozzle Valve Assembly ..............................................................................................................................20
System Layout ............................................................................................................................................21
Install the Valve Assemblies .......................................................................................................................22
Install the Controller ....................................................................................................................................24
Install the Cab Box .....................................................................................................................................25
Install the GPS Puck ...................................................................................................................................26
Install the Valve Harnesses ........................................................................................................................27
Install the Power Harness ...........................................................................................................................28
Chapter 5: Setup ............................................................................................................................... 29
System Dry Test .........................................................................................................................................30
System Wet Test .........................................................................................................................................31

Contents
iv 01/02/24 113100-596, Rev. B 2024 Capstan Ag Systems, Inc.
Rate Control Speed Range ........................................................................................................................32
GPS Status .................................................................................................................................................32
GPS Module Status Lights ...................................................................................................................32
Cab Box Status Light ...........................................................................................................................33
Capstan Synchro Website ..........................................................................................................................34
Make a Prole on the Internet ....................................................................................................................36
Make a Prole on the Controller Wi-Fi ........................................................................................................37
Transmit a Prole........................................................................................................................................38
Chapter 6: Operation .....................................................................................................................41
Spray with the Synchro System ..................................................................................................................42
Spray in Bypass Mode ................................................................................................................................43
Secondary Flow Prole ...............................................................................................................................43
Chapter 7: Maintenance ..............................................................................................................45
Service the System .....................................................................................................................................46
Jump Start, Weld On, or Charge the Machine .....................................................................................46
Recommended Guidelines for Maintenance/Service .................................................................................46
Maintenance Service Interval .....................................................................................................................46
Baseline Evaluation ....................................................................................................................................47
Inspect the System .....................................................................................................................................47
Clean the System .......................................................................................................................................47
Strainers and Screens ................................................................................................................................47
Clean the Nozzle Valve(s) ..........................................................................................................................48
Plunger Seal Inspection ..............................................................................................................................48
Storage of the System ................................................................................................................................49
Winterize for Storage ...........................................................................................................................49
Chapter 8: Troubleshooting ...................................................................................................51
Troubleshooting Charts ..............................................................................................................................52
Interchange Components ...........................................................................................................................54
Nozzle Valves .............................................................................................................................................55
System Dry and Wet Tests .........................................................................................................................55
Coil Assembly Test .....................................................................................................................................55
System Load Capacity Test ........................................................................................................................56
Battery Voltage Test ....................................................................................................................................56

2024 Capstan Ag Systems, Inc. 113100-596, Rev. B 01/02/24 v
Contents
Chapter 9: Schematics ............................................................................................................... 59
System Layout ............................................................................................................................................60
Control Module Pinout ................................................................................................................................61
Index .............................................................................................................................................................. 65

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Contents

2024 Capstan Ag Systems, Inc. 113100-596, Rev. B 01/02/24 7
Chapter 1: Safety
Safety
Topics:
• Signal Words
• Safety Signs
• Presurized Fluid Lines
• Personal Protective Equipment
• Battery Safety
• Chemical Safety
• Emergency Safety

Safety
8 01/02/24 113100-596, Rev. B 2024 Capstan Ag Systems, Inc.
Signal Words
DANGER: Indicates an imminent hazard which, if not avoided, will result in death or serious injury.
This signal word is limited to the most extreme situations, typically for aircraft components that, for
functional purposes, cannot be guarded.
WARNING: Indicates a potential hazard which, if not avoided, could result in death or serious injury,
and includes hazards that are exposed when guards are removed. It may also be used to alert
against unsafe practices.
CAUTION: Indicates a potential hazard which, if not avoided, may result in minor or moderate injury.
It may also be used to alert against unsafe practices.
IMPORTANT: This is used to draw attention to specic information that is necessary for the operation, setup,
or service of the system.
Note: This is used for additional information that can help understand or operate the system.
Safety Signs
Figure 1: Safety Sign Example
The HCS aligned its provisions with the United Nations’ Globally Harmonized System (GHS) Classication
and Labeling of Chemicals in 2012. This is a GHS safety label example for a chemical hazard.
These labels and safety messages warn all personnel about hazardous chemicals or potentially unsafe
chemical conditions that may exist while working around agricultural application equipment.
CapstanAG add-on application systems for OEM and retrot agricultural application equipment
(booms and toolbars) may contain HCS pictographs and GHS safety labels and safety signal word messages.
Figure 1

Safety
2024 Capstan Ag Systems, Inc. 113100-596, Rev. B 01/02/24 9
Pressurized Fluid Lines
Do not heat by welding, soldering, or using a torch near pressurized uid lines or other ammable materials.
Pressurized lines can accidentally burst when too much heat is present.
Personal Protective Equipment
Wear close-tting clothing and the correct personal protective equipment (PPE) for the job. Refer to the
specic chemical manufacturer documentation or other information for correct PPE.
Battery Safety
Use the procedure in the appropriate agricultural equipment manual for connecting, disconnecting, and jump-
starting the machine’s battery.
Keep sparks and ames away from the battery. Battery gas can explode and cause serious injury. Do not
smoke in the battery charging area.
Remove jewelry, which might make electrical contact and create sparks.
Chemical Safety
Chemicals used in agricultural applications can be harmful to your health and/or the environment if not used
correctly. Always follow all label directions for e󰀨ective, safe, and legal use of agricultural chemicals.
Emergency Safety
Fire extinguishing systems must meet the applicable OSHA requirements, and all users of portable/ xed
re suppression equipment must know the types, limitations, and proper uses of this equipment; including
hazards involved with incipient stage reghting.
Keep emergency numbers for doctors, ambulance service, hospital, and re department near your telephone.
Know the location of re extinguishers and rst aid kits and how to use them.
Examine the re extinguisher and service the re extinguisher regularly.
Follow the recommendations on the instructions plate.
Very small res can be put out (extinguished) with a re extinguisher. Use an appropriate method to
extinguish a re (water for paper res, and chemical extinguishers for electrical or chemical res).

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Safety