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

2024 Capstan Ag Systems, Inc. 113100-596, Rev. B 01/02/24 11
Topics:
• Limited Warranty
Chapter 2: Warranty
Warranty

Warranty
12 01/02/24 113100-596, Rev. B 2024 Capstan Ag Systems, Inc.
Limited Warranty
What does the Limited Warranty cover?
The ultimate purchaser/user (“you”), by acceptance of seller Capstan Ag Systems, Inc.’s, (“our,” “we,” or “us”)
product, assume all risk and liability of the consequences of any use or misuse by you, your employees, or
others.
All replacement components furnished under this warranty, but shipped before the failed component is
returned for evaluation, will be invoiced in the usual manner and warranty adjustments will be made after the
component claimed to be defective has been returned to and inspected and deemed defective by us at our
factory.
Upon determining that a component has failed under warranty, the repaired component or replacement
component, furnished under this warranty, will be shipped at our expense, to your location. We will credit you
an amount equal to the incoming freight you paid. We shall not be responsible for installation costs. (You shall
be responsible for all customs and brokerage fees for all international transactions.)
If the component does not prove to be defective, you shall be liable for all freight, inspection, and handling
costs. In no event will any claim for labor or incidental or consequential damages be allowed for removing or
replacing a defective product. Warranty will be denied on any component which has been subject to misuse,
abuse, accidents, or alterations, or to improper or negligent use, maintenance, storage, transportation, and
handling.
Our liability under this warranty, or for any loss or damage to the components whether the claim is based on
contract or negligence, shall not, in any case, exceed the purchase price of the components and upon the
expiration of the warranty period all such liability shall terminate. The foregoing shall constitute your exclusive
remedy and our exclusive liability.
The terms of this warranty do not in any way extend to any product which was not manufactured by us or one
of our a󰀩liates.
While necessary maintenance or repairs on your CapstanAG product can be performed by any company, we
recommend that you use only authorized CapstanAG dealers. Improper or incorrectly performed maintenance
or repair voids this warranty.
The foregoing warranty is exclusive and is in lieu of all other warranties expressed or implied. We shall not be
liable for any incidental or consequential damages resulting from any breach of warranty.
Your exclusive remedy for breach of warranty shall be repair or replacement of defective component(s):
Provided, if the component(s) are incapable of being repaired or replaced, your exclusive remedy shall be
credit issued, but such credit shall not exceed the purchase price of the components.
On any claim of any kind, including negligence, our liability for any loss or damage arising out of, or from the
design, manufacture, sale, delivery, resale, installation, technical direction of installation, inspection, repair,
operation of use of any products shall in no case exceed the purchase price allocable to the components.
In no event, whether as a result of breach of contract or warranty or alleged negligence, shall we be liable for
incidental or consequential damages, including, but not limited to: personal injury, loss of prots or revenue,
loss of use of equipment or any associated equipment, cost of capital, cost of substitute equipment, facilities
or services, downtime costs, environmental damage, crop losses, or claims of customers of you for such
damages.

Warranty
2024 Capstan Ag Systems, Inc. 113100-596, Rev. B 01/02/24 13
What is the period of coverage?
We warrant to you that our products are free from defects in material and workmanship in normal use and
service for a period of one year from date of purchase.
How do you get service?
Our obligation under this warranty shall be limited to the repairing or replacing at our option, the component
which our inspection discloses to be defective, free of charge, return freight paid by us, provided you: (i)
Notify us of defect within thirty (30) days of failure; (ii) Return the defective component to us, freight prepaid;
(iii) Complete the Owner Registration Form and returned it to us; and (iv) Establish that the product has been
properly installed, maintained and operated in accordance with our instructions or instructions contained in
our operations or maintenance manuals and within the limits of normal usage.
Any claim for breach of our warranty must be in writing addressed to us and must set forth the alleged defect
in su󰀩cient detail to permit its easy identication by us. All breach of warranty claims must be made within
thirty (30) days after expiration of the warranty period, which is applicable to the defective product. Any
breach of warranty claim not timely made will not be honored by us and will be of no force and e󰀨ect. Any
component that needs to be repaired or evaluated for warranty has to be authorized before return. Contact
the factory (785-232-4477) to get a Return Materials Authorization (RMA #). This helps to track the part
coming into the factory for repair or replacement.
Before returning any component to the factory, clean the component as well as possible to remove any dirt or
chemical residue. Components received at the factory that are not clean will be returned and warranty denied.
After receiving your RMA #, package the part, making sure to include the RMA #, customer’s name, your
address and phone number and description of problems or failure. If the component(s) are not returned to the
shipping address below within the thirty (30) day period, no credit will be issued for the part. Ship to:
Capstan Ag Systems, Inc.
Attn: Warranty/Repair
4225 SW Kirklawn Ave.
Topeka, KS 66609
Phone: [phone] | Fax: [phone]
Hours: 8 am to 4:30 pm CST
Once the package is received by us, we have thirty (30) days to process the warranty claim. If the warranty
claim is still open after thirty (30) days, the warranty will be accepted, and credit issued to.
How does state law relate to this Limited Warranty?
Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not
apply to you.
Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above
limitation or exclusion may not apply to you.
This warranty gives you specic legal rights, and you may also have other rights which vary from state to
state.1
1 Rev. Date 11/02/2021

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Warranty

2024 Capstan Ag Systems, Inc. 113100-596, Rev. B 01/02/24 15
Topics:
• This Manual
• System Identication
Introduction
Chapter 3: Introduction

Introduction
16 01/02/24 113100-596, Rev. B 2024 Capstan Ag Systems, Inc.
This Manual
This manual includes operation, maintenance, and installation information for the system you purchased.
Make sure that all personnel have read this manual and that they thoroughly understand the safe and correct
operation and maintenance procedures. Failure to do so could result in personal injury or equipment damage.
This manual should be considered a permanent part of your system and should remain with the system at all
times and when you sell it.
Right and left sides of the system are determined by facing the direction of forward travel of the machine on
which the system is installed.
The information, screenshots, and other illustrations were correct at the time of publication. Changes can
occur without notice.
This manual contains important information on how to safely and correctly install, operate, and maintain
CapstanAG products. These instructions will help keep personnel safe, reduce downtime, and increase the
reliability and life of the equipment, its components, and related systems.
Review the safety information in the manual(s) from the Original Equipment Manufacturer (OEM).
Follow the instructions (in this manual) and in the OEM manual(s) for each step, to make sure that work
conditions in and around the OEM equipment are safe.
It is important for all individuals working with chemicals to understand the potential risks, necessary safety
precautions, and proper response in the event of accidental contact.
Review the OEM manual(s) for chemical safety information.
Read, understand, and review the procedures in this manual and OEM manual(s). Use the Safety Data
Sheets (SDS) and the required Personal Protective Equipment (PPE) for hazardous chemicals.
Please keep this manual and all enclosed documentation in an accessible location known to all operators,
installation, and maintenance personnel.
If you do not understand the CapstanAG equipment after reading this manual, please obtain the proper
training before working with equipment, to make sure that your own safety, as well as your coworkers’ safety,
is maintained.
Do not attempt to operate any equipment or system until you completely understand why, when, and how it
operates. If you are uncertain after studying this manual, please contact CapstanAG.

Introduction
2024 Capstan Ag Systems, Inc. 113100-596, Rev. B 01/02/24 17
System Identication
Write the system name, serial number, and other information down in the Service Contact Information on
the inside cover of this manual. Your dealer will use these numbers when you order parts. File a copy of the
identication numbers in a secure place o󰀨 the machine.
If you are not the original owner of this machine, it is in your interest to contact your local CapstanAG dealer
to inform them of this unit’s serial number. Providing this information will help CapstanAG notify you of any
issues or product improvements.
Figure 2: Serial Number
The Synchro™ system serial number is located on the controller (Figure 2, Item 1).
The serial number is used as the name of the controller Wi-Fi network.
Figure 2

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Introduction

2024 Capstan Ag Systems, Inc. 113100-596, Rev. B 01/02/24 19
Installation
Chapter 4: Installation
Topics:
• Clean the Existing System
• Before Installation
• Nozzle Valve Assembly
• System Layout
• Install the Valve Assemblies
• Install the Controller
• Install the Cab Box
• Install the GPS Puck
• Install the Valve Harnesses
• Install the Battery Harness
• Install the ID Decal
• System Dry Test
• System Wet Test

Installation
20 01/02/24 113100-596, Rev. B 2024 Capstan Ag Systems, Inc.
Clean the Existing System
Before installation of a new system, you must make sure that the existing system is clean of debris and the
ltering system is functioning correctly. Flush all plumbing and any inline lters and tips.
For the new system to function correctly, the lter must be 80-mesh or ner.
Note: Debris can cause lodging of the nozzle valves, prevent the system from operating correctly, and
damage internal components.
1. Release pressure from the system before servicing.
2. Thoroughly clean the system.
Avoid high-pressure spray when cleaning the spray system components, valves, and wiring connectors.
Before Installation
CAUTION: Before installation, operation, or service to the system, read and understand the
machine’s operator manual and the system operator manual. Chemical residue may be present on/in
the OEM equipment. Use the correct personal protective equipment.
WARNING: Chemical residues may be present in the agricultural equipment. Always use the proper
personal equipment to avoid personal injury.
IMPORTANT: Before installation, make sure that all parts are included in the shipping boxes using the list of
parts included in the order.
IMPORTANT: Do not connect the battery harness terminals to the battery until the installation of the system
is complete.
IMPORTANT: Do not attach the harnesses with cable ties until the test of the system is complete.
Note: For correct operation, the sprayer must be equipped with a properly functioning Pressure/Flow bypass
valve.
This provides the capability to relieve pressure (bypass ow back to tank) as the nozzle valve assemblies
close when the operator toggles boom switches to OFF position at end of a row.
Nozzle Valve Assembly
Figure 3: Nozzle Valve Assembly
Table 1: Nozzle Valve Assembly Components
Item Description Part Number Item Description Part Number
1Coil 625147-011 3 O-ring 715022-204
2 Plunger 716009-111 4Valve Body 621083-001
Figure 3