CapstanAG Synchro User manual

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Synchro™
Spray Application
Operator Manual
113100-596 Rev. A | Revised 08/2021 | ©2021 Capstan Ag Systems, Inc.

Thank you for your business!
At CapstanAG, our goal is to redefine 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 field 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
[e-mail]
©2021 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.
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Contents
Contents
Chapter 1: Safety...................................................................................5
Signal Words...............................................................................................................................5
Emergency Safety.......................................................................................................................5
Personal Protective Equipment.................................................................................................. 6
Pressurized Fluid Lines.............................................................................................................. 6
Chemical Safety..........................................................................................................................6
Battery Safety..............................................................................................................................6
Chapter 2: Warranty..............................................................................7
Limited Warranty.........................................................................................................................7
Chapter 3: Introduction.........................................................................9
This Manual.................................................................................................................................9
System Identification.................................................................................................................10
Chapter 4: Installation.........................................................................11
Prepare for Installation..............................................................................................................11
Connect the machine with the system to a tractor...................................................................11
System Dry Test.......................................................................................................................12
System Wet Test...................................................................................................................... 13
Chapter 5: Operation...........................................................................15
Website......................................................................................................................................15
Make a profile on the Internet..................................................................................................17
Make a Profile on the Controller Wi-Fi.....................................................................................18
Transmit a Profile......................................................................................................................19
Spray with the CapstanAG System..........................................................................................20
Spray without the CapstanAG System (Manual Mode)............................................................21
Chapter 6: Maintenance......................................................................23
Service the System...................................................................................................................23
Jump Start, Weld On, or Charge the Machine..............................................................23
Recommended Guidelines for Maintenance/Service................................................................23
Maintenance Service Interval................................................................................................... 23
Baseline Evaluation Process.................................................................................................... 24
Inspect the System...................................................................................................................24
Clean the System..................................................................................................................... 24
Strainers and Screens..............................................................................................................24
Clean the Nozzle Valve(s)........................................................................................................25
Plunger Seal Inspection............................................................................................................25
Storage of the System..............................................................................................................26
©2021 Capstan Ag Systems, Inc. iii Synchro™

Winterize for Storage.....................................................................................................26
Chapter 7: Troubleshooting............................................................... 27
Troubleshooting Charts.............................................................................................................27
Interchange the Components................................................................................................... 29
Nozzle Valves........................................................................................................................... 30
Clean the Nozzle Valve(s).............................................................................................30
Plunger Seal Inspection.................................................................................................31
System Dry Test.......................................................................................................................32
System Wet Test...................................................................................................................... 33
Coil Assembly Test...................................................................................................................34
Do a Check of the System Load Capacity...............................................................................34
Battery Voltage Test.................................................................................................................35
Chapter 8: Schematics........................................................................37
System Layout.......................................................................................................................... 37
Parts List........................................................................................................................ 38
Control Module Pinout..............................................................................................................40
Cab Box Harness Pinout..........................................................................................................42
Power Harness Pinout..............................................................................................................43
Battery Harness Pinout.............................................................................................................44
Valve Harness...........................................................................................................................45
Valve Harness—16 Valves Pinout.................................................................................45
Valve Harness—9 Valves Pinout...................................................................................48
Nozzle Valve Assembly............................................................................................................50
Index.........................................................................................................................51

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Safety
Chapter 1: Safety
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 specific 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.
Emergency Safety
Fire extinguishing systems must meet the applicable OSHA requirements, and all users of portable/
fixed fire suppression equipment must know the types, limitations, and proper uses of this equipment;
including hazards involved with incipient stage firefighting.
Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your
telephone.
Know the location of fire extinguishers and first aid kits and how to use them.
Examine the fire extinguisher and service the fire extinguisher regularly.
Follow the recommendations on the instructions plate.
Very small fires can be put out (extinguished) with a fire extinguisher. Use an appropriate method to
extinguish a fire (water for paper fires, and chemical extinguishers for electrical or chemical fires).
©2021 Capstan Ag Systems, Inc. 5Synchro™

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Safety
Personal Protective Equipment
Wear close-fitting clothing and the correct personal protective equipment (PPE) for the job. See the
specific chemical manufacturer documentation or other information for correct PPE.
Pressurized Fluid Lines
Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable
materials. Pressurized lines can accidentally burst when too much heat is present.
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 effective, safe, and legal use of agricultural
chemicals.
Battery Safety
Use the procedure in the appropriate agricultural equipment manual for connecting, disconnecting,
and jump-starting the machine’s battery.
Keep sparks and flames 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.
©2021 Capstan Ag Systems, Inc. 6Synchro™

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Warranty
Chapter 2: Warranty
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 affiliates.
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 profits 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.
©2021 Capstan Ag Systems, Inc. 7Synchro™

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Warranty
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 sufficient detail to permit its easy identification 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 effect. 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. Then 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
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 specific legal rights, and you may also have other rights which vary from
state to state.1
1Rev. Date 7/15/2014
©2021 Capstan Ag Systems, Inc. 8Synchro™

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Introduction
Chapter 3: Introduction
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 co-
workers’ 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.
©2021 Capstan Ag Systems, Inc. 9Synchro™

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Introduction
System Identification
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 identification numbers in a secure place off 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 1:
The Synchro™system serial number (1) is located on the controller (2).
The serial number is used as the name of the controller Wi-Fi network.
©2021 Capstan Ag Systems, Inc. 10 Synchro™