Thunderstone Thunder 6000XR User manual

Thunder 6000XR Troubleshooting Guide –2/16/17
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Thunder 6000XR Tarp System Troubleshooting Guide
Below you will find troubleshooting steps for common tarp system issues and their solutions.
 Tarp system will not power on.
1. Make sure that the 2-pole power cord is plugged into the trailer and has the proper polarity and voltage
to the tarp system.
2. Check that the tarp system circuit breaker near the tractor battery is reset, if applicable.
3. Turn on the tarp system by pressing the (Open) & (Close) buttons on the keypad for 3-5 seconds until
the LED and buttons illuminate.
4. Test the remote functions of the tarp system by pressing the (Open) & (Close) buttons on the remote 3-
5 seconds to verify keypad button failure.
5. Check for grease, dirt, and corroded connections at the battery terminals, circuit breaker and also at
the trailer power receptacle plug and outlet.
6. Check for voltage on the back side of the 2-pole trailer receptacle. Also check for corrosion and looseness at
this location.
7. Check for proper connection of the communications cable between the inner control box and the RF
keypad.
8. Unplug the power receptacle, wait 10 seconds, re-plug truck power and verify operation.
Replace RF keypad. Test functions before re-installation to verify.
  Replace inner control box. Test functions before re-installation to verify.
Tarp system powers on but does not function when pressing either (Open) or
(Close), no flash codes are present.
1. Check for low voltage & loose connections.
2. Test the remote functions of the tarp system to verify keypad button failure.
3. Check for loose & corroded connections at the motor terminals and inspect the wires from the motor to
the inner control box located in the nose of the trailer.
4. Unplug the power receptacle, wait 10 seconds, re-plug truck power and verify operation.
  Replace RF keypad. Test functions before re-installation to verify.
Replace inner control box. Test functions before re-installation to verify.
 Tarp system does not function and a red/orange flashing light is present on the
RF keypad, indicating an error code. See error code explanations below:
a) Three flashes indicates an Overheat Protection issue. This typically occurs if the system has been started
and stopped rapidly in a short period of time. Also, it can indicate increased drag in the tarp system causing
increased amperage. Re-check the tarp system after a cool down period.
b) Four flashes indicates an Over Voltage Protection issue. Using a voltmeter, check the tractor batteries
& alternator for voltage exceeding 15.5 volts.

Thunder 6000XR Troubleshooting Guide –2/16/17
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c) Five flashes indicates an Under Voltage Protection issue. Using a voltmeter, check the system for low
voltage. Also check all connection points for looseness and corrosion including battery terminals, circuit
breaker, power cord, and receptacle plug. Connect an alternate power source toverify.
d) Six flashes indicates Ground Fault Protection. This can be caused by moisture intrusion to the inner
control box, motor, and also wiring faults. To determine which failure has occurred please follow the
below steps:
(1) Remove the motor lead wires from the motor. Touch the ends together completing the circuit and
observe if the flashing stops or continues.
If flashing stops, there is internal motor wire damage. Replace the
defective tarp motor. Test functions before completing installation to verify.
(2) If 6 flashes continue after the wires are touched together, inspect the wiring from the inner
control box to the motor for any frays, pinched areas, or insulation being worn through. Fix or
replace any areas that show insulation wear or damage.
(3) Disconnect the quick connector for the motor wires in the nose of the trailer. Insert a
paperclip, or equivalent, across the contacts in the connector on the side coming from the
inner control box. Verify if flashing stops. DO NOT ATTEMPT TO OPERATE THE TARP SYSTEM
DURING THIS TEST
If flashing stops, there is a ground fault occurring in the wiring to the
motor. Inspect for damage. Replace cable if necessary.
(4) If the 6 flashes continue, disassemble the inner control box located in the nose of the trailer and
inspect for water intrusion. Green corrosion around the amp control relay terminals is a positive
sign of relay failure due to moisture.
If moisture is present, replace the inner control box. Test functions
before re-installation to verify.
e) Seven flashes indicates the drive motor is shorted. Requires removing the power to reset.
Replace motor. Test functions to verify.
f) Eight flashes indicates com failure from the inner control box. Check com cable between RF keypad and
inner control box for damage.
 Tarp system does not make a full cycle or closes/opens intermittently.
a) Two flashes indicates an overcurrent protection issue which is normal if the tarp fully opened or closed. If
not, check for obstructions in the operation of the tarp such as snow or ice buildup. This also could indicate
increased drag in the tarp motor by a failing brake (old style motor) or other motor problems causing
premature tarp stoppage.
b) Remove the motor terminals and connect to a battery source using jumper cables to determine if the motor
labors or stops with direct current indicating a motor brake failure causing excess drag.
Replace the tarp motor if motor brake failure is found to be the cause
of premature tarp stoppage.