We are a long way out from the days when trailers were simple boxes with no real capabilities other than carrying freight from one place to another. Today’s trailers are rapidly closing in on big rigs when it comes to technical capability and complexity.
Modern trailers now have their own telematics and diagnostics systems. They have more sensitive and complex electronic wiring systems. And the need to keep those systems functioning becomes more challenging for technicians by the year. OEMs are already reaching capacity when it comes to circuits coming from the truck and winding their way back to the trailer.
Changing Electrical Requirements for Trailers
There are limit to 7-in trailer connectors. The problem? 7-pin connectors are the go-to standard and have been for a long time. As a result of these limitations, engineers are already looking to 15-pin connectors. Some are even investigations trailers that have self-supporting electrical systems built onboard. This may seem like something from the future, but it is far closer than most fleet managers realize.
There are plenty of examples of false alarms and false positives generated from faulty trailer electrical systems. Technicians must deal with situations where the antilock braking system fails on the trailer, only to find that a center pin on the 7-way plug has failed and won’t put out any power. The center pin is critical and directly responsible for trailer power delivery to the ABS system, automatic tire inflation systems, trailer telematics systems, and more. It isn’t outside the norm for a lot of power to flow between those connectors and pins.
With so much power flowing through a trailer’s electrical components and wiring, if a use blows, the entire circuit is done. Furthermore, if there is corrosion on the connector, voltages can be compromised, which will result in a slew of fault codes and degraded parts performance. If a truck driver complains to a technician that their ABS is out or they cannot operate a lift gate, the first place they should look is at the center pin.
Just about everything that needs power on the trailer (except for lighting) comes through that center pin. When trailer problems pop their head up, a smart technician will first check the fuse or pins for corrosion.
Why Corrosion is Such a Problem for Trailer Electronics
Corrosion is bad period. Whether for the truck and its components, the cab interior, or the trailer wiring, no technician wants to be forced to deal with, mitigate, or repair or replace components for corrosion. Corrosion on a J560 plug and trailer pigtail can cause big issues. And if you are operating in areas where the road is de-iced in the winter, the problems become even more acute.
The main reason for this is that the tractor end of the J560 plus is very rarely disconnected or inspected. And unless it is regularly inspected, it is even more rare that is regularly cleaned or tested. So, with all the multiplexing and power line carrier data being transmitted through this cable, checking it, testing it, and cleaning it is more important than ever.
While there are new wiring systems that prevent corrosion and other problems related to trailer wiring, many fleets remain reluctant to adopt them. There are a lot of sealed connectors available, yet many fleets continue to use a metal plug on the J650 connector. This makes it even more critical to examine all your options and choose the best one for your trucks.
Even more, price should not be a consideration when it comes to wiring and connectors. You are looking at anywhere from a 5% to 10% increase to invest in premium connectors. That is a small price to pay to reduce corrosion and connection problems.
Expect Power Loads to Only Increase
It should be no surprise as we continue to utilize, embrace an adopt new technologies, that the electrical load on a standard metal J650 connector will only increase as more technologies are added to the trailer. OEMs, fleet managers, and technicians will have to move to 15-pin connectors.
On this front, the U.S. is far behind its peers. European truck manufacturers have already moved to 15-pin connectors. American OEMs realize they must make the switch soon. The truth is you must blame the accessories. Take liftgates as one example. Liftgate batteries are fed power from the tractor, yet that doesn’t mean problem won’t arise.
Due to the length of the cable used, or perhaps an inadequate alternator, or even corrosion on the connectors or cabling, the trailer’s liftgate battery may not be getting the power it needs to stay charged. In previous articles, we’ve talked about solar panels on the trailer. They represent a great way to get power to the trailer’s components without worrying about an antiquated and potentially corroded cable.
Power generated by an e-hub motor/generator could solve trailer power problems the same way solar panels would. Wheel-mounted generators store power locally and delivery it via hardened wiring conduits and advanced systems.
Solar Trailer Solutions Come in Handy
Solar panels come in handy if you are operating trailers that have short travel distances between stops. Otherwise, they may not be able to charge the liftgate battery because the truck won’t spend much time idling. Solar power installed on the trailer can solve these issues. They can also save the battery from deep discharge states which, over time, limit the battery’s lifecycle.
Trucking companies that adopt solar technologies for trailer power often find that battery life is vast improved even with a small solar energy solution. Acid-based liftgate batteries may need to be recharged every 8 to 10 months depending on overall usage. Utilizing solar panel arrays on the trailer can extend that time rage out to 30 months without having to replace a single battery.
Even electric climate control systems can be powered by solar cells on the roof of the trailer. And these systems cost significantly less than conventional systems. Diesel APUs will cost significantly more over their lifetime than solar-powered APUs.
Consider the amount of time a fleet keeps a trailer. Tractors usually last around four to five years. Trailers, on the other hand, can often be used for 10 – 12 years. If you are using a solar solution on your trailer, you get are getting twice the payback on the lifecycle of that trailer versus the truck itself. Even better, solar cells generally require little to no maintenance. They are largely self-sufficient and quite durable. Even if a few cells are damaged for whatever reason, the rest of the panel will continue generating power.
Why Trailer Electrical Maintenance Matters So Much
While the trucking industry patiently waits for 15-pin connectors between tractors and trailers, technicians will have to utilize correct cabling size and state of the art technologies to ensure trailer electrical systems remain reliable. And reliability means much more than just ensuring the liftgate can operate.
Truck drivers do not appreciate downtime, so electrical maintenance is important to ensure they don’t have to deal with downtime. If you aren’t ensuring this, then your fleet is going to face problems retaining awesome truck drivers. And since electrical maintenance isn’t the most difficult thing a technician will face, it shouldn’t be a big deal to take care of electrical problems. Keep in mind, however, that maintenance is very different from troubleshooting.
Complex electrical troubleshooting requires disciplined techs who know how to follow troubleshooting and repair procedures generally get the job done quickly and well. Responsible and effective technicians don’t take shortcuts.
Without your trailers, your freight does not get delivered. Your trucks are very important, but trailers are just as important. And as trailer technology become evermore complex, you need to pay attention to wiring, cables, and connectors.
Top Tips for Preventing Wiring Problems
Finally, we want to provide you with some top tips on getting ahead of wiring problems. Just as preventative maintenance gets ahead of hardware problems, you can also get ahead of wiring and electrical problems.
First, pay close attention to cable routing, chafing, and vibration-related cable damage. This step should be completed during your tractor’s pre-delivery inspection. Don’t be afraid to take cable routing issues all the way up to the OEM or dealer.
Also create a wiring repair policy so that all the technicians in your shop know how to complete wiring jobs in the same way. You also should create a corresponding policy or procedure for replacing connectors.
Your final steps should be to train your technicians on how to use multimeters and other diagnostic tools. They need to fully understand battery load testing, parasitic drains, voltage drops and current flows and draws.
Trailer electrical maintenance is important. Without a focus on your trailers’ electrical performance, your drivers may find themselves with downtime they don’t want or need. Keep the tips in today’s article in mind and you’ll surely have no problems keeping your trailer electronics in tip top shape.