Robert Bosch Corporation

Bosch introduces 'Long Haul Extreme' alternators

Bosch has launched the new heavy duty Long Haul Extreme alternator, designed to provide superior power output on the road and at idle, with advanced electronics and design that ensure trouble-free operation, increased battery life and significant fuel savings.

“By optimizing brushed alternator technology and state-of-the-art electronics and components, Bosch is able to eliminate the need for brushless technology and provide a compact, lightweight, rugged 170- or 200-amp alternator highly suited for the severe operating conditions in today’s commercial vehicles,” said Fred Padgett, Group Product Manager, Starters and Alternators for Bosch. “The use of advanced technology in the new Long Haul Extreme brushed alternator (AL9920LL, AL9921LL, and AL9922LL) produces ‘extreme’ long life while exceeding the performance of brushless alternators. Furthermore, it weighs up to 34 percent less than brushless alternators,” he said.

Long Haul Extreme alternators come in 170- and 200-amp versions, producing respectively 170 and 200 amps at 6,000 alternator rpm operating output and 120 and 122 amps at 2,000 alternator rpm. The Long Haul's high charge rate at lower engine rpm prolongs battery life by reducing deep cycling.

According to Padgett, “The new Long Haul Extreme is built to operate under high temperature situations, with dual internal cooling fans optimized for maximum airflow to help maintain its even temperature under all operating conditions. It replaces more than 200 competitive alternator part numbers and operates at up to 74 percent efficiency, resulting in significant fuel savings versus brushless types that operate at 55 percent efficiency.”

“Long HaulExtreme is backed by Bosch's exclusive 36-month, 350,000-mile warranty, and advanced electronics and construction ensure fast installation and efficient, trouble-free operation,” he said.

Intelligent Battery Sense

Long HaulExtreme features Bosch ‘intelligent’ battery sense technology. If the vehicle into which the alternator is going already has battery sense, connect the vehicle’s wiring harness to the proper terminal on the voltage regulator and the Long Haul is ready to go to work. If the vehicle is not equipped with battery sense, there is no vehicle wiring harness connector to attach to the battery sense terminal, and the Long Haul alternator, with Bosch Intelligent Battery Sense, functions without a vehicle’s battery sense. No ‘jumper wire’ must be connected between the battery sense terminal and the B+ terminal of the alternator so that the alternator can function properly, as with other competitive brushless alternators.

This type of a jumper wire creates a potential for alternators to malfunction, due to a loose or badly connected jumper wire, especially on engines with severe vibration characteristics. Bosch Intelligent Battery Sense Voltage regulators reduce the chance for premature failure, and reduce the need for additional SKUs.

Bosch LongHaul Extreme Multifunction Regulator

Not only does the Bosch Long HaulExtreme voltage regulator have an intelligent battery sense function, but it also contains circuitry that allows it to operate/energize via a built in D+ terminal or as a ‘one wire’ alternator as well, with absolutely no modifications.

Optimized Brush Composition

The new Long Haul Extreme is equipped with a ‘brush’ compound that is unique to Bosch and which enables the brushes in the Long Haul Extreme to last as long as, or longer than, brushless alternators. Though packed with power and features, the Long Haul Extreme alternator weighs significantly less than those using brushless technology while providing more available amperage output.

Thermal Protection

Bosch Long Haul Extreme voltage regulators are built with thermal protection, which allows the alternator to sense extremely high underhood temperatures that could potentially damage the internal components of any alternator and cause it to fail prematurely. The temperature-sensing feature of the voltage regulator allows the alternator to continue to operate at a reduced voltage output until the engine compartment reaches normal operating temperature below 257 degrees F (125 degreesC), at which point the voltage output returns to normal.

Brushless units do not contain this feature and allow the alternator to continue to charge at a full rate until they cease to function due to heat damage or at least experience irreversible damage that will lead to premature failure soon after the terminal incident.

Bosch Long Haul Extreme Bearing Technology

Bosch Long Haul Extreme alternator bearing technology provides exceptionally long life not available from brushless alternators.

  • Bosch Long Haul Extreme alternator bearings use steel that has 40 percent longer life than its closest competitor when tested at a 3,000 Newton meter belt load.
  • Due to the type of grease used in Bosch Long Haul Extreme alternator bearings, and the amount of grease installed in the bearings, Bosch Long Haul Extreme alternator grease has a lifetime 30 percent greater than other alternators when tested at 130 amps output.

“These features allow the Bosch alternator bearings to run 10 to 15 percent cooler. When run at 6,000 alternator rpm, the Bosch bearings operate at less than 120 degrees Celsius, while the closest competitor is 125 degrees, with some as high as 140 degrees,” Padgett said.

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