Heavy-Duty Diesel Range Extender 75kW BG-RES-75HD

  • 75 kW rated and 85 kW peak output
  • Designed for heavy-duty EV platforms
  • Fuel consumption as low as 0.25 L/kWh
  • CN-VI compliant diesel engine options
  • Fleet-ready CAN and remote diagnostics support
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The Heavy-Duty Diesel Range Extender 75kW is a high-power range extender system designed for demanding commercial EV applications, including electric heavy trucks, long-range electric buses, municipal service vehicles, and specialty platforms. It delivers 75 kW rated power and 85 kW peak power at 618 Vdc, providing reliable energy support for heavy-duty vehicles operating throughout the day.

Featuring advanced diesel engine technology, the system achieves fuel consumption as low as 0.25 L/kW·h, delivering excellent efficiency for heavy-duty electrification applications. Multiple engine configurations support different regional emission standards and operating requirements, including commercial and off-road vehicle applications. Cold-start capability down to -25°C ensures stable operation in challenging environments.

The 5-in-1 modular design integrates key power generation components with CAN 2.0 communication and online calibration support, enabling seamless integration into complex vehicle architectures. Battery protection functions and intelligent load-following control help optimize energy management and extend battery system reliability. Optional GPRS remote diagnostics enable fleet monitoring and system management.

For medium-duty applications, Brogen also offers 35 to 45kW gasoline range extender solutions, while compact commercial platforms can reference the 20kW diesel range extender series.

Parâmetros principais

75kW-4F20TC 75kW-ZG4
Rated Power / Voltage75 kW / 618 Vdc75 kW / 618 Vdc
Peak Power / Voltage85 kW / 618 Vdc85 kW / 618 Vdc
Faixa de tensão500 ~ 750 Vdc500 ~ 750 Vdc
Fuel Consumption0.25 L/kW·h (Diesel)0.28 L/kW·h (Diesel)
Dimensions (mm)L931 × W685 × H785L1020 × W593 × H739
Peso380 kg426 kg

Find Your Range Extender in 3 Steps

Step 1 of 3
What type of vehicle are you powering?
Light commercial vehicle
Bus & coach
Heavy truck & tractor
Specialty & municipal
A Structured Engineering Process for Successful EV Projects

How We Work

How We Work
Evaluate requirements and feasibility for optimal EV solution

Requirements Analysis

Collaborate to develop technical solutions and specifications

Solution Design

Develop, test, and validate customized EV systems reliably

Development & Production

Deliver worldwide with integration support and technical assistance

Global Delivery

Leading EV Powertrain Solutions Tailored for Commercial Vehicles

Our Solutions

Our Solutions
1

Solução de ônibus elétrico

2

Solução para caminhões elétricos

3

Solução para veículos comerciais leves

4

Solução para veículos fora de estrada

Proven Electrification Solutions Delivered Worldwide

Nossos projetos

Nossos projetos

Perguntas frequentes

Perguntas frequentes

How does the range extender work with the vehicle battery?

The system continuously monitors battery status and vehicle power demand. When required, the engine-driven generator automatically produces electricity and operates in constant-voltage or load-following mode to maintain battery performance and extend driving range.

Can the range extender be integrated with different battery voltages?

Yes. DSM range extender systems support a wide DC voltage range, typically from 144V to 750V depending on the model. This allows compatibility with various electric vehicle architectures and battery pack configurations.

What communication protocols are supported?

All systems support CAN 2.0 communication for integration with vehicle control units (VCU), battery management systems (BMS), and other onboard controllers. Protocol customization can also be supported for specific OEM requirements.

Can you develop a battery system based on my specific requirements?

Yes. We follow a process of requirement analysis, feasibility evaluation, engineering coordination, proposal & quotation, and project development. We work closely with your engineering team to ensure the solution meets your specifications.

Which vehicles are suitable for these range extender systems?

Range extenders are widely used in electric buses, light commercial vehicles, municipal vehicles, specialty equipment, utility vehicles, and heavy-duty trucks that require extended operating range without increasing battery capacity.

What are the advantages of the integrated 5-in-1 design?

The 5-in-1 architecture combines the engine, generator, ECU, GCU, RCU, and wiring harnesses into a compact package. This simplifies vehicle integration, reduces installation time, saves space, and improves overall system reliability.

Can the system operate in extreme temperatures?

Yes. Depending on the model, DSM range extenders can support cold starts down to -40°C and reliable operation in high-temperature environments. Integrated thermal management ensures stable performance across demanding operating conditions.

Does the system include battery protection functions?

Yes. The controller automatically adjusts operating modes when battery SOC becomes critically low or battery temperature falls outside recommended ranges, helping protect battery health and extend overall battery service life.

Is remote diagnostics available?

Yes. Selected models support GPRS-based remote monitoring, calibration, and diagnostics. Fleet operators can access operating data, monitor system status, and troubleshoot issues remotely to reduce maintenance costs and downtime.

How do I choose the right range extender power rating?

The ideal power rating depends on vehicle weight, battery capacity, duty cycle, and operating conditions. Smaller vehicles typically use 10–20 kW systems, while buses and heavy-duty applications often require 35–75 kW configurations.

What fuel options are available?

DSM offers both gasoline and diesel range extender systems. Gasoline models are suitable where fuel availability and emissions requirements are priorities, while diesel models generally provide higher fuel efficiency and lower operating costs.

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