Thermal Systems

Global Leader in Engine Cooling Technology

Thermal Systems delivers innovative flow control products

to improve fuel economy and consumer comfort

through precise temperature management

of powertrain systems.The product portfolio includes all

smart components and systems

which optimize energy efficiency

through direct and indirect man-

agement of the engine operating

temperature by modulating air

and coolant flow.

• fans

• fan drives

• guide vanes

• shutters

• coolant pumps

At the core of BorgWarner’s Thermal Management Solutions lies

industry leading technologies that include airflow and coolant flow

components and modules. These innovative products are the result of

teams of engineers and technicians with a passion for excellence and a

never-faltering sense of responsibility to global communities. Together,

we are committed to exceeding customer expectations worldwide.

P R O D U C T P O R T F O L I O

T H E R M A L S Y S T E M S

1

At BorgWarner, worldwide product

leadership begins with the ability to

recognize and integrate breakthrough

ideas focused on exceeding

customer expectations.

2

T E C H N O L O G Y

S T A I R C A S E

3

MODULES

• Fan/Fan Drive Assemblies

COMPONENTS

• Fan Drives

• Fans

VEHICLE THERMAL MANAGEMENT SYSTEMS

• Control Software Virtual Modeling

COOLANT FLOW SYSTEMS

• Coolant Pumps

AIR FLOW SYSTEMS

• Exit Guide Vanes

• Stators

The engine cooling environment

is one of constant change: new

engine families with higher out-

put result in increased heat load.

More airflow obstructions cause

greater system resistance.

BorgWarner Thermal System’s

unique structure puts technology

and science together with prod-

uct design to create innovative

products through concurrent

engineering. That means better

and faster results and more effi-

cient operations to improve fuel

economy and reduce emissions.

T H E R M A L S Y S T E M S

Thermal Segment Strategy

4

BorgWarner Thermal Systems serves the entire light vehicle market with air

flow technology for light commercial vehicles, pickup trucks and SUVs as

well as coolant flow solutions for the passenger car market. These products

provide precise engine temperature control and improved fuel economy with

no increase in power requirements.

BorgWarner Thermal Systems’ product solutions are available for the global

commercial vehicle market which includes both medium and heavy-duty trucks.

BorgWarner pays close attention to issues specific to this market such as emission

regulations, fuel economy, driver comfort, weight and product packaging.

L I G H T V E H I C L E M A R K E T

C O M M E R C I A L V E H I C L E M A R K E T

The global off highway vehicle market consists of vehicles used primarily

for agriculture and construction applications. BorgWarner Thermal Systems

addresses the unique cooling needs these vehicles require with a full line

of fans and fan drives designed specifically for this market.

BorgWarner produces aftermarket components that are manufactured to

the same standards as our original equipment offerings.

Our reputation for product reliability and our focus on fuel economy,

performance and reduced emissions has made us a global market leader.

O F F - H I G H W A Y V E H I C L E M A R K E T

A F T E R M A R K E T

BorgWarner’s focus on market-related objectives such as fuel

economy, electronically managed air flow, noise reduction

and long-term durability coupled with tightly aligned processes

and speed to market assure product leadership.

5

T H E R M A L S Y S T E M S

• Light duty

• Efficient and low noise blade profile

• Lightweight and optimized for light commercial vehicles

LD7 LD7RF LD97RF XLD9RF

LD Series

• High performance

• For larger light commercial vehicles and small off-highway vehicles

• High efficiency

• Works well with the Visctronic fan drive series

XS11 XS11RF

XS Series

• High performance

• Efficient for use in light vehicle, medium trucks and off-highway vehicles.

• Optimized for use on Gen II and Visctronic fan drives with OD-mount

• Compatible with Viscous drives

SD Series

SD9 SD11 SD11RF SD11RF-k

6

A I R F L O W P R O D U C T S

Fan Technology POLYMER FANS & GUIDE VANES

The BorgWarner polymer cooling fans range from optimized axial flow fans and ring-fans for specific installations, to new hybrid designs to cover future cooling demands. New features include improved aerodynamics and durability in the same light-weight package. Using technology-focused design methods such as FEA, CFD and MoldFlow™, per-formance and reliability are optimized.

BorgWarner’s Guide Vane design provides optimized air-flow potential through its world-class efficiency improve-ments and unique diffuser design. This unique design requires lower torque than fans operating in a traditional shroud, translating into more power to the wheels.

• First generation off-highway and medium duty vehicle fans

• Weight optimized

• High performance and efficiency

• MD Series generation SD and XMS Series fans

MD9 MD9RF

MD Series

XMD9

• Designed for North American medium and heavy duty truck requirements

• High performance and efficiency

• Low noise

XMD Series

HD11 HD11RF

• First generation off-highway and medium duty vehicle fans

• Weight optimized

• High performance and efficiency

• HD Series advantages are the basis of the next generation XD Series fans

HD Series

• High performance

• Meets the highest truck cooling requirements globally

• Peek cooling performance at low rpms’ using our Visctronic fan drives

XD11 XD11RF XD14MRF

XD Series

XL9

• Innovative over-molded blade

• Larger airflow while maintaining the desired efficiency and durability levels

• Off-highway vehicle compatible

XL Series

• High flow• Efficient in covering medium/heavy

on-highway trucks• Delivers benchmark ram air cooling• Designed for use on on/off fan drives• Compatible with Viscous drives

PS6

EGV SGV

• Application specific fan performance boost• Enables benchmark efficiency of the fan system• Suitable for LV / CV vehicles on demand• EGV optimized for use with BorgWarner open fans• SGV optimized for use with BorgWarner ring fans

Guide Vane Systems

7

LIGHT COMMERCIAL OFF-HIGHWAY

FA N D R I V E S

Air-Controlled Technology BI-METAL VISCOUS & ON/OFF FAN DRIVES With Kysor On/Off, DuroSpeed™ & Bi-Metal Viscous Fan Drives, innovative designs with fewer moving parts mean improved belt life and easier (and less) maintenance. Regard-less of the situation, the fan always remains engaged, preventing engine overheating. Combine this fail safe feature with proper maintenance and normal operating conditions and you can expect a million miles of trouble-free service.

Electronically-Controlled Technology VISCTRONIC ® FAN DRIVE

BorgWarner’s Electronically-Controlled Fan Drives provide proven viscous technology with precise fan speed modulation. This translates into superior temperature control, extending the life of the engine and components, while at the same time, improving fuel economy with minimum parasitic loss.

These maintenance free drive provides reduced fan noise and decreased cooling system component stress. Expect 1.5% improved fuel economy, depending on application and duty cycle.

8

• Improved efficiency

• Reduced noise

• No maintenance

• Improved temperature control

• Bimetallic sensor

• Smooth, soft engagement

• No external controls required

• Cost-effective

Viscous Fan Drive

• Improved fuel efficiency

• Maintenance free

• Improved temperature control

• High-speed reservoir and patented fluid distribution

Visctronic® Fan Drive

• Consistent performance and dependability

• Improved cooling capability

• Durability and reliability

• Common clutch serviced independently from hub and pulley

• Provides continuous cooling

• Keeps damaging heat away from the pulley and bearings

• Lighter weight

Kysor™ On/Off Fan Drive

• Modular design

• 5 to 10 lbs. than competitor’s

• Reduces fan clutch cycling

• Easy flux ring removal

• Fewer components

• Capable of multiple disengaged speeds

• Fan thrust adds to torque capacity as opposed to reducing it

DuroSpeed™ 2-Speed Fan Drive

LIGHT COMMERCIAL OFF-HIGHWAY

C O O L A N T F L O W P R O D U C T S

Mechanical and Auxiliary Electric Coolant PumpsThese components deliver advanced technology to customers who need coolant pumps for engine applications.

Dual Mode Coolant Pumps Under most conditions, Dual Mode Coolant Pumps are electrically driven but can also mechanically engage the FEAD for peak cooling demands. These variable speed pumps drive via high efficiency BLDC motors. Peak cooling requirements are met with integrated motor control, drive electronics and clutched mechanical pulley drives, improving fuel economy and cooling during engine shutdown.

Variable Viscous Coolant Pump The innovative concept of the Compact Variable Coolant Pump combines the character-istics of a high performance and efficient fixed pump with the capability to fully control the coolant flow. The transient response of the pump to the engine cooling demands results in increased fuel economy.

9

• Leakage free

• Sensor-less commutation

• Silent operation

• High efficiency

• Easy to implement

• High durability

Electric Pump

• Close impeller design, efficiency improving

• R-safe bearing for high durability

• Lightweight design

• Easy to implement

• Silent operation

Mechanical Pump

• Fuel economy and emissions improvement

• Improved controls and system complexity

• FailSafe™ engine/vehicle cooling

• Modulation through LIN (Local Interconnect Network) communication

Dual Mode Coolant Pump

• High efficiency

• Fully variable coolant flow up to 1000 l / min

• Modulation through PWM (Pulse Width Modulation)

• Failsafe™ engine/vehicle cooling

• Soft engagement limiting system pressure peaks

• Precise impeller speed control and diagnostics

Variable Viscous Coolant Pump

Compact Variable Coolant Pump (CVCP)

LIGHT COMMERCIAL OFF-HIGHWAY

Fletcher, North Carolina

USAAuburn Hills, Michigan

India Chennai

Thailand

Samut Prakan*

ChinaNingbo

Markdorf, Germany

Brazil Itatiba

Facilities

Headquarters

Sales / Admin

Tech Center

Americas

Europe

Asia

JapanShin-Yokohama

Marshall, MI

Cadillac, MI

thermal.borgwarner.com

thermal.aftermarket.borgwarner.com

Auburn Hills, MIPTC - Powertrain Technical Center3800 Automation AveAuburn Hills, MI 48326Tel: + 1 248 754 9600

Cadillac, MIManufacturing Facility1100 Wright Street Cadillac, MI 49601 Tel: +1 231 779 7500 Technical Assistance: + 1 800 927 7811

Changwon, South KoreaBorgWarner Thermal Systems Korea263, Jungang-daero, Uichang-gu,Changwon-si, Gyeongsangnam-do,Korea, Office Plaza 8F 804641-969, South KoreaTel: + 82 55 239 5760

Chennai, IndiaManufacturing FacilityPlot No. E-14, Sipcot Industrial Park,Mambakkam Village,SriperumbudurKancheepuram District,TamilNadu, India 602105Tel: + 91 44 371 83015

Ningbo, China Technology Center Manufacturing FacilityNo.289 Jingu Road YinZhou Country Ningbo 315104, ChinaTel: + 86 574 8309 8353

Yokohama, JapanSales OfficeGerman Industry Park, Room #2091-18-2 Hakusan, Midori-ku, Yokohama-shi, Kanagawa226-0006 Japan Tel: + 8145 938 6770

Samut Prakan, Thailand*Contract Manufacturer

Itatiba, BrazilManufacturing FacilityFioravante Piovani, 2500Jd. das LaranjeirasItatiba, SP 13257-700Tel: + 55 11 3183 0507

Fletcher, NCManufacturing Facility40 Cane Creek Industrial ParkFletcher, NC 28732 Tel: + 1 828 684 3501 Marshall, MITechnology Center1507 South Kalamazoo AvenueMarshall, MI 49068 Tel: + 1 269 565 8100

Markdorf, Germany Technology Center Manufacturing FacilityPlanckstrasse 4+6D-88677 Markdorf, Germanyinfo-markdorf@borgwarner.com

Virginia Water/ London, SurreyTel: + 44 7802 371113

South KoreaChangwon