Geely KX11 PHEV 2023 Manual
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Geely KX11 PHEV 2023 Manual

Geely KX11 PHEV 2023 Manual

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2023 KX11 PHEV
Power Battery Manual (SVOLT)
The manual provides specifications, diagnostics, and repair service information on 113Ah
2023 Geely Automobile International Corporation
All rights reserved.
Information updated to 2023 08
Without the written permission of Geely Automobile International Corporation, any part of this manual can't be reproduced, stored
or transmitted in any form or by any means

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Summary of Contents for Geely KX11 PHEV 2023

  • Page 1 2023 Geely Automobile International Corporation All rights reserved. Information updated to 2023 08 Without the written permission of Geely Automobile International Corporation, any part of this manual can't be reproduced, stored or transmitted in any form or by any means...
  • Page 2 Replacement parts must be Geely original replacement parts or parts matching the quality of Geely original replacement parts. Geely is not responsible for any problems that may arise from the use of this manual. Causes of these problems include lack of training related to the servicing, use of incorrect tools, use of parts of inferior quality to Geely original replacement parts, and other causes.
  • Page 3 Geely Automobile Company reserves the right to make changes to the technical standards and contents of this manual without obligation or prior notice, and all rights belong to Geely Automobile Company. No part of this book may be reproduced or used in any form or by any means, such as electronically or in paper form, including photographic reproduction, recording, etc., without...

  • Page 5: Table Of Contents

    CONTENTS CONTENTS 1 Overview ............1-3 1.1 Overview ............1-3 2 Power battery ..........2-15 2.1 Power battery ..........2-15 2.2 Technical data..........2-63 2.3 Servicing tools ..........2-66 113Ah 2023...
  • Page 6 CONTENTS 113Ah 2023...

  • Page 7: Overview

    Overview Overview 1.1 Overview 1.1.1 Power battery overhaul warnings 1.1.1.1 Warnings and Cautions Warnings about Disassembling the Power Battery Warning！ Warning！ Insulating tools: Servicing Site Requirements: • Pad the servicing area with insulating rubber mats. • Safety isolation measures are required prior to the •...
  • Page 8 Overview Overview Precautions for the Cooling System Caution After the cooling system is installed, perform an air tightness test. Precautions for the Power Battery after Completion of Assembly Caution After the power battery is assembled, it is necessary to perform a airtightness test. 113Ah 2023...

  • Page 9: Repair Procedures

    Overview Overview 1.1.2 How to use this manual 1.1.2.1 Scope of Topics This manual contains procedures for all required overhaul operations, which are divided into the following basic operations: a. Removal b. Disassembly c. Inspection d. Installation 1.1.2.2 Repair Procedures The description of most repair protocols is preceded by a general overview diagram.

  • Page 10: Specifications

    Overview Overview Bracket (plug) Explosion-proof valve (2) Battery pack upper housing Fire filter Explosion-proof valve (1) Sealing strip 1.1.2.3 Symbols The following symbols indicate how to use the material or how to use it during servicing. Symbols Meaning Material type Non-reusable, removal requires re- Sealing gasket, cushioning foam, etc.
  • Page 11 Overview Overview 1.1.3 Unit 1.1.3.1 Unit A (Ampere) Current Electrical power W (Watt) Ω (ohm) Resistance Voltage V (Volt) Capacitance Ah (Ampere-hour) Length mm (millimeter) Torque N·m (Newton metre) Weight g (g), kg (kg) Electricity kWh (kilowatt-hour) Energy density W·h/kg (watt per kilogram) kPa (kilopascal) Pressure 113Ah 2023...
  • Page 12 Overview Overview 1.1.4 Basic procedures 1.1.4.1 Preparation Site Preparation • Servicing of the power battery must be carried out in a dedicated workstation with insulating mats in the servicing area. GE29-0171a • Protective fencing must be placed around the dedicated work station, and safety warning signs such as "High Voltage Work", "High Voltage Danger", and "Stop/High Voltage Danger"...
  • Page 13 Overview Overview • Water-based fire extinguishers must be provided in the site. GE29-0176a • Keep the working environment clean and well ventilated, away from liquids and flammable materials. Preparation of the Protective Equipment and Insulating Tools • Preparation protective equipment: insulating protective clothing, insulating shoes, insulating gloves, goggles, protective mask, anti-acid and alkali gloves.
  • Page 14 1-10 Overview Overview • Preparation insulating tools: commonly used insulating tools. FE27-0124a • Inspection of protective equipment: Check whether the insulating gloves are within the validity period and whether they are dirty, broken or leaking. If there are any of the above problems, a new pair of gloves must be replaced and rechecked;...
  • Page 15 Overview Overview 1-11 The removed copper rows need to be covered with insulating shields. FE27-0120a Warning！ When disconnecting the power battery module harness, follow the order of "low voltage first, then high voltage". 1.1.4.3 Placement of Parts • All removed parts should be sorted and placed in a clean, dust-free environment for reassembly.
  • Page 16 1-12 Overview Overview 1.1.4.4 Reassembly When assembling each part, be sure to strictly adhere to the specification data, such as tightening torque. Caution Sealing trips are not reusable and need to be replaced with new parts after each removal. 113Ah 2023...

  • Page 17: Installing The Connector

    Overview Overview 1-13 1.1.5 Electrical system 1.1.5.1 Connector Disconnecting the connector When disconnecting the harness connector, operate the harness connector by grasping both ends. Disconnect the harness connector by pressing or pulling up the locking handle as shown in the figure. Warning！...
  • Page 18 1-14 Overview Overview 1.1.6 Abbreviations 1.1.6.1 Abbreviations Battery Management System 113Ah 2023...

  • Page 19: Power Battery

    Power battery Power battery 2-15 2.1 Power battery 2.1.1 Removal of the Hybrid Power Battery Assembly Upper Housing 2.1.1.1 Removal of the Battery Pack Upper Housing Remove in the order indicated in the diagram. Bracket (plug) Explosion-proof valve (2) Battery pack upper housing Fire filter Explosion-proof valve (1) Sealing strip...
  • Page 20 2-16 Power battery Power battery 2.1.1.2 Removal of the Battery Pack Upper Housing Remove the 4 fixing nuts connecting the battery pack upper housing and the battery pack lower tray. 113Ah 2023...
  • Page 21 Power battery Power battery 2-17 Remove the 54 fixing bolts connecting the upper housing of the battery pack and the battery pack lower tray. Caution When removing the fixing bolts of the battery pack upper housing, loosen the bolts firstly and then gradually remove the fixing bolts in several passes.
  • Page 22 2-18 Power battery Power battery 2.1.1.3 Removal of the Explosion-proof Valve Remove the four fixing bolts connecting the explosion- proof valve (1) and the battery pack lower tray. Remove the explosion-proof valve (1). Remove the 4 fixing bolts connecting the 2 explosion- proof valves (2) and the battery pack lower tray.
  • Page 23 Power battery Power battery 2-19 2.1.1.4 Removal of the Fire Filter Remove the 4 fixing bolts connecting the fire filter and the battery pack lower tray. Remove the fire filter. 2.1.1.5 Removal of the Sealing Strip Remove the sealing strip. Caution 1.
  • Page 24 2-20 Power battery Power battery 2.1.2 Removal of the Battery Management System 2.1.2.1 Removal of the Battery Management System Remove in the order indicated in the diagram. Power battery control module (master board) Power battery control module bracket Power battery control module (slave board) 113Ah 2023...
  • Page 25 Power battery Power battery 2-21 2.1.2.2 Removal of the Power Battery Control Module (main board) Caution After disconnecting the high-voltage harness connector, the connector protective cover should be installed immediately, and it is strictly prohibited to touch the high-voltage harness connector directly with your fingers;...
  • Page 26 2-22 Power battery Power battery Remove the 4 fixing nuts 1 connecting power battery control module (main board) and the power battery control module bracket. Disconnect the harness connector A connecting the power battery control module (main board) and the low- voltage harness.
  • Page 27 Power battery Power battery 2-23 2.1.2.4 Removal of the Power Battery Control Module Bracket Caution Disconnect the high-voltage harness connector, the connector protective cover should be installed immediately, and it is strictly prohibited to touch the high-voltage harness connector directly with your fingers;...
  • Page 28 2-24 Power battery Power battery Remove the harness clip 1 connecting the low-voltage harness and the high-voltage control box. Disconnect the harness clip 2 connecting the low-voltage harness and the battery pack lower tray. Disconnect the harness connector A connecting the low- voltage harness and the battery pack lower tray.
  • Page 29 Power battery Power battery 2-25 Remove the protective cover. Remove the 2 fixing bolts connecting the copper row (1) and the high-voltage plug (ODP). Remove the copper row (1). Remove the 5 fixing bolts connecting the hybrid power battery assembly bracket and the battery pack lower tray. Remove the hybrid power battery assembly bracket.
  • Page 30 2-26 Power battery Power battery 2.1.3 Removal of the High-voltage Control Box 2.1.3.1 Removal of the High-voltage Control Box Remove in the order indicated in the diagram. High-voltage control box 113Ah 2023...
  • Page 31 Power battery Power battery 2-27 2.1.3.2 Removal of the High-voltage Control Caution The removed copper rows need to be wrapped with insulating tape. Caution Disconnect the high-voltage harness connector, the connector protective cover should be installed immediately, and it is strictly prohibited to touch the high-voltage harness connector directly with your fingers;...
  • Page 32 2-28 Power battery Power battery Remove the protective cover. Remove the 2 fixing bolts 1 connecting the copper rows (2) and (3) to the high-voltage control box. Remove the 2 fixing bolts 2 connecting the copper rows (2) and (3) to the high-voltage plug (PCM). Remove the copper rows (2) and (3).
  • Page 33 Power battery Power battery 2-29 Remove the fixing bolt 1 connecting the high-voltage control box and the high-voltage plug (ACCM). Remove the 4 fixing bolts 2 connecting the high-voltage control box and the battery pack lower tray. Remove the high-voltage control box. 113Ah 2023...
  • Page 34 2-30 Power battery Power battery 2.1.4 Removal of the Low-voltage Harness and Accessories 2.1.4.1 Removal of the Low-voltage Harness and Accessories Remove in the order indicated in the diagram. Low-voltage harness High-voltage plug (PCM) High-voltage plug (ODP) High-voltage plug (ACCM) 113Ah 2023...
  • Page 35 Power battery Power battery 2-31 2.1.4.2 Removal of the Low-voltage Harness Caution Disconnect the high-voltage harness connector, the connector protective cover should be installed immediately, and it is strictly prohibited to touch the high-voltage harness connector directly with your fingers; no part of the high-voltage harness should be damaged during disconnection, and any metal tools should be prevented from touching the high- voltage harness connector.
  • Page 36 2-32 Power battery Power battery 2.1.4.3 Removal of the Accessories Caution Disconnect the high-voltage harness connector, the connector protective cover should be installed immediately, and it is strictly prohibited to touch the high-voltage harness connector directly with your fingers; no part of the high-voltage harness should be damaged during disconnection, and any metal tools should be prevented from touching the high- voltage harness connector.
  • Page 37 Power battery Power battery 2-33 Remove the high-voltage plug (ODP). Remove the 4 fixing screws 1 connecting the high- voltage plug (PCM) and the battery pack lower tray. Remove the high-voltage plug (PCM). Remove the 4 fixing screws 2 connecting the high- voltage plug (ACCM) and the battery pack lower tray.
  • Page 38 2-34 Power battery Power battery Remove the fixing bolts 1 connecting the copper row (4) and the battery module. Remove the fixing bolts 2 connecting the copper row (5) and the battery module. Remove the 2 fixing clips 3 connecting the copper row (4) and the battery pack lower tray.
  • Page 39 Power battery Power battery 2-35 2.1.5 Checking the Harness Connector Joint 2.1.5.1 Checking the Harness Connector Joint Check the harness connector joint for ablation, the ablated part of the harness connector is black, as shown in the figure. If there is any erosion, the harness needs to be checked for short circuit or broken faults, and the harness needs to be replaced with a new one after troubleshooting.
  • Page 40 2-36 Power battery Power battery 2.1.6 Inspect the copper row 2.1.6.1 Checking the Copper Row Check the joints of the copper row for signs of ablation; if there is ablation, the condition may appear as shown in the figure. After the copper row appears to be ablated, it is necessary to check whether the copper row bolts are tightened according to the standard torque, whether the surface of the copper row is oxidized by the oxide layer,...
  • Page 41 Power battery Power battery 2-37 2.1.7 Check the Battery Module 2.1.7.1 Check the Battery Module Check the battery module for deformation, protrusion, breakage, etc. If so, the power battery module needs to be replaced. FE27-0114a 113Ah 2023...
  • Page 42 2-38 Power battery Power battery 2.1.8 Install the harness, water tube and accessories 2.1.8.1 Installation of the Low-voltage Harness and Accessories Install in the order indicated in the diagram. High-voltage plug (ACCM) High-voltage plug (ODP) High-voltage plug (PCM) Low-voltage harness 113Ah 2023...

  • Page 43: Installation Of The Accessories

    Power battery Power battery 2-39 2.1.8.2 Installation of the Accessories Warning！ During the installation, always wear safety glasses, high-voltage insulating gloves, and use insulating tools when working. Install the copper row (7) and copper row (6) to the battery module and the battery pack lower tray. Install and tighten the 2 fixing bolts 2 connecting the copper row (7) and the battery module.

  • Page 44: Power Battery

    2-40 Power battery Power battery Install the protective cover. Install the high-voltage plug (ACCM) and fasten the 4 fixing screws 2 connecting the high-voltage plug (ACCM) and the battery pack lower tray. Torque: 3N·m Install the high-voltage plug (PCM) and fasten the 4 fixing screws 1 connecting the high-voltage plug (PCM) and the battery pack lower tray.
  • Page 45 Power battery Power battery 2-41 Install the high-voltage plug (ODP). Install the bracket (plug) and tighten the 4 set screws connecting the bracket (plug) and the high-voltage plug (ODP). Torque: 7N·m 113Ah 2023...
  • Page 46 2-42 Power battery Power battery 2.1.8.3 Installation of the Low-voltage Harness Warning！ During the installation, always wear safety glasses, high-voltage insulating gloves, and use insulating tools when working. Install the low-voltage harness and tighten the 4 fixing bolts connecting the low-voltage harness and the battery pack lower tray.
  • Page 47 Power battery Power battery 2-43 2.1.9 Installation of the High-voltage Control 2.1.9.1 Installation of the High-voltage Control Box Install in the order indicated in the diagram. High-voltage control box 113Ah 2023...
  • Page 48 2-44 Power battery Power battery 2.1.9.2 Installation of the High-voltage Control Warning！ During the installation, always wear safety glasses, high-voltage insulating gloves, and use insulating tools when working. Install the high-voltage control box. Install and tighten the 4 fixing bolts 2 connecting the high- voltage control box and the battery pack lower tray.
  • Page 49 Power battery Power battery 2-45 Install the protective cover. Install and tighten the 2 fixing bolt connecting the copper row (4) and copper row (5) to the high-voltage control box. Torque: 9N·m Install the protective cover. 113Ah 2023...
  • Page 50 2-46 Power battery Power battery 2.1.10 Installation of the Battery Management System 2.1.10.1 Installation of the Battery Management System Install in the order indicated in the diagram. Power battery control module bracket Power battery control module (master board) Power battery control module (slave board) 113Ah 2023...
  • Page 51 Power battery Power battery 2-47 2.1.10.2 Installation of the Power Battery Control Module Bracket Warning！ During the installation, always wear safety glasses, high-voltage insulating gloves, and use insulating tools when working. Install the hybrid power battery assembly bracket and tighten the 5 fixing bolts connecting the hybrid power battery assembly bracket and the battery pack lower tray.
  • Page 52 2-48 Power battery Power battery Install the protective cover. Install the 6 fixing clips 2 connecting the copper row (1) and the battery module. Install and tighten the 2 fixing bolts 1 connecting the copper row (1) and the high-voltage control box. Torque: 9N·m Install the protective cover.
  • Page 53 Power battery Power battery 2-49 Connect the harness connector A connecting the low- voltage harness and the battery pack lower tray. Install the harness clip 2 connecting the low-voltage harness and the battery pack lower tray. Install the harness clip 1 connecting the low-voltage harness and the high-voltage control box.
  • Page 54 2-50 Power battery Power battery 2.1.10.3 Installation of Power Battery Control Module (slave plate) Warning！ During the installation, always wear safety glasses, high-voltage insulating gloves, and use insulating tools when working. Install the power battery control module (slave board). Connect the harness connector A connecting the power battery control module (slave plate) and the low-voltage harness.
  • Page 55 Power battery Power battery 2-51 Install the copper row (8) and tighten the 2 fixing bolts connecting the copper row (8) and the battery module. Torque: 9N·m Install the protective cover. 113Ah 2023...
  • Page 56 2-52 Power battery Power battery 2.1.11 Installation of the hybrid power battery assembly upper housing and peripheral parts 2.1.11.1 Installing the Power Battery Upper Housing and Peripheral Parts Install in the order indicated in the diagram. Sealing strip Explosion-proof valve (1) Fire filter Battery pack upper housing Explosion-proof valve (2)
  • Page 57 Power battery Power battery 2-53 2.1.11.2 Installation of the Sealing Strip Install the sealing strip. Caution The sealing strip must be installed by attaching it in a circle right down the center of the battery pack lower tray. 2.1.11.3 Installation of the Fire Filter Install the fire filter and tighten the 4 fixing bolts connecting the fire filter and the battery pack lower tray.
  • Page 58 2-54 Power battery Power battery 2.1.11.4 Installation of the Explosion-proof Valve Install the 2 explosion-proof valves (2) and tighten the 4 fixing bolts connecting the 2 explosion-proof valves (2) and the attery pack lower tray. Torque: 6N·m Install the explosion-proof valve (1) and tighten the 4 fixed bolts connecting the explosion-proof valve (1) and the battery pack lower tray.
  • Page 59 Power battery Power battery 2-55 2.1.11.5 Installation of the Battery Pack Upper Housing Place the battery pack upper housing in the mounting position. Caution Two people are required to do this work. 113Ah 2023...
  • Page 60 2-56 Power battery Power battery Install and tighten the 54 fixing bolts connecting the battery pack upper housing and the battery pack lower tray. Torque: 6N·m Install and tighten the 4 fixing nuts connecting the battery pack upper housing and the battery pack lower tray. Torque: 10N·m 113Ah 2023...
  • Page 61 Power battery Power battery 2-57 2.1.12 Checking the Airtightness of the Water Tube 2.1.12.1 Checking the Airtightness of the Water Tube Perform the airtightness test of power battery cooling water line. Plug the water-cooling pipe ports using the water-cooling pipe tooling. Specialized tool: 4114870581 Use 400kPar air pressure to inflate the water-cooled tube, inflation lasts for 60s, air pressure range is 360-...
  • Page 62 2-58 Power battery Power battery 2.1.13 Check the Power Battery Compartment for Airtightness 2.1.13.1 Check the Power Battery Compartment for Airtightness Plug the high/low-voltage harness connector using the harness connector protector shield. Specialized tool: 4114870581 Plug the blast valve holes using the blast valve tooling. Specialized tool: 4114870580 113Ah 2023...
  • Page 63 Power battery Power battery 2-59 Use the inflation equipment to inflate the battery compartment with 4kpa, inflation time lasts for 100s, air pressure gets up to 3.6-4.4kap. Specialized tool: 4114870566 Pressure stabilization lasts for 80s. Exhaust lasts for 5s. Test the leakage rate is <100Pa/min inside the battery compartment, then the airtightness is qualified.
  • Page 64 2-60 Power battery Power battery 2.1.14 Check the Power Battery Equipotential 2.1.14.1 Check the Power Battery Equipotential Firstly, adjust the testing equipment resistance gear down, and then dock the red and black meter pens, and test whether the resistance is zeroed after the red and black pens are docked.
  • Page 65 Power battery Power battery 2-61 2.1.15 Check the Insulation of Power Battery 2.1.15.1 Check the Insulation of Power Battery Set the insulation meter voltage to 500VDC and check the insulation resistance. Connect the testing device red meter pen to the positive terminal.
  • Page 66 2-62 Power battery Power battery Connect the testing device red meter pen to the negative terminal. Connect the testing equipment black meter pen to the fixing bolt on the upper housing of the battery pack and check the data. The data measured by the above check should be ≥550MΩ, otherwise it needs to be recharged and rechecked.

  • Page 67: Technical Data

    Power battery Technical data 2-63 2.2 Technical data 2.2.1 Power battery technical data 2.2.1.1 Power Battery Specifications Specification Item Rated voltage 352V Capacity 113Ah Nominal voltage of energy storage device monobloc 3.67V Mass of energy storage unit 1.80±0.03kg Number of energy storage device units Total storage capacity of energy storage device 39.81 kWh Total mass of energy storage device...
  • Page 68 2-64 Technical data Power battery Torque range Fastener name Model Metric system (N·m) Fixing bolt connecting the low-voltage M4×10 2.5-3.5 harness and the battery pack lower tray Fixing bolt connecting the high-voltage control box and the battery pack lower M6×20 8-10 tray Fixed bolt connecting the high-voltage...
  • Page 69 Power battery Technical data 2-65 Torque range Fastener name Model Metric system (N·m) Fixing bolt connecting the explosion- proof valve (2) and the battery pack M5×16 lower tray Fixing bolt connecting the explosion- proof valve (1) and the battery pack M5×16 lower tray Fixing bolt connecting the battery pack...

  • Page 70: Servicing Tools

    2-66 Servicing tools Power battery 2.3 Servicing tools 2.3.1 Servicing tools 2.3.1.1 Specialized Tools List Insulating protective cap Insulating gloves Insulation meter FE27-0142a FE27-0141a FE27-0143a Goggles Insulating shoes Protective mask FE27-0144a FE27-0145a FE27-0146a Insulating clothing Insulating servicing tools Safety warning signs Stop High vlotage...

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