Xantrex Powerpack 600 HD Battery Replacement


This was a great portable power pack back in its day.  I used it many times to start other people's vehicles, supply power during hurricane related outages, and even used it at work to power test equipment in the field.  This was the predecessor to the Jackery type of power packs now available.  I've had this portable power pack more than 7 years.  This is the second time I've replaced the battery.  It lived a hard life in the back of my truck, with little more than a rain cover over it.  I did keep it charged, but think corrosion on a battery terminal cut its life short.  I bought a replacement on Amazon..  There are quite a few screws to get it apart, but it's a fairly straightforward job.

This product is now discontinued, but there are a number of them that are still going.  The batteries only last a few years, but are fairly easy to replace.  The plastic case eventually started breaking on mine, which is why I finally discarded it when the battery died for the final time.  I share this information for those who still have theirs in service, and want to replace the battery.



Remove all the hex head screws in the orange outer frame, on both sides.

Once both halves of the orange frame are removed, a number of phillips head screws exposed.  Remove all those too.  The only screws that didn't need to be removed were the feet.  Learned that after the fact.

It pull apart easily, and the large battery is easy to get to.  Other than the electrical connections, nothing else needs to be removed to pull the battery.

Think this was the culprit.  The green/yellow ground wire had rotted off ther terminal.

A new ring terminal was installed.

The terminals on the cables were cleaned with a Dremel moto-tool and a wire brush.  The thin foam padding was pulled from the old battery, a little spray adhesive applied, then adhered to the front/back of the new battery.  It was then set into place.  All the terminals were connected using new hardware that came with the replacement battery.

I had charged the battery prior to installation but verified all the functions of the power pack, including the inverter, radio, etc.

All cleaned up and ready for several years more use.


These are the products I used for this project, or are recommended:

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Last updated 02/02/22    All rights reserved.