How to fit a new Drive Controller (missing images and prod dev to check)
Table of Contents
Whether you’re replacing a failed unit or upgrading to the latest 2025 electronics, fitting a new drive controller is a straightforward job. Follow this step-by-step guide to safely install your new unit and get your Power Porter back on the bank.
Step 1 – Power Down and Remove the Wheel (Optional)
Start by switching the barrow off and removing the battery.
Since the drive controller sits beneath the battery tray, you may find it easier to remove the front wheel for better access. To do this:
- Disconnect the centre cable from the wheel unit.
- Remove the four thumbscrews holding the wheel assembly in place.
While the job can be done with the wheel in place, removing it gives you more working room.
Step 2 – Remove the Old Drive Controller
Look at the opposite side of the wheel unit to the battery tray—you’ll see the cylindrical motor unit. On top of it sits a rubber seal protecting the terminals. Peel this cover up and off to reveal two terminals (one black, one orange).
- Pull downward on the cables to disconnect them. Don’t worry about mixing them up—the terminals are colour-coded with matching rivets.
- Next, gently pull the cables back through the crossbar connecting the wheel forks. Tip: Tie a piece of string or line to the connectors before pulling them through. This makes it easier to guide the new cables back through later.
Now, remove the controller unit from the frame. You’ll find two screws securing it—these may be Phillips or Allen bolts depending on the age of your barrow. Undo these, and the unit will drop away from the tray.
Step 3 – Fit the New Drive Controller
Position the new unit beneath the battery tray, ensuring the cable exits facing towards the rear of the barrow.
- Line up the two mounting holes and loosely insert the bolts by hand to avoid cross-threading.
- Once aligned, tighten them fully using your screwdriver or Allen key.
Now, feed the orange and black cables through the crossbar:
- Either poke them through carefully or use the string you left inside the tube to pull them through.
- Reconnect the cables to the motor terminals—black to black, orange to orange. Note: If the cables are accidentally swapped, the motor will run in reverse—it won’t cause any damage.
Re-seat the rubber cover over the motor terminals to protect them from moisture and debris.
Step 4 – Reconnect and Test
If you removed the wheel unit, reattach it now using the four thumbscrews, then reconnect the central cable to the new drive controller.
Insert the battery, power on the barrow, and give it a quick test. Check forward and reverse functionality to ensure everything is wired correctly.
That’s it—your new drive controller is now installed and ready for action. If you run into any issues during fitting, feel free to contact our support team for help.
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