Power Porter Trouble Shooting (missing images and prod dev to check)

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Table of Contents

Power Porter Troubleshooting Guide

If your Power Porter isn’t working, don’t worry—many issues can be resolved with a few simple checks. Use this guide to go through each component step by step. If you’re still having problems after following the instructions below, feel free to reach out to our support team and we’ll be happy to help further.

Step 1 – Check Your Control Connections

Start by ensuring all cables are securely connected:

Handlebar Connection: Locate the connector that links the hand controller to the centre cable. Make sure it’s properly seated.
Wheel Unit Connection: Next, follow the centre cable to the front of the barrow. Ensure the connection to the wheel unit is fully plugged in.

Loose plugs are a common culprit—secure connections are essential for everything to function.

Step 2 – Check Battery Connections

Locate the black and orange connector that links the wheel unit to the battery wiring. Make sure it’s connected properly and not partially loose.
Open the battery bag and inspect the terminals. Ensure the spade connectors are firmly pushed onto the battery terminals.
Double-check the wiring layout matches our recommended configuration. (see wiring diagram below)

Thermal Overload Protector:

Stuck to the battery is a thermal overload reset switch. If this has tripped, the barrow won’t operate.
Press the button—if it feels firm and doesn’t click, it’s already engaged. If it pops in, the system was previously shut off due to overheating.
Overheating can occur if the batteries are left in direct sunlight or overworked on rough terrain—avoid where possible.

Battery Condition:

Inspect your batteries for swelling, wrinkling, or damage.
Any leakage or visible signs of impact could indicate a faulty battery, which should be disposed of and replaced immediately.

Step 3 – Check the Wheel Unit

Clutch Check (If fitted):

Ensure your clutch unit is disengaged if your model includes one. If it’s engaged, the drive won’t operate.
Need help with clutch operation? [Read our clutch operation guide here.]

Axle Clip:

Look for the large R-clip located on the axle.
If this clip is missing, the drive won’t be engaged, and the motor can’t move the wheel.

Motor Connections:

Peel back the rubber sock from the top of the motor unit to inspect the terminals.
Ensure the orange wire connects to the orange rivet, and the black wire to the black rivet.
Check for corrosion or loose connectors. Clean and reattach if necessary.
Once complete, refit the rubber sock for protection.

Step 4 – Hand Controller Checks

Inspect the rubber covers on the direction selector and green go button for signs of moisture.
- Moisture inside the unit can affect the internal PCB, causing erratic or unresponsive behaviour.
Check the speed dial is secure. Use a small Allen key to tighten the set screw on the side of the dial.
- If the dial is loose, turning it won’t affect speed. Be gentle—it’s plastic and can be damaged with excessive force.

Step 5 – Check Battery Voltage (Optional)

If you have a multimeter:

Test the voltage of each battery individually by placing the probes on the positive and negative terminals.
A healthy, fully charged 12V battery should read around 12–13 volts.
Significantly lower readings may indicate a faulty battery, especially if one battery is much lower than the other.
It’s important to test each battery individually so only touch the terminals of the same battery instead of across the two

⚠️ This is a basic check and doesn’t provide a full performance analysis. At Carp Porter HQ, we use advanced diagnostic tools to test batteries under load. If in doubt, contact us—we’re happy to help assess your setup.

Still Not Working?

If you’ve followed all of the steps above and your Power Porter is still not functioning properly, don’t panic.

Our customer service team is here to help. Reach out with a description of the issue and what you’ve checked so far, and we’ll guide you through the next steps—whether it’s a repair, replacement, or further diagnostics.