Forklift Plugging

forklift plugging

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Forklift plugging is common practice that should be encouraged for its benefit of reducing brake wear.

What is forklift plugging?

Plugging, also called regenerative braking, regen or switch-back, occurs when an operator traveling in one direction uses the directional selector to switch to the opposite direction. The motor control circuit, motor and forklift battery combine to slow and then smoothly accelerate the forklift in the newly selected direction.

Taking its cue from the accelerator pedal, the motor control circuit determines how fast the directional change occurs. If the operator’s foot is down on the accelerator, an aggressive, faster switch happens; however, if the operator removes his foot off the pedal, the switch-back slows a bit and becomes less aggressive.

Forklift Plugging Adjustments

Operators should be trained that the position of the accelerator pedal determines the quickness of forklift plugging. Similar to forklift speed, plugging aggressiveness can be adjusted or turned off by a trained forklift technician. The stability of your product, load, operator experience or concern about forklift brake maintenance costs may influence your decision to make an adjustment.

ProLift is your material handling partner for Toyota electric forklifts. Ask us your question about forklift plugging, or explore the Toyota Forklift product line!