It is a Yale truck, 38VDC. I doubled checked the accelerator pot and it is all good. Linkages are good, condition is good, pin located good and the travel is good.
I also tried aKevin_K's suggestion of adjusting it so that the voltage was below 3.6VDC at start and it gave the same error code 07. I also tried it at 0.1VDC increments down all the way to 1.5VDC but still error code 07.
I have checked the wiring right through and it is all good. I suspect a faulty controller. When I decided to open up the controller and found that it has water droplets on the inside of the casing and looks like the boards have been water damaged. I have found a company in the US which repair these for only $275 but I have since been told that we are getting a new folklift so I won't be spending any more time on the broken Yale one.
Thanks again for your help
thats an AC truck right?
i had one a month ago do the same thing
its the accelerator pot
the pot has an arm with an oblong slot in it
the the pedal has a pin coming out of the left face to the left to engage the slot in the pot arm
make sure the pin from the pedal is in the slot not on the outside of the lever (the pot is spring loaded internally so it will move with the pedal even if its not in the correct spot)
this pin looked like it was driven in too far (apprentice day at the yale factory lol) and the pin jumped out of the slot and made the machine pop code 07
make sure that pin is flush on the right hand side of the pedal
if that looks good adjust the pot
if you do indeed find that this is the issue
then dont touch the pot
remove the pedal and drive the pin into its correct spot
(protruding to the left and flush to the right side of the pedal)
install the pedal and make sure that pin engages the slot
and that you set up the actuator tab for the start switch right
(its a lil trickier than it looks, lining up the tab + slot takes some finagling, i missed it twice 3rd time was a charm lol)
i also fount that it kinda chewed up the end of the pin a bit when it jumped out of its slot
if yours looks kinda messy just clean up the end of the pin with a file (the exposed end not the end in the pedal)
if you need a picture of it (from the manual) then click my screenname that brings up my profile and there you shall find my email lol
your digging in the right place mate. you need to adjust that pot so that tha start voltage is below 3.6 voltsdc. if it still doesn,t go check the wiring and connections from front to back