Operator’s Manual
with Maintenance Information
First Edition
Sixth Printing
Part No. 41313
Operator's Manual First Edition • Sixth Printing
Important
Read, understand and obey these safety rules and
operating instructions before operating this machine.
Only trained and authorized personnel shall be
permitted to operate this machine. This manual should
be considered a permanent part of your machine and
should remain with the machine at all times. If you
have any questions, call Genie Industries.
Contents
Page
Safety ........................................................................ 1
Controls ..................................................................... 8
Pre-operation Inspection ........................................... 10
Maintenance ............................................................. 12
Function Tests .......................................................... 14
Work Place Inspection .............................................. 18
Operating Instructions ............................................... 19
Transport Instructions ............................................... 23
Decals ...................................................................... 24
Specifications ........................................................... 26
Contact us:
Internet: http://www.genielift.com
e-mail: techpub@genieind.com
Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 Part No. 41313
Copyright © 1997 by Genie Industries
First Edition: Sixth Printing, May 2002
Genie and "Z" are registered trademarks of
Genie Industries in the USA and many other
countries.
These machines comply with
ANSI/SIA 92.5-1992.
Printed on recycled paper
Printed in U.S.A.
First Edition • Sixth Printing
Operator's Manual
Safety Rules
Danger
Failure to obey the instructions and
safety rules in this manual will
result in death or serious injury.
Do Not Operate Unless:
You learn and practice the principles of safe
machine operation contained in this operator's
manual.
1 Avoid hazardous situations.
Know and understand the safety rules before
going on to the next section.
2 Always perform a pre-operation inspection.
3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
You read, understand and obey:
Manufacturer's instructions and safety
rules—safety and operator's manuals
and machine decals
employer's safety rules and worksite
regulations
applicable governmental regulations
You are properly trained to safely operate the
machine.
Part No. 41313 Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 1
Operator's Manual First Edition • Sixth Printing
SAFETY RULES
Electrocution Hazards
This machine is not electrically insulated and will
not provide protection from contact with or
proximity to electrical current.
Maintain safe distances from electrical power lines
and apparatus in accordance with applicable
governmental regulations and the following chart.
Voltage Minimum Safe
Phase to Phase Approach Distance
Feet Meters
0 to 300V Avoid Contact
Tip-over Hazards
Occupants and equipment shall not exceed the
maximum platform capacity.
Maximum platform capacity - Z-20/8N 400 lbs
- ANSI & CSA 181 kg
Maximum platform capacity - Z-20/8N 440 lbs
- CE 200 kg
Maximum platform capacity - Z-20/8 & Z-25/8
- ANSI, CSA & CE 500 lbs
227 kg
Maximum occupants 2
300V to 50KV 10 3.05
50KV to 200KV 15 4.60
200KV to 350KV 20 6.10
350KV to 500KV 25 7.62
500KV to 750KV 35 10.67
750KV to 1000KV 45 13.72
Allow for platform movement, electrical line sway
or sag and beware of strong or gusty winds.
Keep away from the machine if it contacts
energized power lines. Personnel on the ground or
in the platform must not touch or operate the
machine until energized power lines are shut off.
Do not operate the machine during lightning or
storms.
Do not use the machine as a ground for welding.
Do not raise the boom unless the machine is on a
firm, level surface.
2 Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 Part No. 41313
First Edition • Sixth Printing
Operator's Manual
SAFETY RULES
Do not depend on the tilt alarm as a level indicator.
The tilt alarm sounds in the platform only when the
machine is on a severe slope.
If the tilt alarm sounds:
The jib boom will not rotate and the platform will not
raise. Move the machine to a firm, level surface. If
the tilt alarm sounds when the platform is raised,
use extreme caution to lower the platform. The jib
boom will rotate and the platform will raise when the
machine is level and the tilt alarm is off.
Do not alter or disable the limit switch.
Do not drive over 0.6 mph / 1 km/h with the
secondary boom raised.
Do not operate the machine in strong or gusty
winds. Do not increase the surface area of the
platform or the load. Increasing the area exposed to
the wind will decrease machine stability.
Do not push off or pull
toward any object outside
of the platform.
Maximum allowable
side force - ANSI & CSA
150 lbs / 667 N
Maximum allowable
side force - CE
90 lbs / 400 N
Do not alter or disable machine components that in
any way affect safety and stability.
Do not replace items critical to machine stability
with items of different weight or specification.
Do not modify or alter an aerial work platform.
Mounting attachments for holding tools or other
materials onto the platform, toeboards or guard rail
system can increase the weight in the platform and
the surface area of the platform or the load.
Do not place or attach overhanging loads to any
part of this machine.
Use extreme care and slow speeds while driving
the machine in a stowed position across uneven
terrain, debris, unstable or slippery surfaces and
near holes and drop-offs.
Do not drive the machine on or near uneven terrain,
unstable surfaces or other hazardous conditions
with the jib boom or the secondary boom raised.
Part No. 41313 Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 3
Do not place ladders or scaffolds in the platform or
against any part of this machine.
Do not use the machine on a moving or mobile
surface or vehicle.
Operator's Manual First Edition • Sixth Printing
SAFETY RULES
Be sure all tires are in good condition, castle nuts
are properly tightened and cotter pins are properly
installed.
Do not use batteries that weigh less than the
original equipment. Batteries are used as
counterweight and are critical to machine stability.
Each battery must weigh at least 65 lbs / 29.4 kg.
Each battery box including 4 batteries must weigh a
minimum of 340 lbs / 154.2 kg.
Do not use the machine as a crane.
Do not push the machine or other objects with the
boom.
Do not contact adjacent structures with the boom.
Do not tie the boom or platform to adjacent
structures.
Do not place loads outside the platform perimeter.
Do not operate the machine with the chassis trays
open.
Do not release the brakes with the manual brake
release unless the machine is on a firm, level
surface or secured.
Fall Hazards
Occupants must wear a
safety belt or harness and
comply with applicable
governmental regulations.
Attach lanyard to the anchor
provided in the platform.
Do not sit, stand or climb on the platform guard
rails. Maintain a firm footing on the platform floor at
all times.
Do not climb down from the platform when raised.
Keep the platform floor clear of debris.
Lower the platform entry mid-rail or close the entry
gate before operating.
4 Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 Part No. 41313
First Edition • Sixth Printing
Operator's Manual
SAFETY RULES
Collision Hazards
Be aware of limited
sight distance and
blind spots when
driving or operating.
Be aware of the platform position when rotating the
jib boom.
The machine must be on a level surface or secured
before releasing the brakes.
Check the work area for overhead obstructions or
other possible hazards.
Do not lower the platform unless the area below is
clear of personnel and obstructions.
Limit travel speed according to condition of ground
surface, congestion, slope, location of personnel,
and any other factors which may cause collision.
Do not operate a machine in the path of any crane
or moving overhead machinery unless the controls
of the crane have been locked out and/or
precautions have been taken to prevent any
potential collision.
Component Damage Hazard
Be aware of crushing hazards when grasping the
platform guard rail.
It is recommended that operators wear an
approved hard hat when operating the machine.
Observe and use the color-coded direction arrows
on the platform controls and drive chassis for drive
and steer functions.
Do not use the machine as a ground for welding.
Bodily Injury Hazard
Do not operate the machine with a hydraulic oil or
air leak. An air leak or hydraulic oil leak can
penetrate and/or burn skin.
Part No. 41313 Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 5
Operator's Manual First Edition • Sixth Printing
SAFETY RULES
Damaged Machine Hazards
Do not use a damaged or malfunctioning machine.
Conduct a thorough pre-operation inspection of the
machine and test all functions before each work
shift. Immediately tag and remove from service a
damaged or malfunctioning machine.
Be sure all maintenance has been performed as
specified in this manual and the
Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8
Service Manual.
Be sure all decals are in place and legible.
Be sure the operator’s, safety and responsibilities
manuals are complete, legible and in the storage
container located on the platform.
Decal Legend
Genie product decals use symbols, color coding
and signal words to identify the following:
Safety alert symbol—used to alert
personnel to potential personal injury
hazards. Obey all safety messages that
follow this symbol to avoid possible
injury or death.
Red—used to indicate the
presence of an imminently
hazardous situation which, if not
avoided, will result in death or
serious injury.
Orange—used to indicate the
presence of a potentially
hazardous situation which, if not
avoided, could result in death or
serious injury.
Yellow with safety alert symbol—
used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause
minor or moderate injury.
Yellow without safety alert
symbol—used to indicate the
presence of a potentially
hazardous situation which, if not
avoided, may result in property
damage.
Green—used to indicate operation
or maintenance information.
6 Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 Part No. 41313
First Edition • Sixth Printing
Operator's Manual
SAFETY RULES
Battery Safety
Burn Hazards
Batteries contain acid. Always wear protective
clothing and eyewear when working with batteries.
Avoid spilling or contacting battery acid. Neutralize
battery acid spills with baking soda and water.
Do not expose the batteries or the charger to
water or rain.
Explosion Hazards
Keep sparks, flames
and lighted tobacco
away from batteries.
Batteries emit an
explosive gas.
Component Damage Hazards
Do not use any battery charger greater than 48V to
charge the batteries.
Disconnect the battery pack plug before removing
the battery pack.
Electrocution Hazards
Connect the battery charger to
a grounded, AC 3-wire
electrical outlet only.
Inspect daily for damaged cord,
cables and wires. Replace
damaged items before
operating.
Avoid electrical shock from contact with battery
terminals. Remove all rings, watches and other
jewelry.
Tip-over Hazard
Do not use batteries that weigh less than the
original equipment. Batteries are used as
counterweight and are critical to machine stability.
Each battery must weigh at least 65 lbs / 29.4 kg.
Each battery box including 4 batteries must weigh a
minimum of 340 lbs / 154.2 kg.
The battery tray should
remain open during the
entire charging cycle.
Do not contact the
battery terminals or the
cable clamps with tools
that may cause sparks.
Part No. 41313 Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 7
Lifting Hazard
Use a forklift to remove or install the battery
pack(s).
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