Genie Z-25/8, Z-20/8N, Z20/8 Operator's Manual

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: [e-mail]

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).

Operator's Manual First Edition • Sixth Printing

Controls

Platform Control Panel

1 Auxiliary power switch
2 Secondary boom up/down switch
3 Horn button
4 Jib boom up/down switch
5 Emergency Stop button
6 Jib boom rotate switch

8 Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 Part No. 41313

7 Battery charge indicator (option)
8 Not used
9 Proportional control handle for drive function and

thumb rocker for steer function
10 Drive speed select switch
11 Boom function speed controller

First Edition • Sixth Printing

Operator's Manual

CONTROLS

Ground Control Panel

1 Auxiliary power switch
2 Function enable switch
3 10A breaker for coil circuits
4 10A breaker for control circuits
5 Hour meter

Part No. 41313 Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 9

6 Key switch for platform/off/ground selection
7 Emergency Stop button
8 Jib boom rotate switch
9 Jib boom up/down switch
10 Boom up/down switch

Operator's Manual First Edition • Sixth Printing

Pre-operation Inspection

Fundamentals

It is the responsibility of the operator to perform a
Pre-operation Inspection and routine maintenance.

The Pre-operation Inspection is a visual inspection
performed by the operator prior to each work shift.

Do Not Operate Unless:

You learn and practice the principles of safe

machine operation contained in this operator's
manual.

1 Avoid hazardous situations.

2 Always perform a pre-operation

inspection.

Know and understand the pre-operation

inspection before going on to the next
section.

3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.

The inspection is designed to discover if anything
is apparently wrong with a machine before the
operator performs the function tests.

The Pre-operation inspection also serves to
determine if routine maintenance procedures are
required. Only routine maintenance items
specified in this manual may be performed by the
operator.

Refer to the list on the next page and check each
of the items and locations for modifications,
damage or loose or missing parts.

A damaged or modified machine must never be
used. If damage or any variation from factory
delivered condition is discovered, the machine
must be tagged and removed from service.

Repairs to the machine may only be made by a
qualified service technician, according to the
manufacturer's specifications. After repairs are
completed, the operator must perform a
pre-operation inspection again before going on to
the function tests.

10 Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 Part No. 41313

Scheduled maintenance inspections shall be
performed by qualified service technicians,
according to the manufacturer's specifications and
the requirements listed in the responsibilities
manual.

First Edition • Sixth Printing

Pre-operation Inspection

Operator's Manual

PRE-OPERATION INSPECTION

o Be sure that the operator's, safety and

responsibilities manuals are complete, legible
and in the storage container located on the
platform.

o Be sure that all decals are legible and in place.

See Decals section.

o Check for hydraulic oil leaks and proper oil level.

Add oil if needed. See Maintenance section.

o Check for battery fluid leaks and proper fluid

level. Add distilled water if needed. See
Maintenance section.

Check the following components or areas for
damage, modifications and improperly installed or
missing parts:

o Electrical components, wiring and electrical

cables

o Hydraulic power unit, tank, hoses,

fittings, cylinders and manifolds

o Drive motors
o Boom wear pads

o Be sure that all structural and other critical

components are present and all associated

fasteners and pins are in place and properly

tightened.
o Be sure that the chassis trays are in place,

latched and properly connected.

o Tires and wheels
o Limit switch, alarms and horn
o Nuts, bolts and other fasteners
o Platform entry mid-rail/gate
o Beacon and alarms (if equipped)
o Brake release components

Check entire machine for:

o Cracks in welds or structural components
o Dents or damage to machine

Part No. 41313 Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 11

Operator's Manual First Edition • Sixth Printing

Maintenance

Check the Hydraulic Oil Level

Maintaining the hydraulic oil at the proper level is
essential to machine operation. Improper hydraulic

Observe and Obey:

Only routine maintenance items specified in

this manual shall be performed by the operator.

oil levels can damage hydraulic components. Daily
checks allow the inspector to identify changes in
oil level that might indicate the presence of
hydraulic system problems.

Scheduled maintenance inspections shall be

completed by qualified service technicians,
according to the manufacturer's specifications
and the requirements specified in the
responsibilities manual.

Maintenance Symbols Legend

The following symbols have been
used in this manual to help
communicate the intent of the
instructions. When one or more of
the symbols appear at the
beginning of a maintenance
procedure, it conveys the meaning
below.

Indicates that tools will be required to
perform this procedure.

1 Be sure the boom is in the stowed position.
2 Check the hydraulic oil filler cap/dipstick,

located at the top of the hydraulic tank.

Result: The hydraulic oil level should be at the

FULL mark.

Hydraulic oil specifications

Hydraulic oil type Dexron equivalent

Indicates that new parts will be
required to perform this procedure.

12 Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 Part No. 41313

First Edition • Sixth Printing

Operator's Manual

MAINTENANCE

Check the Batteries

Proper battery condition is essential to good
engine performance and operational safety.
Improper fluid levels or damaged cables and
connections can result in engine component
damage and hazardous conditions.

Electrocution hazard. Contact with
hot or live circuits could result in
death or serious injury. Remove
all rings, watches and other
jewelry.

Bodily injury hazard. Batteries
contain acid. Avoid spilling or
contacting battery acid. Neutralize
battery acid spills with baking
soda and water.

Perform this test after fully
charging the batteries.

1 Put on protective clothing and eye wear.

Scheduled Maintenance

Maintenance performed quarterly, annually and
every two years must be completed by a person
trained and qualified to perform maintenance on this
machine according to the procedures found in the
service manual for this machine.

Machines that have been out of service for more
than three months must receive the quarterly
inspection before they are put back into service.

2 Be sure that the battery cable connections are

tight and free of corrosion.
3 Remove the battery vent caps.
4 Check the battery acid level. If needed,

replenish with distilled water to the bottom of

the battery fill tube. Do not overfill.
5 Install the vent caps.

Part No. 41313 Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 13

Operator's Manual First Edition • Sixth Printing

Function Tests

1 Select a test area that is firm, level and free of

obstruction.

2 Be sure both battery connectors are connected.

At the Ground Controls

3 Turn the key switch to ground control.

Do Not Operate Unless:

You learn and practice the principles of safe

machine operation contained in this operator's

manual.

1 Avoid hazardous situations.
2 Always perform a pre-operation

inspection.

3 Always perform function tests prior to

use.

Know and understand the function tests

before going on to the next section.

4 Inspect the work place.
5 Only use the machine as it was intended.

4 Pull out the red Emergency Stop button to

the on position.

Result: The beacon (if equipped) should flash.

Test Emergency Stop

5 Push in the red Emergency Stop button to the

off position.

Result: No ground or platform control functions

should operate.

6 Pull out the red Emergency Stop button to

the on position.

Test the Boom Functions

7 Do not hold the function enable switch to either

side. Attempt to activate each boom and
platform function toggle switch.

Fundamentals

The Function Tests are designed to discover any
malfunctions before the machine is put into
service. The operator must follow the step-by-step
instructions to test all machine functions.

A malfunctioning machine must never be used. If
malfunctions are discovered, the machine must be
tagged and removed from service. Repairs to the
machine may only be made by a qualified service
technician, according to the manufacturer's
specifications.

After repairs are completed, the operator must
perform a pre-operation inspection and function
tests again before putting the machine into service.

14 Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 Part No. 41313

Result: No boom or platform functions should

operate.

8 Hold the function enable switch to either side

and activate each boom and platform function
toggle switch.

Result: All boom and platform functions should

operate through a full cycle. The descent alarm
(if equipped) should sound while the boom is
lowering.

First Edition • Sixth Printing

Operator's Manual

FUNCTION TESTS

Test Auxiliary Controls

9 Turn the key switch to ground control.
10 Simultaneously hold the auxiliary power switch

on and activate each boom function toggle

switch.
Note: To conserve battery power, test each

function through a partial cycle.

Result: All boom functions should operate.

Test the Tilt Sensor

11 Pull out the platform red Emergency Stop button

to the on position.
12 Fully lower the platform.
13 Locate the tilt sensor on the chassis under the

boom.
14 Press down one side of

the tilt sensor and place

the tilt sensor test tool

under one of the posts.

Result: The alarm,

located in the platform,

should sound.
15 Raise the secondary boom.

Result: The secondary boom should stop raising

when the bottom of the platform is

approximately 6 feet / 1.8 m from the ground
16 Test all ground control functions.

Result: The up function should not operate. The

jib rotation function should not operate. The

down function should operate.
17 Fully lower the platform.
18 Turn the key switch to platform control. Do not

remove the tilt sensor test tool.

At the Platform Controls

Test the Tilt Sensor

19 Move the lift/drive select switch to the lift

position (if equipped).

20 Raise the secondary boom.

Result: The secondary boom should stop raising

when the bottom of the platform is
approximately 6 feet / 1.8 m from the ground.

21 Test all boom functions.

Result: The up function should not operate. The

jib rotation function should not operate. The
down function should operate.

22 Move the lift/drive select switch to the drive

position (if equipped).

23 Test the drive functions.

Result: The drive functions should not operate.

24 Move the lift/drive select switch to the lift

position (if equipped).

25 Lower the boom and remove the tilt sensor test

tool.

Test Emergency Stop

26 Push in the platform red Emergency Stop button

to the off position.

Result: No platform control functions should

operate.

Test the Horn

27 Pull out the red Emergency Stop button to the

on position.

28 Push the horn button.

Result: The horn should sound.

Part No. 41313 Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 15

Operator's Manual First Edition • Sixth Printing

FUNCTION TESTS

Test the Foot Switch

29 Move the lift/drive select switch to the

appropriate position (if equipped).
30 Do not press down the foot switch. Activate

each machine function.

Result: No machine functions should operate.

Test Machine Functions

31 Move the lift/drive select switch to the lift

position (if equipped).
32 Press down the foot switch.
33 Activate each machine function control handle

or toggle switch.

Result: All boom and platform functions should

operate through a full cycle.
Note: Control the speed of boom functions by

adjusting the boom function speed controller.
Platform, drive and steer functions are not affected
by the boom function speed controller.

Test the Steering

34 Move the lift/drive select switch to the drive

position (if equipped).
35 Press down the foot switch.
36 Depress the thumb rocker switch on top of the

drive control handle in the direction identified

by the blue triangle on the control panel.

37 Depress the thumb rocker switch in the direction

identified by the yellow triangle on the control
panel.

Result: The steer wheels should turn in the

direction that the yellow triangle points on the
control panel.

Test Drive and Braking

38 Press down the foot switch.
39 Slowly move the drive control handle in the

direction indicated by the blue arrow on the
control panel until the machine begins to move,
then return the handle to the center position.

Result: The machine should move in the

direction that the blue arrow points on the drive
chassis, then come to an abrupt stop.

40 Slowly move the drive control handle in the

direction indicated by the yellow arrow on the
control panel until the machine begins to move,
then return the handle to the center position.

Result: The machine should move in the

direction that the yellow arrow points on the
drive chassis, then come to an abrupt stop.

Note: The brakes must be able to hold the machine
on any slope it is able to climb.

Result: The steer wheels should turn in the

direction that the blue triangle points on the

control panel.

16 Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 Part No. 41313

First Edition • Sixth Printing

Operator's Manual

FUNCTION TESTS

Test Limited Drive Speed

41 Move the lift/drive select switch to the lift

position (if equipped).
42 Press down the foot switch.
43 Fully lower the platform.
44 Raise the secondary boom until the platform

clears the counterweights.
45 Move the lift/drive select switch to the drive

position (if equipped).
46 Slowly move the drive control handle to the full

drive position.

Result: The maximum achievable drive speed

with the secondary boom raised should not

exceed 1 foot / 30 cm per second.
If the drive speed with the secondary boom raised

exceeds 1 foot / 30 cm per second, immediately
tag and remove the machine from service.

Test Auxiliary Controls

47 Move the lift/drive select switch to the

appropriate position (if equipped).
48 Press down the foot switch.
49 Simultaneously hold the auxiliary power switch

on and activate each function control handle or

toggle switch.
Note: To conserve battery power, test each

function through a partial cycle.

Result: All boom, steer and drive functions

should operate.

Test the Lift/Drive Select Function
(CE models)

Machines with lift/drive select switch:

50 Move the lift/drive select switch to the lift

position.
51 Press down the foot switch.
52 Move the drive control handle off center.

Result: No drive functions should operate.

53 Activate each boom function toggle switch.

Result: All boom functions should operate.

54 Move the lift/drive select switch to the drive

position.
55 Press down the foot switch.
56 Activate each boom function toggle switch.

Result: No boom functions should operate.

57 Move the drive control handle off center.

Result: The drive functions should operate.

58 Repair any malfunctions before operating the

machine.

Machines without lift/drive select switch:

59 Press down the foot switch.
60 Move the drive control handle off center and

activate a boom function toggle switch.

Result: No boom functions should operate. The

machine will move in the direction indicated on

the control panel.

Part No. 41313 Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 17

61 Repair any malfunctions before operating the

machine.

Operator's Manual First Edition • Sixth Printing

Workplace Inspection

Workplace Inspection

Be aware of and avoid the following hazardous
situations:

· drop-offs or holes

· bumps, floor obstructions or debris

· overhead obstructions and high voltage

Do Not Operate Unless:

conductors

You learn and practice the principles of safe

machine operation contained in this operator's

manual.
1 Avoid hazardous situations.
2 Always perform a pre-operation

inspection.

3 Always perform function tests prior to use.

4 Inspect the workplace.
Know and understand the workplace

inspection before going on to the next

section.

5 Only use the machine as it was intended.

Fundamentals

The Workplace Inspection helps the operator
determine if the workplace is suitable for safe
machine operation. It should be performed by the
operator prior to moving the machine to the
workplace.

· hazardous locations

· inadequate surface support to withstand all load

forces imposed by the machine

· wind and weather conditions

· the presence of unauthorized personnel

· other possible unsafe conditions

It is the operator's responsibility to read and
remember the workplace hazards, then watch for
and avoid them while moving, setting up and
operating the machine.

18 Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 Part No. 41313

First Edition • Sixth Printing

Do Not Operate Unless:

You learn and practice the principles of safe

machine operation contained in this operator's

manual.
1 Avoid hazardous situations.
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.

Operator's Manual

Operating Instructions

Fundamentals

The Operating Instructions section provides
instructions for each aspect of machine operation.
It is the operator's responsibility to follow all the
safety rules and instructions in the operator's,
safety and responsibilities manuals.

Using the machine for anything other than lifting
personnel and tools to an aerial work site is unsafe
and dangerous.

Only trained and authorized personnel should be
permitted to operate a machine. If more than one
operator is expected to use a machine at different
times in the same work shift, they must all be
qualified operators and are all expected to follow all
safety rules and instructions in the operator's,
safety and responsibilities manuals. That means
every new operator should perform a pre-operation
inspection, function tests, and a work place
inspection before using the machine.

Emergency Stop

Push in the red Emergency Stop button to the off
position to stop all ground and platform control
functions.

Repair any function that operates from the ground
or platform controls when the Emergency Stop
button at the ground controls is pushed in.

Repair any function that operates from the
platform when the Emergency Stop button at the
platform controls is pushed in.

Selecting and operating the ground controls will
override the platform Emergency Stop button.

Part No. 41313 Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 19

Operator's Manual First Edition • Sixth Printing

OPERATING INSTRUCTIONS

Auxiliary Controls

Use auxiliary power if the primary power source
fails.

1 Turn the key switch to ground or platform

control.

2 Pull out the red Emergency Stop button to the

on position.

3 Be sure that both battery packs are connected

before operating the machine.

4 Press down the foot switch when operating the

auxiliary controls from the platform.

5 Move the lift/drive select switch to the

appropriate position (if equipped) when operating
the auxiliary controls from the platform.

6 Simultaneously hold the auxiliary power switch

on and activate the desired function.

Note: The boom, steer and drive functions will
operate with auxiliary power.

Operation from Ground

1 Be sure that both battery packs are connected

before operating the machine.
2 Turn the key switch to ground control.
3 Pull out the red Emergency Stop button to

the on position.

To Position Platform

Operation from Platform

1 Be sure that both battery packs are connected

before operating the machine.
2 Turn the key switch to platform control.
3 Pull out both ground and platform red

Emergency Stop buttons to the on position.

To Position Platform

1 Set the boom function speed controller to the

desired speed.
2 Move the lift/drive select switch to the lift

position (if equipped).
3 Press down the foot switch.
4 Move the appropriate toggle switch according to

the markings on the control panel.
Note: Platform, drive and steer functions are not

affected by the boom function speed controller.

To Steer

1 Move the lift/drive select switch to the drive

position (if equipped).
2 Press down the foot switch.
3 Turn the steering wheels with the thumb rocker

switch located on top of the drive control

handle.
Use the color-coded direction arrows on the

platform controls and the chassis to identify the
direction the wheels will turn.

1 Hold the function enable switch to either side.
2 Move the appropriate toggle switch according

to markings on the control panel.

Note: Drive and steer functions and boom function
speed control are not available from the ground
controls.

20 Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 Part No. 41313

First Edition • Sixth Printing

Operator's Manual

OPERATING INSTRUCTIONS

To Drive

1 Move the lift/drive select switch to the drive

position (if equipped).
2 Press down the foot switch.
3 Increase speed: Slowly move the drive control

handle off center.

Decrease speed: Slowly move the drive control

handle toward center.

Stop: Return the drive control handle to center or

release the foot switch.
Use the color-coded direction arrows on the

platform controls and the chassis to identify the
direction the machine will travel.

Machine travel speed is restricted when the
secondary boom is raised.

Battery condition will affect machine performance.

Drive Speed Select

· Machine on incline symbol: Low range operation

for inclines

After Each Use

1 Select a safe parking location—firm level

surface, clear of obstruction and traffic.
2 Lower the boom to the stowed position.
3 Turn the key switch to the off position and

remove the key to secure from unauthorized

use.
4 Chock the wheels.
5 Charge the batteries.

· Machine on level surface symbol: High range
operation for maximum drive speed

Low Voltage Interrupt

Light on indicates that the battery charge is almost
gone and the boom up function will not work. The
batteries need to be charged.

Part No. 41313 Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 21

Operator's Manual First Edition • Sixth Printing

OPERATING INSTRUCTIONS

Dry Battery Filling and
Charging Instructions

1 Remove the battery vent caps and permanently

remove the plastic seal from the battery vent
openings.

Battery and Charger Instructions
Observe and Obey:

Do not use an external charger or booster

battery.

Charge the battery in a well-ventilated area.

Use proper AC input voltage for charging as

indicated on the charger.

Use only Genie authorized battery and charger.

To Charge Battery

1 Be sure the batteries are connected before

charging the batteries.

2 Open the battery compartment. The

compartment should remain open for the entire
charging cycle.

3 Remove the battery vent caps and check the

battery acid level. If necessary, add only
enough distilled water to cover the plates. Do
not overfill prior to the charge cycle.

2 Fill each cell with battery acid (electrolyte) until

the level is sufficient to cover the plates.

Do not fill to maximum level until the battery
charge cycle is complete. Overfilling can cause the
battery acid to overflow during charging.
Neutralize battery acid spills with baking soda and
water.

3 Install the battery vent caps.
4 Charge the battery.
5 Check the battery acid level when the charging

cycle is complete. Replenish with distilled water
to the bottom of the fill tube. Do not overfill.

4 Replace the battery vent caps.
5 Connect the battery charger to a grounded AC

circuit.

6 Turn the battery charger on.
7 The charger will indicate when the battery is fully

charged.

8 Check the battery acid level when the charging

cycle is complete. Replenish with distilled water
to the bottom of the fill tube. Do not overfill.

22 Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 Part No. 41313

First Edition • Sixth Printing

Observe and Obey:

Common sense and planning must be applied to

control the movement of the machine when
lifting it with a crane or forklift.

The transport vehicle must be parked on a level

surface.

The transport vehicle must be secured to

prevent rolling while the machine is being
loaded.

Be sure the vehicle capacity, loading surfaces

and chains or straps are sufficient to withstand
the machine weight. See the serial plate for the
machine weight.

The machine must be on a level surface or

secured before releasing the brakes.

Operator's Manual

Transport Instructions

Brake Release Operation

1 Chock the wheels to prevent the machine from

rolling.

2 Be sure the winch line is properly secured to

the drive chassis tie points and the path is clear
of all obstructions.

3 Turn the brake release knob counterclockwise to

open the brake valve.

4 Pump the brake release pump knob

approximately 20 times until resistance is felt.

The brakes are now released.
After the machine is loaded:
1 Chock the wheels to prevent the machine from

rolling.
2 Turn the brake release knob clockwise to reset

the brakes.

Due to the low ground clearance of the machine,
the maximum break-over angle for loading and
unloading is shown for each model.

Z-20/8N

Securing to Truck or Trailer for
Transit

Always chock the machine wheels in preparation
for transport.

Use the tie points on the drive chassis for
anchoring down to the transport surface.

Use the lower platform mount between the boom
end and the platform to secure the boom from side­to-side movement. Do not use excessive downward
force when securing the boom section.

Use chains or straps of ample load capacity.

Turn the key switch to the off position and remove
the key before transporting.

Inspect the entire machine for loose or unsecured
items.

Part No. 41313 Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 23

Z-20/8 & Z-25/8

Operator's Manual First Edition • Sixth Printing

Decals

PlatformDecal Inspection

Use the pictures on this and the next page to verify
that all decals are legible and in place.

Below is a numerical list with quantities and
descriptions.

Part No. Description Quantity

27564 Danger - Electrocution Hazard 2
28157 Label - Dexron 1
28161 Warning - Crush Hand 3
28164 Notice - Hazardous Materials 1
28165 Notice - Foot Switch 1
28171 Label - No Smoking 1
28174 Power to Platform, 230V 2
28175 Caution - Compartment Access 1
28176 Notice - Missing Manuals 1
28177 Warning - Platform Rotate 2
28181 Warning - No Step Or Ride 1
28235 Power to Platform, 115V 2
28236 Warning - Failure To Read . . . 1
28372 Caution - Component Damage 2
31060 Danger - Do Not Alter Limit Switch 1
31508 Notice - Power to Battery Charger 1
31785 Notice - Battery Charger Operating

Instructions 2
31788 Danger - Battery/Charger Safety 2
32700 Danger - General Safety Rules 2
37051 Notice - Maximum Side Force, 150 lbs 1
37052 Notice - Max Load 500 lbs, Z-20/8 & Z-25/8 1
40434 Label - Lanyard Anchorage 2
41323 Platform Control Panel 1
41324 Ground Control Panel 1
43653 Notice - Operating Instructions - Ground 1
43658 Label - Power to Charger, 230V 1

Part No. Description Quantity

44220 Notice - Brake Release Instructions 1
44238 Danger - Tip-over (batteries) 2
44239 Notice - Tire Specifications 4
44237 Battery Connection Diagram 2
44240 Notice - Operating Instructions - Platform 1
44242 Label - 2 Directional Arrows 2
44248 Notice - Max Load 440 lbs, Z-20/8N 1
44737 Danger - Tipover, Trays 2
44768 Danger - Tilt Alarm 1
44980 Label - Power to Charger, 115V 1
44981 Airline to Platform 2
44983 Notice - Max Load 400 lbs, Z-20/8N 1
44986 Notice - Max Manual Force 90 lbs 1
46305 Warning - Crushing Hazard 2
52969 Cosmetic - Genie Boom 1
62935 Cosmetic - Genie Z-20/8 2
62936 Cosmetic - Genie Z-20/8N 2
62937 Cosmetic - Genie Z-25/8 2
72173 Platform Control Panel 1
72174 Ground Control Panel 1

24 Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 Part No. 41313

First Edition • Sixth Printing

Operator's Manual

DECALS

Part No. 41313 Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 25

Shading indicates
decal is hidden
from view, i.e.
under covers

Operator's Manual First Edition • Sixth Printing

Specifications

Z-20/8N

Height, working maximum 26 ft 7.9 m

Height, platform maximum 20 ft 6.1 m

Height, stowed maximum 6 ft 7 in 2.01 m

Horizontal reach maximum 8 ft 8 in 2.6 m

Width 32 in 81.3 cm

Length, stowed 12 ft 4 in 3.76 m

Maximum load capacity
ANSI & CSA 400 lbs 181 kg
CE 440 lbs 200 kg

Wheelbase 5 ft 4 in 1.63 m

Turning radius (outside) 4 ft 9 in 1.4 m

Turning radius (inside) 10 in 25.4 cm

Ground clearance 1.625 in 4.1 cm

Jib boom rotation (degrees) 180°

Power source 8 6V 255AH batteries

Drive speeds (maximum)

Boom stowed 2.6 mph 4.2 km/h

40 ft/10.5 sec 12.2 m/10.5 sec

Boom 0.6 mph 1.0 km/h
raised or extended 40 ft/40 sec 12.2 m/40 sec

Gradeability (boom stowed) 18%

Controls 24V DC proportional

Platform dimensions, 31 x 40 in
(length x width) 78.7 cm x 1.01 m

AC outlet in platform standard

Hydraulic pressure (maximum) 3500 psi
(boom functions) 241 bar

Weight See Serial Plate
(Machine weights vary with option configurations)

Airborne noise emissions 67 dB
Maximum sound level at normal operating workstations
(A-weighted)

Z-20/8

Height, working maximum 26 ft 7.9 m

Height, platform maximum 20 ft 6.1 m

Height, stowed maximum 6 ft 7 in 2.01 m

Horizontal reach maximum 7 ft 11 in 2.4 m

Width 46 in 2.9 cm

Length, stowed 11 ft 9 in 3.58 m

Maximum load capacity 500 lbs 227 kg

Wheelbase 5 ft 4 in 1.63 m

Turning radius (outside) 6 ft 4 in 1.9 m

Turning radius (inside) 11 in 28 cm

Ground clearance 2 in 5 cm

Jib boom rotation (degrees) 180°

Power source 8 6V 255AH batteries

Drive speeds (maximum)

Boom stowed 2.7 mph 4.3 km/h

40 ft/10.1 sec 12.2 m/10.1 sec

Boom 0.6 mph 1.0 km/h
raised or extended 40 ft/40 sec 12.2 m/40 sec

Gradeability (boom stowed) 20%

Controls 24V DC proportional

Platform dimensions, 46 x 30 in
(length x width) 2.9 m x 76 cm

AC outlet in platform standard

Hydraulic pressure (maximum) 3500 psi
(boom functions) 241 bar

Weight See Serial Plate
(Machine weights vary with option configurations)

Airborne noise emissions 67 dB
Maximum sound level at normal operating workstations
(A-weighted)

Continuous improvement of our products is a Genie
policy. Product specifications are subject to change
without notice or obligation.

26 Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 Part No. 41313

First Edition • Sixth Printing

Z-25/8

Height, working maximum 31 ft 9.5 m

Height, platform maximum 25 ft 7.6 m

Height, stowed maximum 6 ft 7 in 2.01 m

Horizontal reach maximum 7 ft 11 in 2.4 m

Width 46 in 2.9 m

Length, stowed 16 ft 4.9 m

Maximum load capacity 500 lbs 227 kg

Wheelbase 5 ft 4 in 1.6 m

Turning radius (outside) 6 ft 4 in 1.9 m

Turning radius (inside) 11 in 28 cm

Ground clearance 2 in 5 cm

Operator's Manual

SPECIFICATIONS

Jib boom rotation (degrees) 180°

Power source 8 6V 255AH batteries

Tail swing 18 in 45.7 cm

Nose swing 4 ft 10 in 1.5 m

Drive speeds (maximum)

Boom stowed 2.7 mph 4.3 km/h

40 ft/10.1 sec 12.2 m/10.1 sec

Boom 0.6 mph 1.0 km/h
raised or extended 40 ft/40 sec 12.2 m/40 sec

Gradeability (boom stowed) 20%

Controls 24V DC proportional

Platform dimensions, 46 x 30 in
(length x width) 2.9 m x 76 cm

AC outlet in platform standard

Hydraulic pressure (maximum) 3500 psi
(boom functions) 241 bar

Weight See Serial Plate
(Machine weights vary with option configurations)

Airborne noise emissions 67 dB
Maximum sound level at normal operating workstations
(A-weighted)

Part No. 41313 Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 27

Genie North America

Phone [phone]

Toll Free USA and Canada

Genie Australia Pty Ltd.

800.536.1800

Fax [phone]

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