Operator’s Manual First Edition

Sixth Printing
Part No. 41313
with Maintenance Information
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

Copyright © 1997 by Genie Industries

Contact us:
First Edition: Sixth Printing, May 2002
Internet: http://www.genielift.com
Genie and "Z" are registered trademarks of
e-mail: techpub@genieind.com 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.

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

This machine is not electrically insulated and will Occupants and equipment shall not exceed the
not provide protection from contact with or maximum platform capacity.
proximity to electrical current.
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

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

300V to 50KV 10 3.05

50KV to 200KV 15 4.60

Do not raise the boom unless the machine is on a
200KV to 350KV 20 6.10
firm, level surface.
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.

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SAFETY RULES

Do not depend on the tilt alarm as a level indicator. Do not push off or pull
The tilt alarm sounds in the platform only when the toward any object outside
machine is on a severe slope. of the platform.
If the tilt alarm sounds: Maximum allowable
The jib boom will not rotate and the platform will not side force - ANSI & CSA
raise. Move the machine to a firm, level surface. If 150 lbs / 667 N
the tilt alarm sounds when the platform is raised,
use extreme caution to lower the platform. The jib Maximum allowable
boom will rotate and the platform will raise when the side force - CE
90 lbs / 400 N
machine is level and the tilt alarm is off.

Do not alter or disable the limit switch.

Do not alter or disable machine components that in
Do not drive over 0.6 mph / 1 km/h with the any way affect safety and stability.
secondary boom raised.
Do not replace items critical to machine stability
Do not operate the machine in strong or gusty with items of different weight or specification.
winds. Do not increase the surface area of the
platform or the load. Increasing the area exposed to Do not modify or alter an aerial work platform.
the wind will decrease machine stability. 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 Do not place ladders or scaffolds in the platform or
with the jib boom or the secondary boom raised. against any part of this machine.

Do not use the machine on a moving or mobile

surface or vehicle.

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SAFETY RULES

Be sure all tires are in good condition, castle nuts Fall Hazards
are properly tightened and cotter pins are properly
installed. Occupants must wear a
safety belt or harness and
Do not use batteries that weigh less than the comply with applicable
original equipment. Batteries are used as governmental regulations.
counterweight and are critical to machine stability. Attach lanyard to the anchor
Each battery must weigh at least 65 lbs / 29.4 kg. provided in the platform.
Each battery box including 4 batteries must weigh a
minimum of 340 lbs / 154.2 kg. Do not sit, stand or climb on the platform guard
rails. Maintain a firm footing on the platform floor at
Do not use the machine as a crane. all times.
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 Do not climb down from the platform when raised.
release unless the machine is on a firm, level
surface or secured. Keep the platform floor clear of debris.

Lower the platform entry mid-rail or close the entry

gate before operating.

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SAFETY RULES

Collision Hazards Do not lower the platform unless the area below is
clear of personnel and obstructions.
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. 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 Do not use the machine as a ground for welding.
platform guard rail.
Bodily Injury Hazard
It is recommended that operators wear an
approved hard hat when operating the machine. Do not operate the machine with a hydraulic oil or
air leak. An air leak or hydraulic oil leak can
Observe and use the color-coded direction arrows
penetrate and/or burn skin.
on the platform controls and drive chassis for drive
and steer functions.

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 Decal Legend

Do not use a damaged or malfunctioning machine. Genie product decals use symbols, color coding
and signal words to identify the following:
Conduct a thorough pre-operation inspection of the
machine and test all functions before each work
shift. Immediately tag and remove from service a Safety alert symbol—used to alert
damaged or malfunctioning machine. personnel to potential personal injury
hazards. Obey all safety messages that
Be sure all maintenance has been performed as
follow this symbol to avoid possible
specified in this manual and the
injury or death.
Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8
Service Manual. Red—used to indicate the
presence of an imminently
Be sure all decals are in place and legible. hazardous situation which, if not
Be sure the operator’s, safety and responsibilities avoided, will result in death or
manuals are complete, legible and in the storage serious injury.
container located on the platform. 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
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SAFETY RULES

Battery Safety Component Damage Hazards

Do not use any battery charger greater than 48V to
Burn Hazards charge the batteries.
Batteries contain acid. Always wear protective Disconnect the battery pack plug before removing
clothing and eyewear when working with batteries. 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 spilling or contacting battery acid. Neutralize
Avoid electrical shock from contact with battery
battery acid spills with baking soda and water.
terminals. Remove all rings, watches and other
Do not expose the batteries or the charger to jewelry.
water or rain.
Tip-over Hazard
Explosion Hazards Do not use batteries that weigh less than the
Keep sparks, flames original equipment. Batteries are used as
and lighted tobacco counterweight and are critical to machine stability.
away from batteries. Each battery must weigh at least 65 lbs / 29.4 kg.
Batteries emit an Each battery box including 4 batteries must weigh a
explosive gas. minimum of 340 lbs / 154.2 kg.

The battery tray should Lifting Hazard

remain open during the
entire charging cycle. Use a forklift to remove or install the battery
pack(s).
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
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Controls

Platform Control Panel

1 Auxiliary power switch 7 Battery charge indicator (option)
2 Secondary boom up/down switch 8 Not used
3 Horn button 9 Proportional control handle for drive function and
4 Jib boom up/down switch thumb rocker for steer function
5 Emergency Stop button 10 Drive speed select switch
6 Jib boom rotate switch 11 Boom function speed controller

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CONTROLS

Ground Control Panel

1 Auxiliary power switch 6 Key switch for platform/off/ground selection
2 Function enable switch 7 Emergency Stop button
3 10A breaker for coil circuits 8 Jib boom rotate switch
4 10A breaker for control circuits 9 Jib boom up/down switch
5 Hour meter 10 Boom up/down switch

Part No. 41313 Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 9
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.
The inspection is designed to discover if anything
Do Not Operate Unless: is apparently wrong with a machine before the
operator performs the function tests.
You learn and practice the principles of safe
machine operation contained in this operator's The Pre-operation inspection also serves to
manual. determine if routine maintenance procedures are
1 Avoid hazardous situations. required. Only routine maintenance items
specified in this manual may be performed by the
2 Always perform a pre-operation operator.
inspection.
Refer to the list on the next page and check each
Know and understand the pre-operation of the items and locations for modifications,
inspection before going on to the next damage or loose or missing parts.
section.
A damaged or modified machine must never be
3 Always perform function tests prior to use. used. If damage or any variation from factory
4 Inspect the workplace. delivered condition is discovered, the machine
must be tagged and removed from service.
5 Only use the machine as it was intended.
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.
Scheduled maintenance inspections shall be
performed by qualified service technicians,
according to the manufacturer's specifications and
the requirements listed in the responsibilities
manual.

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PRE-OPERATION INSPECTION

Pre-operation Inspection
! Be sure that the operator's, safety and ! Be sure that all structural and other critical
responsibilities manuals are complete, legible components are present and all associated
and in the storage container located on the fasteners and pins are in place and properly
platform. tightened.
! Be sure that all decals are legible and in place. ! Be sure that the chassis trays are in place,
See Decals section. latched and properly connected.
! Check for hydraulic oil leaks and proper oil level.
Add oil if needed. See Maintenance section.
! 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:

! Electrical components, wiring and electrical

cables
! Hydraulic power unit, tank, hoses,
fittings, cylinders and manifolds
! Drive motors
! Boom wear pads
! Tires and wheels
! Limit switch, alarms and horn
! Nuts, bolts and other fasteners
! Platform entry mid-rail/gate
! Beacon and alarms (if equipped)
! Brake release components
Check entire machine for:
! Cracks in welds or structural components
! Dents or damage to machine

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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: oil levels can damage hydraulic components. Daily
checks allow the inspector to identify changes in
Only routine maintenance items specified in oil level that might indicate the presence of
this manual shall be performed by the operator. hydraulic system problems.

Scheduled maintenance inspections shall be 1 Be sure the boom is in the stowed position.
completed by qualified service technicians, 2 Check the hydraulic oil filler cap/dipstick,
according to the manufacturer's specifications located at the top of the hydraulic tank.
and the requirements specified in the
responsibilities manual. Result: The hydraulic oil level should be at the
FULL mark.

Hydraulic oil specifications

Hydraulic oil type Dexron equivalent

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.

Indicates that new parts will be

required to perform this procedure.

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MAINTENANCE

Check the Batteries Scheduled Maintenance

Maintenance performed quarterly, annually and
every two years must be completed by a person
Proper battery condition is essential to good trained and qualified to perform maintenance on this
engine performance and operational safety. machine according to the procedures found in the
Improper fluid levels or damaged cables and service manual for this machine.
connections can result in engine component
damage and hazardous conditions. Machines that have been out of service for more
than three months must receive the quarterly
Electrocution hazard. Contact with inspection before they are put back into service.
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.
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: 4 Pull out the red Emergency Stop button to
the on position.
You learn and practice the principles of safe
machine operation contained in this operator's Result: The beacon (if equipped) should flash.
manual.
Test Emergency Stop
1 Avoid hazardous situations.
5 Push in the red Emergency Stop button to the
2 Always perform a pre-operation off position.
inspection.
Result: No ground or platform control functions
3 Always perform function tests prior to should operate.
use.
6 Pull out the red Emergency Stop button to
Know and understand the function tests the on position.
before going on to the next section.
Test the Boom Functions
4 Inspect the work place.
7 Do not hold the function enable switch to either
5 Only use the machine as it was intended. side. Attempt to activate each boom and
platform function toggle switch.
Result: No boom or platform functions should
Fundamentals operate.
The Function Tests are designed to discover any 8 Hold the function enable switch to either side
malfunctions before the machine is put into and activate each boom and platform function
service. The operator must follow the step-by-step toggle switch.
instructions to test all machine functions.
Result: All boom and platform functions should
A malfunctioning machine must never be used. If operate through a full cycle. The descent alarm
malfunctions are discovered, the machine must be (if equipped) should sound while the boom is
tagged and removed from service. Repairs to the lowering.
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
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FUNCTION TESTS

Test Auxiliary Controls At the Platform Controls

9 Turn the key switch to ground control. Test the Tilt Sensor
10 Simultaneously hold the auxiliary power switch
on and activate each boom function toggle 19 Move the lift/drive select switch to the lift
switch. position (if equipped).

Note: To conserve battery power, test each 20 Raise the secondary boom.
function through a partial cycle. Result: The secondary boom should stop raising
Result: All boom functions should operate. when the bottom of the platform is
approximately 6 feet / 1.8 m from the ground.
Test the Tilt Sensor
21 Test all boom functions.
11 Pull out the platform red Emergency Stop button Result: The up function should not operate. The
to the on position. jib rotation function should not operate. The
12 Fully lower the platform. down function should operate.
13 Locate the tilt sensor on the chassis under the 22 Move the lift/drive select switch to the drive
boom. position (if equipped).
14 Press down one side of 23 Test the drive functions.
the tilt sensor and place Result: The drive functions should not operate.
the tilt sensor test tool
under one of the posts. 24 Move the lift/drive select switch to the lift
position (if equipped).
Result: The alarm,
located in the platform, 25 Lower the boom and remove the tilt sensor test
should sound. tool.
15 Raise the secondary boom. Test Emergency Stop
Result: The secondary boom should stop raising 26 Push in the platform red Emergency Stop button
when the bottom of the platform is to the off position.
approximately 6 feet / 1.8 m from the ground Result: No platform control functions should
16 Test all ground control functions. operate.
Result: The up function should not operate. The Test the Horn
jib rotation function should not operate. The 27 Pull out the red Emergency Stop button to the
down function should operate. on position.
17 Fully lower the platform. 28 Push the horn button.
18 Turn the key switch to platform control. Do not Result: The horn should sound.
remove the tilt sensor test tool.

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 37 Depress the thumb rocker switch in the direction
identified by the yellow triangle on the control
29 Move the lift/drive select switch to the
panel.
appropriate position (if equipped).
Result: The steer wheels should turn in the
30 Do not press down the foot switch. Activate
each machine function. direction that the yellow triangle points on the
control panel.
Result: No machine functions should operate.
Test Drive and Braking
Test Machine Functions
38 Press down the foot switch.
31 Move the lift/drive select switch to the lift
39 Slowly move the drive control handle in the
position (if equipped).
direction indicated by the blue arrow on the
32 Press down the foot switch. control panel until the machine begins to move,
33 Activate each machine function control handle then return the handle to the center position.
or toggle switch. Result: The machine should move in the
Result: All boom and platform functions should direction that the blue arrow points on the drive
operate through a full cycle. chassis, then come to an abrupt stop.

Note: Control the speed of boom functions by 40 Slowly move the drive control handle in the
adjusting the boom function speed controller. direction indicated by the yellow arrow on the
Platform, drive and steer functions are not affected control panel until the machine begins to move,
by the boom function speed controller. then return the handle to the center position.

Test the Steering Result: The machine should move in the

direction that the yellow arrow points on the
34 Move the lift/drive select switch to the drive drive chassis, then come to an abrupt stop.
position (if equipped).
Note: The brakes must be able to hold the machine
35 Press down the foot switch. on any slope it is able to climb.
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.
Result: The steer wheels should turn in the
direction that the blue triangle points on the
control panel.

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FUNCTION TESTS

Test Limited Drive Speed Test the Lift/Drive Select Function

(CE models)
41 Move the lift/drive select switch to the lift
position (if equipped). Machines with lift/drive select switch:
42 Press down the foot switch.
50 Move the lift/drive select switch to the lift
43 Fully lower the platform. position.
44 Raise the secondary boom until the platform 51 Press down the foot switch.
clears the counterweights.
52 Move the drive control handle off center.
45 Move the lift/drive select switch to the drive
Result: No drive functions should operate.
position (if equipped).
53 Activate each boom function toggle switch.
46 Slowly move the drive control handle to the full
drive position. Result: All boom functions should operate.
Result: The maximum achievable drive speed 54 Move the lift/drive select switch to the drive
with the secondary boom raised should not position.
exceed 1 foot / 30 cm per second. 55 Press down the foot switch.
If the drive speed with the secondary boom raised 56 Activate each boom function toggle switch.
exceeds 1 foot / 30 cm per second, immediately
tag and remove the machine from service. Result: No boom functions should operate.
Test Auxiliary Controls 57 Move the drive control handle off center.
47 Move the lift/drive select switch to the Result: The drive functions should operate.
appropriate position (if equipped). 58 Repair any malfunctions before operating the
48 Press down the foot switch. machine.
49 Simultaneously hold the auxiliary power switch Machines without lift/drive select switch:
on and activate each function control handle or
59 Press down the foot switch.
toggle switch.
60 Move the drive control handle off center and
Note: To conserve battery power, test each
activate a boom function toggle switch.
function through a partial cycle.
Result: No boom functions should operate. The
Result: All boom, steer and drive functions
machine will move in the direction indicated on
should operate.
the control panel.
61 Repair any malfunctions before operating the
machine.

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

machine operation contained in this operator's · inadequate surface support to withstand all load
manual. forces imposed by the machine
1 Avoid hazardous situations. · wind and weather conditions
2 Always perform a pre-operation · the presence of unauthorized personnel
inspection.
· other possible unsafe conditions
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.
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.

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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

Do Not Operate Unless: personnel and tools to an aerial work site is unsafe
and dangerous.
You learn and practice the principles of safe
machine operation contained in this operator's Only trained and authorized personnel should be
manual. permitted to operate a machine. If more than one
operator is expected to use a machine at different
1 Avoid hazardous situations. times in the same work shift, they must all be
2 Always perform a pre-operation qualified operators and are all expected to follow all
inspection. safety rules and instructions in the operator's,
safety and responsibilities manuals. That means
3 Always perform function tests prior to use. every new operator should perform a pre-operation
inspection, function tests, and a work place
4 Inspect the workplace.
inspection before using the machine.
5 Only use the machine as it was intended.

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 Operation from Platform

Use auxiliary power if the primary power source 1 Be sure that both battery packs are connected
fails. before operating the machine.
2 Turn the key switch to platform control.
1 Turn the key switch to ground or platform
control. 3 Pull out both ground and platform red
Emergency Stop buttons to the on position.
2 Pull out the red Emergency Stop button to the
on position. To Position Platform

3 Be sure that both battery packs are connected 1 Set the boom function speed controller to the
before operating the machine. desired speed.
2 Move the lift/drive select switch to the lift
4 Press down the foot switch when operating the
position (if equipped).
auxiliary controls from the platform.
3 Press down the foot switch.
5 Move the lift/drive select switch to the
appropriate position (if equipped) when operating 4 Move the appropriate toggle switch according to
the auxiliary controls from the platform. the markings on the control panel.

6 Simultaneously hold the auxiliary power switch Note: Platform, drive and steer functions are not
on and activate the desired function. affected by the boom function speed controller.

Note: The boom, steer and drive functions will To Steer

operate with auxiliary power. 1 Move the lift/drive select switch to the drive
position (if equipped).
Operation from Ground 2 Press down the foot switch.
1 Be sure that both battery packs are connected 3 Turn the steering wheels with the thumb rocker
before operating the machine. switch located on top of the drive control
2 Turn the key switch to ground control. handle.
Use the color-coded direction arrows on the
3 Pull out the red Emergency Stop button to
platform controls and the chassis to identify the
the on position.
direction the wheels will turn.
To Position Platform
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 After Each Use

1 Move the lift/drive select switch to the drive 1 Select a safe parking location—firm level
position (if equipped). surface, clear of obstruction and traffic.
2 Press down the foot switch. 2 Lower the boom to the stowed position.
3 Increase speed: Slowly move the drive control 3 Turn the key switch to the off position and
handle off center. remove the key to secure from unauthorized
Decrease speed: Slowly move the drive control use.
handle toward center. 4 Chock the wheels.
Stop: Return the drive control handle to center or 5 Charge the batteries.
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
· 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 2 Fill each cell with battery acid (electrolyte) until
the level is sufficient to cover the plates.

Observe and Obey: Do not fill to maximum level until the battery
charge cycle is complete. Overfilling can cause the
Do not use an external charger or booster battery acid to overflow during charging.
battery. Neutralize battery acid spills with baking soda and
water.
Charge the battery in a well-ventilated area.
3 Install the battery vent caps.
Use proper AC input voltage for charging as
indicated on the charger. 4 Charge the battery.
5 Check the battery acid level when the charging
Use only Genie authorized battery and charger.
cycle is complete. Replenish with distilled water
to the bottom of the fill tube. Do not overfill.

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.
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 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.
Observe and Obey:
3 Turn the brake release knob counterclockwise to
Common sense and planning must be applied to open the brake valve.
control the movement of the machine when
lifting it with a crane or forklift. 4 Pump the brake release pump knob
approximately 20 times until resistance is felt.
The transport vehicle must be parked on a level The brakes are now released.
surface.
After the machine is loaded:
The transport vehicle must be secured to 1 Chock the wheels to prevent the machine from
prevent rolling while the machine is being rolling.
loaded.
2 Turn the brake release knob clockwise to reset
Be sure the vehicle capacity, loading surfaces the brakes.
and chains or straps are sufficient to withstand
the machine weight. See the serial plate for the Due to the low ground clearance of the machine,
machine weight. the maximum break-over angle for loading and
The machine must be on a level surface or unloading is shown for each model.
secured before releasing the brakes.
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 side- Z-20/8 & Z-25/8
to-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
Operator's Manual First Edition • Sixth Printing

Decals

Decal Inspection Platform

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
Part No. Description Quantity
28174 Power to Platform, 230V 2
44220 Notice - Brake Release Instructions 1
28175 Caution - Compartment Access 1
44238 Danger - Tip-over (batteries) 2
28176 Notice - Missing Manuals 1
44239 Notice - Tire Specifications 4
28177 Warning - Platform Rotate 2
44237 Battery Connection Diagram 2
28181 Warning - No Step Or Ride 1
44240 Notice - Operating Instructions - Platform 1
28235 Power to Platform, 115V 2
44242 Label - 2 Directional Arrows 2
28236 Warning - Failure To Read . . . 1
44248 Notice - Max Load 440 lbs, Z-20/8N 1
28372 Caution - Component Damage 2
44737 Danger - Tipover, Trays 2
31060 Danger - Do Not Alter Limit Switch 1
44768 Danger - Tilt Alarm 1
31508 Notice - Power to Battery Charger 1
44980 Label - Power to Charger, 115V 1
31785 Notice - Battery Charger Operating
Instructions 2 44981 Airline to Platform 2
31788 Danger - Battery/Charger Safety 2 44983 Notice - Max Load 400 lbs, Z-20/8N 1
32700 Danger - General Safety Rules 2 44986 Notice - Max Manual Force 90 lbs 1
37051 Notice - Maximum Side Force, 150 lbs 1 46305 Warning - Crushing Hazard 2
37052 Notice - Max Load 500 lbs, Z-20/8 & Z-25/8 1 52969 Cosmetic - Genie Boom 1
40434 Label - Lanyard Anchorage 2 62935 Cosmetic - Genie Z-20/8 2
41323 Platform Control Panel 1 62936 Cosmetic - Genie Z-20/8N 2
41324 Ground Control Panel 1 62937 Cosmetic - Genie Z-25/8 2
43653 Notice - Operating Instructions - Ground 1 72173 Platform Control Panel 1
43658 Label - Power to Charger, 230V 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

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

Part No. 41313 Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 25
Operator's Manual First Edition • Sixth Printing

Specifications

Z-20/8N Z-20/8

Height, working maximum 26 ft 7.9 m Height, working maximum 26 ft 7.9 m

Height, platform maximum 20 ft 6.1 m Height, platform maximum 20 ft 6.1 m
Height, stowed maximum 6 ft 7 in 2.01 m Height, stowed maximum 6 ft 7 in 2.01 m
Horizontal reach maximum 8 ft 8 in 2.6 m Horizontal reach maximum 7 ft 11 in 2.4 m
Width 32 in 81.3 cm Width 46 in 2.9 cm
Length, stowed 12 ft 4 in 3.76 m Length, stowed 11 ft 9 in 3.58 m
Maximum load capacity Maximum load capacity 500 lbs 227 kg
ANSI & CSA 400 lbs 181 kg
Wheelbase 5 ft 4 in 1.63 m
CE 440 lbs 200 kg
Turning radius (outside) 6 ft 4 in 1.9 m
Wheelbase 5 ft 4 in 1.63 m
Turning radius (inside) 11 in 28 cm
Turning radius (outside) 4 ft 9 in 1.4 m
Ground clearance 2 in 5 cm
Turning radius (inside) 10 in 25.4 cm
Jib boom rotation (degrees) 180°
Ground clearance 1.625 in 4.1 cm
Power source 8 6V 255AH batteries
Jib boom rotation (degrees) 180°
Drive speeds (maximum)
Power source 8 6V 255AH batteries
Boom stowed 2.7 mph 4.3 km/h
Drive speeds (maximum)
40 ft/10.1 sec 12.2 m/10.1 sec
Boom stowed 2.6 mph 4.2 km/h
Boom 0.6 mph 1.0 km/h
40 ft/10.5 sec 12.2 m/10.5 sec
raised or extended 40 ft/40 sec 12.2 m/40 sec
Boom 0.6 mph 1.0 km/h
Gradeability (boom stowed) 20%
raised or extended 40 ft/40 sec 12.2 m/40 sec
Gradeability (boom stowed) 18% Controls 24V DC proportional
Platform dimensions, 46 x 30 in
Controls 24V DC proportional
(length x width) 2.9 m x 76 cm
Platform dimensions, 31 x 40 in
AC outlet in platform standard
(length x width) 78.7 cm x 1.01 m
Hydraulic pressure (maximum) 3500 psi
AC outlet in platform standard
(boom functions) 241 bar
Hydraulic pressure (maximum) 3500 psi Weight See Serial Plate
(boom functions) 241 bar (Machine weights vary with option configurations)
Weight See Serial Plate
Airborne noise emissions 67 dB
(Machine weights vary with option configurations)
Maximum sound level at normal operating workstations
Airborne noise emissions 67 dB (A-weighted)
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 Operator's Manual

SPECIFICATIONS

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
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 425.881.1800
Toll Free USA and Canada
Distributed By:
800.536.1800
Fax 425.883.3475

Genie Australia Pty Ltd.

Phone +61 7 3375 1660
Fax +61 7 3375 1002

Genie Scandinavia Genie China

Phone +46 31 3409612 Phone +86 21 53852570
Fax +46 31 3409613 Fax +86 21 53852569

Genie France Genie Malaysia

Phone +33 (0)2 37 26 09 99 Phone +65 98 480 775
Fax +33 (0)2 37 26 09 98 Fax +65 67 533 544

Genie Iberica Genie Japan

Phone +34 93 579 5042 Phone +81 3 3453 6082
Fax +34 93 579 5059 Fax +81 3 3453 6083

Genie Germany Genie Korea

Phone +49 (0)4202 88520 Phone +82 25 587 267
Fax +49 (0)4202 8852-20 Fax +82 25 583 910

Genie U.K. Genie Brasil

Phone +44 (0)1476 584333 Phone +55 11 41 665 755
Fax +44 (0)1476 584334 Fax +55 11 41 665 754

Genie Mexico City Genie Holland

Phone +52 55 5666 5242 Phone +31 183 581 102
Fax +52 55 5666 3241 Fax +31 183 581 566