Genie Z-25/8 User manual

Service
Manual
Technical
Publications
First Edition Third Printing
Part No. 41314
•
Z-20 8
Z-20 8
Z-25 8

Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 Part No. 41314
First Editon • Third Printing
ii
Introduction
Important
Read, understand and obey the safety rules and
operating instructions in the Genie Z-25/8 & Genie
Z-20/8 & Genie Z-20/8N Operator’s Manual before
attempting any maintenance or repair procedure.
This manual provides detailed scheduled
maintenance information for the machine owner
and user. It also provides troubleshooting and
repair procedures for qualified service
professionals.
Basic mechanical, hydraulic and electrical
skills are required to perform most procedures.
However, several procedures require specialized
skills, tools, lifting equipment and a suitable
workshop. In these instances, we strongly
recommend that maintenance and repair be
performed at an authorized Genie dealer
service center.
Genie Industries has endeavored to deliver the
highest degree of accuracy possible. However,
continuous improvement of our products is a
Genie policy. Therefore product specifications
are subject to change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and other manuals. Please
write to the technical publications team in care of
Genie Industries, PO Box 97030, Redmond WA
98073-9730 USA.
If you have any questions, please call Genie
Industries.
®
Copyright©1997byGenieIndustries
FirstEdition: FirstPrinting,September1997
SecondPrinting,February1998
ThirdPrinting,April2000
Genie and "Z" are registered trademarks of
Genie Industries in the USA and many other
countries.
Printedonrecycledpaper
PrintedinU.S.A.
Contactus:
http://www.genielift.com
e-mail: [email protected]

Part No. 41314 Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8
First Edition • Third Printing
iii
Danger
Failure to obey the instructions and safety rules
in this manual and the Genie Z-20/8N &
Genie Z-20/8 & Genie Z-25/8 Operator’s Manual
will result in death or serious injury.
Many of the hazards identified in the
operator’s manual are also safety hazards
when maintenance and repair procedures
are performed.
Do Not Perform Maintenance
Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
- manufacturer’s instructions and safety rules
- employer’s safety rules and worksite
regulations
- applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.
Safety Rules

Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 Part No. 41314
First Editon • Third Printing
SAFETY RULES
iv
PersonalSafety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Read each procedure thoroughly. This
manual and the decals on the machine,
use 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 sitiuation 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.
Indicates special operation or
maintenance information.
Be sure to wear protective eye wear and
other protective clothing if the situation
warrants it.
Be aware of potential crushing hazards
such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved steel-toed
shoes.
WorkplaceSafety
Be sure to keep sparks, flames and
lighted tobacco away from flammable and
combustible materials like battery gases
and engine fuels. Always have an approved fire
extinguisher within easy reach.
Be sure that all tools and working areas
are properly maintained and ready for
use. Keep work surfaces clean and free
of debris that could get into machine components
and cause damage.
Be sure that your workshop or work area
is properly ventilated and well lit.
Be sure any forklift, overhead crane or
other lifting or supporting device is fully
capable of supporting and stabilizing the
weight to be lifted. Use only chains or straps that
are in good condition and of ample capacity.
Be sure that fasteners intended for one
time use (i.e., cotter pins and self-locking
nuts) are not re-used. These components
may fail if they are used a second time.
Be sure to properly dispose of old oil or
other fluids. Use an approved container.
Please be environmentally safe.

Part No. 41314 Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8
First Edition • Third Printing
Theory of Operation
PowerSource
The Genie Z-20/8N & Genie Z-20/8 &
Genie Z-25/8 machines are powered by eight six-
volt (255 AH) batteries. Each 4-battery pack, is
wired in series/parallel to produce 24V DC. The
two battery packs are then wired in series to
produce 48V DC. The drive system uses 48V DC
and the control system uses 24V DC.
Hydraulic System
All machine functions are performed by the
hydraulic system. The hydraulic system is
powered by a two-section pressure balanced gear
pump. The lift and steer functions use pump #2.
The drive function utilizes pump #1 combined with
pump #2 for a total of 12 cc's displacement per
revolution. To protect from over-pressurization of
the hydraulic system, the pumps are provided with
a pressure relief valve set at 3500 psi (241 bar).
Activating a machine function is accomplished by
actuating or moving a toggle switch and/or control
handle, which sends voltage to the appropriate
directional control valve. The directional control
valve determines which direction the hydraulic fluid
will travel. The amount of hydraulic fluid volume is
determined by the proportional valve input voltage
from the boom function speed controller at the
platform controls. The boom lift cylinder and the jib
boom lift cylinder incorporate counterbalance
valves to prevent movement in the event of a
hydraulic line failure.
Electrical System
Drive speed limit switch
The drive speed limit switch, located in the boom
storage area, is used to restrict drive speed when
the boom is raised. An improperly functioning drive
speed limit switch will allow the boom to raise
and/or drive into an unsafe position.
MachineControls
The Genie Z-20/8N & Genie Z-20/8 &
Genie Z-25/8 machines are equipped with
operational controls which are found in two
locations: the ground controls, and platform
controls. All lift and drive functions are available at
the platform controls. Only boom functions are
available at the ground controls. Moving a boom
toggle switch in the direction indicated on the
control panel decal will indicate which boom
function will operate and its direction of travel.
The platform controls incorporates a boom
function speed controller which, by varying the
position of the controller, controls the amount of
voltage sent to the proportional valve. This
determines the speed at which the function will
operate.
The drive controller (joystick) is fitted with a
potentiometer that communicates the joystick
position with the motor controller. A thumb rocker
switch on the top of the joystick is used for
steering.
Washing electronic components is not suggested.
Instead, use compressed air to remove debris
from these components.
v

Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 Part No. 41314
First Editon • Third Printing
vi
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Part No. 41314 Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8
First Edition • Third Printing
Table of Contents
vii
Introduction
Important Information .....................................................................................................ii
Section One Safety Rules
General Safety Rules .................................................................................................... iii
Theory Of Operation...................................................................................................... v
Section Two Specifications
Machine and Performance Specifications, Z-25/8 Models ....................................... 2 - 1
Machine and Performance Specifications, Z-20/8 Models ....................................... 2 - 2
Machine and Performance Specifications, Z-20/8N Models..................................... 2 - 3
Hydraulic Specifications - All Models........................................................................ 2 - 4
Hydraulic Hose and Fitting Torque Specifications .................................................... 2 - 5
Section Three Scheduled Maintenance Inspections
Introduction............................................................................................................... 3 - 1
Table A ..................................................................................................................... 3 - 2
Table B ..................................................................................................................... 3 - 2
Table C..................................................................................................................... 3 - 3
Table D..................................................................................................................... 3 - 3
Maintenance Inspection Report................................................................................ 3 - 4
Section Four Scheduled Maintenance Procedures
Introduction............................................................................................................... 4 - 1
A-1 Inspect the Operator’s and Safety Manuals.................................................... 4 - 2
A-2 Inspect the Decals and Placards .................................................................... 4 - 2
A-3 Inspect for Damage and Loose or Missing Parts ............................................ 4 - 3
A-4 Check the Hydraulic Oil Level......................................................................... 4 - 3

Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 Part No. 41314
First Editon • Third Printing
TABLE OF CONTENTS
viii
Section Four Scheduled Maintenance Procedures, continued
A-5 Check for Hydraulic Leaks.............................................................................. 4 - 4
A-6 Test the Platform and Ground Controls .......................................................... 4 - 5
A-7 Test the Auxiliary Power Operation ................................................................ 4 - 6
A-8 Test the Tilt Sensor ........................................................................................ 4 - 6
A-9 Test the Drive Speed Limit Switch.................................................................. 4 - 7
A-10 Perform 30 Day Service.................................................................................. 4 - 9
B-1 Check the Batteries ...................................................................................... 4 - 10
B-2 Inspect the Electrical Wiring ......................................................................... 4 - 11
B-3 Inspect the Tires and Wheels (including castle nut torque) .......................... 4 - 12
B-4 Test the Key Switch...................................................................................... 4 - 12
B-5 Test the Emergency Stop Buttons................................................................ 4 - 13
B-6 Test the Ground Control Override ................................................................ 4 - 13
B-7 Test the Horn................................................................................................ 4 - 14
B-8 Test the Foot Switch..................................................................................... 4 - 14
B-9 Test the Drive Brakes ................................................................................... 4 - 15
B-10 Test the Drive Speed - Stowed Position ....................................................... 4 - 16
B-11 Test the Drive Speed - Raised Position ........................................................ 4 - 17
B-12 Test the Alarm Package (if equipped) .......................................................... 4 - 18
B-13 Perform Hydraulic Oil Analysis ..................................................................... 4 - 19
B-14 Check the Electrical Contactors.................................................................... 4 - 19
B-15 Replace the Hydraulic Tank Return Filter ..................................................... 4 - 19
C-1 Bleed the Jib Boom Rotator.......................................................................... 4 - 21
D-1 Test or Replace the Hydraulic Oil ................................................................. 4 - 22

Part No. 41314 Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8
First Edition • Third Printing
TABLE OF CONTENTS
ix
Section Five Troubleshooting Flow Charts
Introduction............................................................................................................... 5 - 1
1 All Functions Will Not Operate........................................................................ 5 - 3
2 Pump Motor Will Not Operate......................................................................... 5 - 6
3 Auxiliary Functions Inoperative ....................................................................... 5 - 8
4 All Functions Inoperative, Power Unit Starts and Runs ................................ 5 - 10
5 Ground Controls Inoperative, Platform Controls Operate Normally .............. 5 - 11
6 Platform Controls Inoperative, Ground Controls Operate Normally .............. 5 - 12
7 Boom Up Function Inoperative ..................................................................... 5 - 15
8 Boom Down Function Inoperative................................................................. 5 - 17
9 Jib Boom Up Function Inoperative................................................................ 5 - 19
10 Jib Boom Down Function Inoperative ........................................................... 5 - 22
11 Jib Boom Rotate Left Function Inoperative................................................... 5 - 25
12 Jib Boom Rotate Right Function Inoperative ................................................ 5 - 28
13 Steer Left Function Inoperative..................................................................... 5 - 31
14 Steer Right Function Inoperative .................................................................. 5 - 32
15 All Drive Functions Inoperative, All Other Functions Operate Normally........ 5 - 33
16 Drive Forward Function Inoperative.............................................................. 5 - 36
17 Drive Reverse Function Inoperative.............................................................. 5 - 37
18 Machine Will Not Drive At Full Speed ........................................................... 5 - 38
19 Machine Drives At Full Speed With Platform Raised.................................... 5 - 41
20 Brake Release Function Inoperative............................................................. 5 - 42

Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 Part No. 41314
First Editon • Third Printing
TABLE OF CONTENTS
x
Section Six Schematics
Introduction............................................................................................................... 6 - 1
Electrical Components.............................................................................................. 6 - 2
Electrical Symbols Legend ....................................................................................... 6 - 4
Abbreviation Legend................................................................................................. 6 - 5
Electrical Schematic,
Z-25/8 (before serial number 229)
Z-20/8 (before serial number 125)
Z-20/8N (before serial number 968)................................................................ 6 - 7
Electrical Schematic,
Z-25/8 (after serial number 228)
Z-20/8 (after serial number 124)
Z-20/8N (after serial number 967) .................................................................. 6 - 8
Ground Control Panel Wiring Diagram ..................................................................... 6 - 9
Platform Control Box Wiring Diagram,
Z-25/8 (before serial number 229)
Z-20/8 (before serial number 125)
Z-20/8N (before serial number 968).............................................................. 6 - 10
Platform Control Box Wiring Diagram,
Z-25/8 (after serial number 228)
Z-20/8 (after serial number 124)
Z-20/8N (after serial number 967) ................................................................ 6 - 11
Power Cable Diagram ............................................................................................ 6 - 12
Hydraulic Symbols Legend..................................................................................... 6 - 14
Hydraulic Schematic,
Z-25/8 (before serial number 229)
Z-20/8 (before serial number 125)
Z-20/8N (before serial number 968).............................................................. 6 - 15
Hydraulic Schematic,
Z-25/8 (after serial number 228)
Z-20/8 (after serial number 124)
Z-20/8N (after serial number 967) ................................................................ 6 - 16

Part No. 41314 Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8
First Edition • Third Printing
Section Seven Repair Procedures
Introduction............................................................................................................... 7 - 1
Platform Controls
1-1 Joystick Controller .......................................................................................... 7 - 2
1-2 Foot Switch..................................................................................................... 7 - 5
1-3 Toggle Switches ............................................................................................. 7 - 6
1-4 Control Relays ................................................................................................ 7 - 7
Platform Components
2-1 Platform .......................................................................................................... 7 - 9
Jib Boom Components
3-1 Jib Boom....................................................................................................... 7 - 10
3-2 Jib Boom Cylinder......................................................................................... 7 - 12
3-3 Jib Boom Rotator .......................................................................................... 7 - 13
Boom Components
4-1 Boom ............................................................................................................ 7 - 17
4-2 Boom Lift Cylinder ........................................................................................ 7 - 21
Ground Controls
5-1 Toggle Switches, See 1-3, Toggle Switches................................................... 7 - 6
5-2 Control Relays, See 1-4, Control Relays ........................................................ 7 - 7
5-3 Wago®Components ..................................................................................... 7 - 22
TABLE OF CONTENTS
xi

Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 Part No. 41314
First Editon • Third Printing
Section Seven Repair Procedures, continued
Hydraulic Pumps
6-1 Auxiliary Pump.............................................................................................. 7 - 23
6-2 Main Function Pump..................................................................................... 7 - 24
Manifolds
7-1 Function Manifold Components .................................................................... 7 - 26
7-2 Valve Adjustments - Function Manifold......................................................... 7 - 28
7-3 Jib Boom and Jib Boom Rotate Manifold Components................................. 7 - 30
7-4 Brake Release Hand Pump Components ..................................................... 7 - 31
Steering Axle Components
8-1 Yoke and Drive Motor ................................................................................... 7 - 32
8-2 Steering Cylinder .......................................................................................... 7 - 34
8-3 Steering Bellcrank......................................................................................... 7 - 35
Non-steering Axle Components
9-1 Drive Brake ................................................................................................... 7 - 37
xii
TABLE OF CONTENTS

Part No. 41314 Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 2 - 1
Section 2 • SpecificationsFirst Edition • Third Printing
Specifications
MachineSpecifications
Z-25/8 Models
Stowed dimensions
Length 16 ft 4.9 m
Width 46 in 1.2 m
Height 79 in 2 m
Ground clearance,
at machine center 5 in 12.7 cm
at pothole bars 2 in 5.1 cm
Operational dimensions
Maximum platform height 25 ft 7.6 m
Maximum platform working height 31 ft 9.4 m
Maximum horizontal reach 7 ft 11 in 2.4 m
Tailswing 18 in 45.7 cm
Noseswing 58 in 147.3 cm
Wheelbase 5 ft 4 in 1.6 m
Minimum turning circle, 12 ft 7 in 3.8 m
outside
Minimum turning circle, 22 in 56 cm
inside
Jib boom rotation 180°
Jib boom range of motion 144°
Platform dimensions
Length 30 in 76.2 cm
Width 46 in 116.8 cm
Maximum load capacity 500 lbs 227 kg
Fluid capacities
Hydraulic tank capacity 8 gallons 30.3 liters
Hydraulic system capacity 10 gallons 37.9 liters
(including tank)
Tires and wheels
Tire size (solid rubber) 18 x 14 x 6 in
46 x 36 x 15 cm
Tire contact area 5.8 sq in 37.4 sq cm
Load range 3200 lbs 1873 Nm
Overall tire diameter 18 in 46 cm
Wheel diameter 14 in 36 cm
Wheel width 6 in 15 cm
Castle nut torque 300 ft-lbs 407 Nm
Gradeability (boom stowed) 20%
PerformanceSpecifications
Z-25/8 Models
Drive speeds, maximum
Boom stowed, 2.7 mph 4.3 km/h
high range 40 ft/11 sec 12.2 m/11 sec
Boom stowed, 1.4 mph 2.25 km/h
low range 40 ft/27.3 sec 12.2 m/27 sec
Boom raised 0.6 mph 0.8 km/h
40 ft/52 sec 12.2 m/52 sec
Boom function speeds, maximum
from platform controls
Elevate up 27 to 33 seconds
Elevate down 32 to 38 seconds
Jib boom up 27 to 33 seconds
Jib boom down 17 to 23 seconds
Jib rotate, 180° 28 to 34 seconds
Continuous improvement of our products is a
Genie policy. Product specifications are subject to
change without notice.

2 - 2 Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 Part No. 41314
Section 2 • Specifications First Edition • Third Printing
MachineSpecifications
Z-20/8 Models
Stowed dimensions
Length 11 ft 9 in 3.6 m
Width 46 in 1.2 m
Height 79 in 2 m
Ground clearance,
at machine center 5 in 12.7 cm
at pothole bars 2 in 5.1 cm
Operational dimensions
Maximum platform height 20 ft 6.1 m
Maximum platform working height 26 ft 7.9 m
Maximum horizontal reach 7 ft 11 in 2.4 m
Tailswing 0 in 0 cm
Noseswing 0 in 0 cm
Wheelbase 5 ft 4 in 1.6 m
Minimum turning circle, 12 ft 7 in 3.8 m
outside
Minimum turning circle, 22 in 56 cm
inside
Jib boom rotation 180°
Jib boom range of motion 144°
Platform dimensions
Length 30 in 76.2 cm
Width 46 in 116.8 cm
Maximum load capacity 500 lbs 227 kg
Fluid capacities
Hydraulic tank capacity 8 gallons 30.3 liters
Hydraulic system capacity 10 gallons 37.9 liters
(including tank)
Tires and wheels
Tire size (solid rubber) 18 x 14 x 6 in
46 x 36 x 15 cm
Tire contact area 5.8 sq in 37.4 sq cm
Load range 3200 lbs 1873 Nm
Overall tire diameter 18 in 46 cm
Wheel diameter 14 in 36 cm
Wheel width 6 in 15 cm
Castle nut torque 300 ft-lbs 407 Nm
Gradeability (boom stowed) 20%
PerformanceSpecifications
Z-20/8 Models
Drive speeds, maximum
Boom stowed, 2.7 mph 4 km/h
high range 40 ft/11 sec 12.2 m/11 sec
Boom stowed, 1.4 mph 1.6 km/h
low range 40 ft/27.3 sec 12.2 m/27 sec
Boom raised 0.6 mph 0.8 km/h
40 ft/52 sec 12.2 m/52 sec
Boom function speeds, maximum
from platform controls
Elevate up 14 to 20 seconds
Elevate down 14 to 20 seconds
Jib boom up 27 to 33 seconds
Jib boom down 17 to 23 seconds
Jib rotate, 180° 28 to 34 seconds
Continuous improvement of our products is a
Genie policy. Product specifications are subject to
change without notice.
SPECIFICATIONS

Part No. 41314 Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 2 - 3
Section 2 • SpecificationsFirst Edition • Third Printing
MachineSpecifications
Z-20/8N Models
Stowed dimensions
Length 12 ft 4 in 3.8 m
Width 32 in 81.3 cm
Height 79 in 2 m
Ground clearance,
at machine center 5 in 12.7 cm
at pothole bars 1.625 in 4.1 cm
Operational dimensions
Maximum platform height 20 ft 6.1 m
Maximum platform working height 26 ft 7.9 m
Maximum horizontal reach 8 ft 8 in 2.6 m
Tailswing 0 in 0 cm
Noseswing 0 in 0 cm
Wheelbase 5 ft 4 in 1.9 m
Minimum turning circle, 9 ft 6 in 2.9 m
outside
Minimum turning circle, 20 in 51 cm
inside
Jib boom rotation 180°
Jib boom range of motion 144°
Platform dimensions
Length 31 in 79 cm
Width 40 in 102 cm
Maximum load capacity,
ANSI & CSA 400 lbs 181 kg
CE 440 lbs 200 kg
Fluid capacities
Hydraulic tank capacity 8 gallons 30.3 liters
Hydraulic system capacity 10 gallons 37.9 liters
(including t ank)
Tires and wheels
Tire size (solid rubber) 18 x 14 x 6 in
46 x 36 x 15 cm
Tire contact area 5.8 sq in 37.4 sq cm
Load range 3200 lbs 1873 Nm
Overall tire diameter 18 in 46 cm
Wheel diameter 14 in 36 cm
Wheel width 6 in 15 cm
Castle nut torque 300 ft-lbs 407 Nm
Gradeability (boom stowed) 18%
Continuous improvement of our products is a
Genie policy. Product specifications are subject to
change without notice.
PerformanceSpecifications
Z-20/8N Models
Drive speeds, maximum
Boom stowed, 2.6 mph 4 km/h
high range 40 ft/11 sec 12.2 m/11 sec
Boom stowed, 1.3 mph 1.6 km/h
low range 40 ft/27.3 sec 12.2 m/27 sec
Boom raised 0.6 mph 0.8 km/h
40 ft/52 sec 12.2 m/52 sec
Boom function speeds, maximum
from platform controls
Elevate up 14 to 20 seconds
Elevate down 14 to 20 seconds
Jib boom up 27 to 33 seconds
Jib boom down 17 to 23 seconds
Jib rotate, 180° 28 to 34 seconds
SPECIFICATIONS

2 - 4 Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 Part No. 41314
Section 2 • Specifications First Edition • Third Printing
SPECIFICATIONS
HydraulicSpecifications
All Models
Hydraulic fluid Dexron equivalent
Lift/Drive pump
Z-25/8 before serial number 212
Z-20/8 before serial number 122
Z-20/8N before serial number 896:
Type: 2 section pressure balanced gear pump
Displacement 0.37 cu in
per revolution (pump #1) 6 cc
Displacement 2 gallons per minute
(2500 psi/172 bar) 7.6 liters per minute
Displacement 0.37 cu in
per revolution (pump #2) 6 cc
Displacement 2 gallons per minute
(2500 psi/172 bar) 7.6 liters per minute
Lift/Drive pump
Z-25/8 after serial number 211
Z-20/8 after serial number 121
Z-20/8N after serial number 895:
Type: 2 section pressure balanced gear pump
Displacement 0.488 cu in
per revolution (pump #1) 8 cc
Displacement 4 gallons per minute
(2500 psi/172 bar) 15.2 liters per minute
Displacement 0.25 cu in
per revolution (pump #2) 4 cc
Displacement 1.6 gallons per minute
(2500 psi/172 bar) 6.05 liters per minute
Auxiliary pump
Type fixed displacement gear pump
Displacement 0.6 gpm
2.3 liters/minute
Auxiliary pump 3200 psi
relief pressure 221 bar
Drive motors
Displacement per revolution 22.8 cu in
374 cc
Function manifold
Steering relief 2500 psi
valve pressure 172 bar
Boom down 1500 psi
relief valve pressure 103 bar
System relief 3500 psi
valve pressure 241 bar

Part No. 41314 Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 2 - 5
Section 2 • SpecificationsFirst Edition • Third Printing
SPECIFICATIONS
Hydraulic Hose and Fitting Torque Specifications
Your machine is equipped with either 37° flared fittings and hose ends OR Parker Seal-Lok®fittings and
hose ends. Machines that utilize Parker Seal-Lok®hoses and fittings require that the fittings and hose
ends be torqued to specification when they are removed and installed or when new hoses or fittings are
installed. Machines equipped with 37° flared fittings and hose ends do not need to be torqued to these
specifications.
TorqueProcedure
1 Replace the O-ring. The O-ring must be
replaced anytime the seal has been broken.
The O-ring cannot be re-used if the fitting or
hose end has been tightened beyond finger
tight.
The O-rings used in the Parker
Seal Lok® fittings and hose ends
are a custom-size O-ring. They
are not a standard SAE size
O-ring. They are available in the
O-ring field service kit
(Genie part number 49612).
2 Lubricate the O-ring before installation.
3 Be sure that the face seal O-ring is seated and
retained properly.
4 Position the tube and nut squarely on the face
seal end of the fitting and tighten the nut finger
tight.
5 Tighten the nut or fitting to the appropriate
torque per given size as shown in the table
above.
6 Operate all machine functions and inspect the
hoses and fittings and related components to
be sure that there are no leaks.
Hydraulic Hose and Fitting Torque Specifications
SAE O-ring Boss Port - tube fitting Seal-Lok® - hose end
SAE Dash
Size Installing into... ft. lbs. Nm SAE Dash Size ft. lbs. Nm
-4 Aluminum 11 14.9 -4 18 24.4
Steel 16 21.7 -6 27 36.6
-6 Aluminum 23 31.2 -8 40 54.2
Steel 35 47.5 -10 63 85.4
-8 Aluminum 40 54.2 -12 90 122
Steel 60 81.3 -16 120 162.7
-10 Aluminum 69 93.6 -20 140 190
Steel 105 142.4 -24 165 223.7
-12 Aluminum 93 126.1
Steel 140 190
-16 Aluminum 139 188.5
Steel 210 284.7
-20 Aluminum 172 233.2
Steel 260 352.5
-24 Aluminum 208 282
Steel 315 427.1

2 - 6 Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 Part No. 41314
Section 2 • Specifications First Edition • Third Printing
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Part No. 41314 Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 3 - 1
Section 3 • Scheduled Maintenance InspectionsFirst Edition • Third Printing
Tools are
required New parts required
Dealer
service
suggested
Scheduled Maintenance Inspections
Observe and Obey:
Maintenance inspections shall be completed by
a person trained and qualified on the
maintenance of this machine.
Scheduled maintenance inspections shall be
completed daily, quarterly, annually and every
2 years as specified on the Maintenance
Inspection Report.
Failure to properly complete each
inspection when required may
cause death, serious injury or
substantial machine damage.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating machine.
Keep records on all inspections for three years.
Machines that have been out of service for a
period longer than 3 months must complete the
quarterly inspection.
About This Section
The Schedule
There are four types of maintenance inspections
that must be performed according to a schedule—
daily, quarterly, annual and two year. To account
for repeated procedures, the Maintenance Tables
and the Maintenance Inspection Report have been
divided into four subsections—A, B, C, D. Use the
following chart to determine which group(s) of
procedures are required to perform a scheduled
inspection.
Inspection Table or Checklist
Daily A
Quarterly A + B
Annual A + B + C
Two year A + B + C + D
Maintenance Tables
The maintenance tables contained in this section
provide summary information on the specific
physical requirements for each inspection.
Complete step-by-step instructions for each
scheduled maintenance procedure are provided in
section 4, Scheduled Maintenance Procedures.
Maintenance Inspection Report
The maintenance inspection report contains
checklists for each type of scheduled inspection.
Make copies of the Maintenance Inspection
Report to use for each inspection. Store
completed forms for three years.

3 - 2 Genie Z-20/8N & Genie Z-20/8 & Genie Z-25/8 Part No. 41314
Section 3 • Scheduled Maintenance Inspections First Edition • Third Printing
Tools are
required New parts required
Dealer
service
suggested
Table A
A-1 Inspect the Operator's and Safety Manuals
A-2 Inspect the Decals and Placards
A-3 Inspect for Damage and Loose or Missing Parts
A-4 Check the Hydraulic Oil Level
A-5 Check for Hydraulic Leaks
A-6 Test the Platform and Ground Controls
A-7 Test the Auxiliary Power Operation
A-8 Test the Tilt Sensor
A-9 Test the Drive Speed Limit Switch
A-10 Perform 30 Day Service
Table B
B-1 Check the Batteries
B-2 Inspect the Electrical Wiring
B-3 Inspect the Tires and Wheels
(including castle nut torque)
B-4 Test the Key Switch
B-5 Test the Emergency Stop Buttons
B-6 Test the Ground Control Override
Maintenance Tables