Service Manual

S160 Skid-Steer Loader

S/N 529960001 & Above
S/N 530060001 & Above
S/N AC3260001 & Above

EQUIPPED WITH
BOBCAT INTERLOCK
CONTROL SYSTEM (BICS)

6987034 (5-08) Printed in U.S.A. © Bobcat Company 2008

 MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0903

Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.

CORRECT CORRECT CORRECT

B-10731a B-15590 B-15591

Never service the Bobcat Skid- Use the correct procedure to lift or Cleaning and maintenance are
Steer Loader without instructions. lower operator cab. required daily.

WRONG WRONG WRONG

B-15592 B-15593 B-15599

Have good ventilation when Disconnecting or loosening any Never work on loader with lift
welding or grinding painted hydraulic tubeline, hose, fitting, arms up unless lift arms are held
parts. component or a part failure can by an approved lift arm support
Wear dust mask when grinding cause lift arms to drop. Do not go device. Replace if damaged.
painted parts. Toxic dust and gas under lift arms when raised Never modify equipment or add
can be produced. unless supported by an attachments not approved by
Avoid exhaust fume leaks which approved lift arm support device. Bobcat Company.
can kill without warning. Exhaust Replace it if damaged.
system must be tightly sealed.
WRONG WRONG WRONG

B-15600 B-15601 B-6589

B-16102 B-16102
Stop, cool and clean engine of Keep body, jewelry and clothing Lead-acid batteries produce
flammable materials before away from moving parts, flammable and explosive gases.
checking fluids. electrical contact, hot parts and Keep arcs, sparks, flames and
Never service or adjust loader exhaust. lighted tobacco away from
with the engine running unless Wear eye protection to guard batteries.
instructed to do so in the from battery acid, compressed Batteries contain acid which
manual. springs, fluids under pressure burns eyes or skin on contact.
Avoid contact with leaking and flying debris when engines Wear protective clothing. If acid
hydraulic fluid or diesel fuel are running or tools are used. contacts body, flush well with
under pressure. It can penetrate Use eye protection approved for water. For eye contact flush well
the skin or eyes. type of welding. and get immediate medical
Never fill fuel tank with engine Keep rear door closed except for attention.
running, while smoking or when service. Close and latch door
near open flame. before operating the loader.
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/
operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance
Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat
replacement parts. The Service Safety Training Course is available from your Bobcat dealer.
MSW08-0805
 ALPHABETICAL INDEX

ACCESS PANEL (INSIDE) ..................................... 50-01 ENGINE COOLING SYSTEM .................................70-01

ACCESS PANEL (INSIDE) (SJC) ........................... 50-01 ENGINE INFORMATION .........................................70-01
AIR CLEANER ........................................................70-01 ENGINE SPEED CONTROL ...................................70-01
AIR CLEANER SERVICE .......................................10-01 ENGINE SPEED CONTROL (SJC) .........................70-01
AIR CONDITIONING SYSTEM FLOW ................... 80-01 EVAPORATOR COIL ...............................................80-01
ALTERNATOR ........................................................ 60-01 EVAPORATOR/HEATER UNIT................................80-01
EXPANSION VALVE ................................................80-01
BACK-UP ALARM SYSTEM ................................... 60-01
BATTERY................................................................ 60-01 FINAL DRIVE TRANSMISSION (CHAINCASE)......10-01
BLOWER FAN ........................................................ 80-01 FLYWHEEL AND HOUSING ...................................70-01
BOBCAT CONTROLLER (ACS) ............................ 60-01 FLYWHEEL RPM SENSOR ....................................60-01
BOBCAT CONTROLLER (GATEWAY AND FRONT AUXILIARY HYDRAULIC
AUXILIARY) .......................................................... 60-01 COUPLER BLOCK ...............................................20-01
BOBCAT CONTROLLER (SJC) (DRIVE) ............... 60-01 FUEL SYSTEM.............................................10-01, 70-01
BOBCAT INTERLOCK CONTROL FUEL TANK .............................................................50-01
SYSTEM (BICS) ................................................... 60-01
BOB-TACH (HAND LEVER) ........................ 10-01, 50-01 HEATER COIL .........................................................80-01
BOB-TACH (POWER).................................. 10-01, 50-01 HEATER VALVE ......................................................80-01
BOB-TACH (POWER) BLOCK................................ 20-01 HIGH FLOW VALVE ................................................20-01
BRAKE (SINGLE SPEED) ...................................... 40-01 HYDRAULIC CONNECTION SPECS ............... SPEC-01
BRAKE (TWO-SPEED)........................................... 40-01 HYDRAULIC CONTROL VALVE (ACS) OR (SJC) ..20-01
BUCKET POSITION VALVE ................................... 20-01 HYDRAULIC CONTROL VALVE (STANDARD) ......20-01
HYDRAULIC/HYDROSTATIC FILTERS ..................20-01
CAB DOOR ............................................................. 50-01 HYDRAULIC FLUID RESERVOIR ..........................20-01
CALIBRATION ........................................................ 60-01 HYDRAULIC/HYDROSTATIC
CAMSHAFT AND TIMING GEARS......................... 70-01 FLUID SPECIFICATIONS................................ SPEC-01
CASE DRAIN FILTER ............................................. 30-01 HYDRAULIC/HYDROSTATIC SYSTEM..................10-01
CHAINCASE ........................................................... 40-01 HYDRAULIC PUMP (STANDARD)..........................20-01
CHARGE PRESSURE ........................................... 30-01 HYDRAULIC PUMP (STANDARD) (HIGH FLOW)..20-01
COMPRESSOR ...................................................... 80-01 HYDRAULIC PUMP (SJC) ......................................20-01
CONDENSER ......................................................... 80-01 HYDRAULIC PUMP (SJC) (HIGH FLOW)...............20-01
CONTROL HANDLE/LEVER .................................. 50-01 HYDRAULIC SYSTEM INFORMATION ..................20-01
CONTROL HANDLE/LEVER (ACS) ....................... 50-01 HYDROSTATIC MOTOR .........................................30-01
CONTROL HANDLE/LEVER (SJC) ........................ 50-01 HYDROSTATIC MOTOR (TWO SPEED) ................30-01
CONTROL PANEL .................................................. 50-01 HYDROSTATIC MOTOR CARRIER
CONTROL PANEL (SJC)........................................ 50-01 (SINGLE ANDTWO-SPEED WITH MANUAL
CONTROL PANEL SETUP ..................................... 60-01 CONTROLS) .........................................................30-01
CONTROL PEDALS AND LINKAGE ...................... 50-01 HYDROSTATIC MOTOR CARRIER
CONTROL PEDALS (ACS) .................................... 50-01 (SINGLE AND TWO-SPEED WITH SJC
CONTROL SYSTEM (ACS) .................................... 60-01 CONTROLS) .........................................................30-01
CONVERSIONS ................................................SPEC-01 HYDROSTATIC PUMP ............................................30-01
CRANKSHAFT AND PISTONS ............................. 70-01 HYDROSTATIC PUMP (SJC) ..................................30-01
CYLINDER (BOB-TACH) ........................................ 20-01 HYDROSTATIC SYSTEM INFORMATION..............30-01
CYLINDER (LIFT) ................................................... 20-01
CYLINDER (TILT) ................................................... 20-01 INSTRUMENT PANELS .........................................60-01
CYLINDER HEAD ................................................... 70-01

DIAGNOSTICS SERVICE CODES......................... 60-01

DRIVE BELT ........................................................... 30-01
DRIVE COMPONENTS .......................................... 40-01

ELECTRICAL/HYD. CONTROLS ........................... 60-01

ELECTRICAL/HYD. CONTROLS (SJC) ................. 60-01
ELECTRICAL SYSTEM INFORMATION ................ 60-01
ENGINE COOLING SYSTEM ................................. 10-01
ENGINE LUBRICATION SYSTEM ......................... 10-01

S160 Service Manual

 ALPHABETICAL INDEX (CONT’D)

LIFT ARMS ..............................................................50-01 WHEEL SPEED SENSOR (SJC) ............................ 60-01

LIFT ARM BYPASS CONTROL VALVE...................20-01 WINDOW (CAB DOOR) .......................................... 50-01
LIFT ARM SUPPORT DEVICE................................10-01 WINDOW (REAR) ................................................... 50-01
LIFTING AND BLOCKING THE LOADER...............10-01 WINDOW (SIDE)..................................................... 50-01
LIGHTS....................................................................60-01 WINDOW (TOP) ...................................................... 50-01
S160 LOADER SPECIFICATIONS .................... SPEC-01
LOADER STORAGE AND RETURN TO SERVICE 10-01
LUBRICATING THE LOADER .................................10-01
LUBRICATION SYSTEM .........................................70-01

MAIN RELIEF VALVE ..............................................20-01

MAINTENANCE CLOCK .........................................60-01
MUFFLER................................................................70-01
OIL COOLER...........................................................20-01
OPERATOR CAB..........................................10-01, 50-01
OPERATOR SEAT...................................................50-01
OPERATOR SEAT (SUSPENSION)........................50-01

PASSWORD SETUP ...............................................60-01

PIVOT PINS.............................................................10-01

REAR AUXILIARY DIVERTER VALVE ....................20-01

REAR DOOR ..........................................................50-01
REAR GRILL ..........................................................50-01
RECEIVER/DRIER ..................................................80-01
REGULAR MAINTENANCE ....................................80-01
REMOTE START TOOL KIT-MEL1563 ...................10-01
REMOTE START TOOL (SERVICE TOOL) ‘
KIT - 6689779 ........................................................10-01

SEAT BAR ...............................................................50-01

SEAT BAR SENSOR ...............................................60-01
SERVICE PC (LAPTOP COMPUTER) ....................60-01
SERVICE SCHEDULE.............................................10-01
SPARK ARRESTOR MUFFLER ..............................10-01
STARTER ................................................................60-01
STEERING DRIFT COMPENSATION .....................60-01
STOPPING THE ENGINE AND
LEAVING THE LOADER .......................................10-01
SYSTEM CHARGING AND RECLAMATION ..........80-01

THERMOSTAT.........................................................80-01
TIRE MAINTENANCE .............................................10-01
TORQUE SPECIFICATIONS FOR BOLTS........ SPEC-01
TOWING THE LOADER ..........................................10-01
TRACTION LOCK....................................................60-01
TRANSPORTING THE LOADER ON A TRAILER ..10-01
TROUBLESHOOTING.............................................80-01
TURBOCHARGER ..................................................70-01
TWO-SPEED VALVE ...............................................30-01

S160 Service Manual

 SAFETY &
CONTENTS MAINTENANCE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V HYDRAULIC

SYSTEM
FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX HYDROSTATIC

SYSTEM
DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X

BOBCAT LOADER IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . XI DRIVE

SYSTEM
SAFETY AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 10-01

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01

MAIN FRAME
HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01 ELECTRICAL

SYSTEM &
MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01 ANALYSIS
ELECTRICAL SYSTEM & ANALYSIS. . . . . . . . . . . . . . . . . . . . . 60-01
ENGINE
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01 SERVICE

HEATING, VENTILATION, AIR CONDITIONING . . . . . . . . . . . . 80-01

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01 HVAC

SPECIFICATIONS

SPECIFICATIONS

i S160 Service Manual

 FOREWORD
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment
procedures for the Bobcat loader and its component parts and systems. Refer to the Operation &
Maintenance Manual for operating instructions, starting procedure, daily checks, etc.
A general inspection of the following items must be made after the loader has had service or repair:
1. Check that the ROPS/FOPS 9. The parking brake must
(Including side screens) is in function correctly.
good condition and is not
modified.

2. Check that ROPS mounting 10. Enclosure door latches must

hardware is tightened and is open and close freely.
Bobcat approved.

3. The seat belt must be 11. Bob-Tach wedges and

correctly installed, functional linkages must function
and in good condition. correctly and be in good
condition.

4. The seat bar must be 12. Safety treads must be in good

correctly adjusted, clean and condition.
lubricated.

5. Check lift arm support device, 13. Check for correct function of
replace if damaged. indicator lamps.

6. Machine signs (decals) must 14. Check hydraulic fluid level,

be legible and in the correct engine oil level and fuel
location. supply.

7. Steering levers, hand controls 15. Inspect for fuel, oil or

and foot pedals must return to hydraulic fluid leaks.
neutral (as applicable).

8. Check for correct function of 16. Lubricate the loader.

the work lights.

FW SSL-0308 SM

ii S160 Service Manual

17. Check the condition of the 22. Check for any field
battery and cables. modification not completed.

18. Inspect the air cleaner for 23. Operate the machine and
damage or leaks. Check the check all functions.
condition of the element.

19. Check the electrical charging 24. Check for correct function of
system. the Bobcat Interlock Control
System (BICS™) before the
machine is returned to the
customer.
20. Check tires for wear and 25. Check function or condition of
pressure. Check tracks for all equipped options and
wear and tension. Use only accessories (examples: back-
approved tires or tracks. up alarm, fire extinguisher,
rotating beacon, lift kits, etc.).
21. Inspect for loose or broken 26. Recommend to the owner
parts or connections. that all necessary corrections
be made before the machine
is returned to service.

CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its
constituents are known to the state of California
to cause cancer, birth defects and other
reproductive harm.

FW SSL-0308 SM

iii S160 Service Manual

SAFETY INSTRUCTIONS The following publications provide information on the
safe use and maintenance of the Bobcat machine and
attachments:
Safety Alert Symbol
• The Delivery Report is used to assure that complete
This symbol with a warning statement means: instructions have been given to the new owner and
“Warning, be alert! Your safety is involved!” that the machine is in safe operating condition.
Carefully read the message that follows.
• The Operation & Maintenance Manual delivered with
the machine or attachment contains operating
information as well as routine maintenance and
service procedures. It is a part of the machine and can
WARNING be stored in a container provided on the machine.
Replacement Operation & Maintenance Manuals can
be ordered from your Bobcat dealer.
Instructions are necessary before operating or
servicing machine. Read and understand the • Machine signs (decals) instruct on the safe operation
Operation & Maintenance Manual, Operator’s and care of your Bobcat machine or attachment. The
Handbook and signs (decals) on machine. Follow signs and their locations are shown in the Operation
warnings and instructions in the manuals when & Maintenance Manual. Replacement signs are
making repairs, adjustments or servicing. Check for available from your Bobcat dealer.
correct function after adjustments, repairs or service.
Untrained operators and failure to follow instructions • An Operator’s Handbook fastened to the operator
can cause injury or death. cab. It’s brief instructions are convenient to the
W-2003-0903
operator. The handbook is available from your dealer
in an English edition or one of many other languages.
See your Bobcat dealer for more information on
translated versions.
IMPORTANT
• The AEM Safety Manual delivered with the machine
This notice identifies procedures which must be gives general safety information.
followed to avoid damage to the machine.
I-2019-0284 • The Service Manual and Parts Manual are available
from your dealer for use by mechanics to do shop-
type service and repair work.

• The Skid-Steer Loader Operator Training Course is

DANGER available through your local dealer or at

www.training.bobcat.com or www.bobcat.com.
This course is intended to provide rules and practices
The signal word DANGER on the machine and in the of correct operation of the Skid-Steer Loader. The
manuals indicates a hazardous situation which, if not course is available in English and Spanish versions.
avoided, will result in death or serious injury.
D-1002-1107 • Service Safety Training Courses are available from
your Bobcat dealer or at www.training.bobcat.com
or www.bobcat.com. They provide information for
safe and correct service procedures.

WARNING • The Skid-Steer Loader Safety Video is available from

your Bobcat dealer or at www.training.bobcat.com
The signal word WARNING on the machine and in the or www.bobcat.com.
manuals indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
W-2044-1107

SI SSL-0308 SM

v S160 Service Manual

FIRE PREVENTION Hydraulic System

Check hydraulic tubes, hoses and fittings for damage

and leakage. Never use open flame or bare skin to check
for leaks. Hydraulic tubes and hoses must be properly
routed and have adequate support and secure clamps.
Tighten or replace any parts that show leakage.

Maintenance Always clean fluid spills. Do not use gasoline or diesel

fuel for cleaning parts. Use commercial nonflammable
The machine and some attachments have components
solvents.
that are at high temperatures under normal operating
conditions. The primary source of high temperatures is
Fueling
the engine and exhaust system. The electrical system, if
damaged or incorrectly maintained, can be a source of
arcs or sparks.

Flammable debris (leaves, straw, etc.) must be removed

regularly. If flammable debris is allowed to accumulate, it
can cause a fire hazard. Clean often to avoid this
accumulation. Flammable debris in the engine
compartment is a potential fire hazard. Stop the engine and let it cool before adding fuel. No
smoking! Do not refuel a machine near open flames or
The operator’s area, engine compartment and engine sparks. Fill the fuel tank outdoors.
cooling system must be inspected every day and cleaned
if necessary to prevent fire hazards and overheating. Starting

All fuels, most lubricants and some coolants mixtures are Do not use ether or starting fluids on any engine that has
flammable. Flammable fluids that are leaking or spilled glow plugs. These starting aids can cause explosion and
onto hot surfaces or onto electrical components can injure you or bystanders.
cause a fire.
Use the procedure in the Operation & Maintenance
Operation Manual for connecting the battery and for jump starting.

Do not use the machine where exhaust, arcs, sparks or

hot components can contact flammable material, Spark Arrestor Exhaust System
explosive dust or gases. The spark arrestor exhaust system is designed to control
the emission of hot particles from the engine and exhaust
Electrical system, but the muffler and the exhaust gases are still
hot.

Check the spark arrestor exhaust system regularly to

make sure it is maintained and working properly. Use the
procedure in the Operation & Maintenance Manual for
cleaning the spark arrestor muffler (if equipped).
Check all electrical wiring and connections for damage.
Keep the battery terminals clean and tight. Repair or
replace any damaged part or wires that are loose or
frayed.

Battery gas can explode and cause serious injury. Use

the procedure in the Operation & Maintenance Manual
for connecting the battery and for jump starting. Do not
jump start or charge a frozen or damaged battery. Keep
any open flames or sparks away from batteries. Do not
smoke in battery charging area.

SI SSL-0308 SM

vii S160 Service Manual

FIRE PREVENTION (CONT’D)

Welding And Grinding

Always clean the machine and attachment, disconnect

the battery, and disconnect the wiring from the Bobcat
controllers before welding. Cover rubber hoses, battery
and all other flammable parts. Keep a fire extinguisher
near the machine when welding.

Have good ventilation when grinding or welding painted

parts. Wear dust mask when grinding painted parts.
Toxic dust or gas can be produced.

Dust generated from repairing nonmetallic parts such as

hoods, fenders or covers can be flammable or explosive.
Repair such components in a well ventilated area away
from open flames or sparks.

Fire Extinguishers

Know where fire extinguishers and first aid kits are

located and how to use them. Inspect the fire
extinguisher and service the fire extinguisher regularly.
Obey the recommendations on the instructions plate.

SI SSL-0308 SM

viii S160 Service Manual

SERIAL NUMBER LOCATIONS Engine Serial Number

Always use the serial number of the loader when Figure 2

requesting service information or when ordering parts.
Early or later models (identification made by serial
number) may use different parts, or it may be necessary
to use a different procedure in doing a specific service
operation.

Figure 1

P-48387

The engine serial number is located on the side of the

engine [Figure 2].

P-45263

Loader Serial Number

The loader serial number plate is located on the outside

of the loader frame [Figure 1].

Explanation of loader Serial Number:

XXXX XXXXX

Module 2. - Production
Sequence (Series)

Module 1. - Model / Engine

Combination

1. The four digit Model/Engine Combination Module

number identifies the model number and engine
combination.

2. The five digit Production Sequence Number identifies

the order which the loader is produced.

ix S160 Service Manual

DELIVERY REPORT

Figure 3

B-16315

The delivery report must be filled out by the dealer and

signed by the owner or operator when the Bobcat loader
is delivered. An explanation of the form must be given to
the owner. Make sure it is filled out completely [Figure
3].

x S160 Service Manual

BOBCAT LOADER IDENTIFICATION

FRONT
LIGHTS
OPERATOR SEAT
with SEAT BELT
& SEAT BAR

GRAB
HANDLES

TILT
CYLINDERS
FRONT AUXILIARY
QUICK COUPLERS

BUCKET STEPS
STEPS

† BUCKET B-19876A

● OPERATOR CAB
(ROPS / FOPS)

◆ REAR AUXILIARY LIFT ARM

QUICK COUPLERS SUPPORT DEVICE

LIFT ARM

REAR
GRILL LIFT
CYLINDER

REAR
DOOR

REAR
LIGHT
TAIL
LIGHT
✽ TIRES B-19877A

◆ Optional or Field Accessory (Not Standard Equipment)

✽ TIRES - Tires shown may not be standard. The machine is factory equipped with standard tires. Other tires are available.
† Bucket - Several different buckets and other attachments are available for this machine.
● ROPS, FOPS - Roll Over Protective Structure, per SAE / ISO 3471, and Falling Object Protective Structure per ISO 3449,
Level I. Level I I is available.

xi S160 Service Manual

 SAFETY &
SAFETY AND MAINTENANCE MAINTENANCE
AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
Replacing Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
SAFETY &
BOB-TACH (HAND LEVER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1 MAINTENANCE
Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

BOB-TACH (POWER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-141-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 10-141-1

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1

Checking Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-2
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1 DRIVE
Removing And Replacing Coolant . . . . . . . . . . . . . . . . . . . . . . . 10-90-3 SYSTEM

ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1

Checking And Adding Engine Oil. . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Engine Oil Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Removing And Replacing Oil And Filter. . . . . . . . . . . . . . . . . . 10-110-2

FINAL DRIVE TRANSMISSION (CHAINCASE) . . . . . . . . . . . . . . 10-130-1 ELECTRICAL

Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1 SYSTEM &
Removing And Replacing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1 ANALYSIS

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1

Biodiesel Blend Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1 ENGINE
Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-2 SERVICE
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-3
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . 10-100-3
SPECIFICATIONS
HYDRAULIC / HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . 10-120-1
Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-7
Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Hydraulic / Hydrostatic Fluid Chart . . . . . . . . . . . . . . . . . . . . . 10-120-1
Removing And Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . 10-120-2
Removing And Replacing Hydraulic / Hydrostatic Filter . . . . . 10-120-2
Removing And Replacing Hydraulic Case Drain Filters (Single Speed
Loaders). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-3
Removing And Replacing Hydraulic Case Drain Filters (Two-Speed
Loaders). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-4
Removing And Replacing Hydraulic Charge Filter. . . . . . . . . . 10-120-6

LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1

Installing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1
Removing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-2

LIFTING AND BLOCKING THE LOADER . . . . . . . . . . . . . . . . . . . 10-10-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
Continued On Next Page

10-01 S160 Service Manual

 SAFETY AND MAINTENANCE (CONT’D)

LOADER STORAGE AND RETURN TO SERVICE . . . . . . . 10-190-1

Return to Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1
Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1

LUBRICATING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . 10-150-1

Lubrication Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1

OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
Cab Door Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-4
Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-3
Raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-2
Special Applications Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-4
Special Applications Kit Inspection And Maintenance . . . . 10-30-4

PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . 10-180-1

REMOTE START TOOL KIT -MEL1563 . . . . . . . . . . . . . . . . . 10-60-1

Remote Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-4
Remote Start Tool - MEL1563 . . . . . . . . . . . . . . . . . . . . . . 10-60-1
Service Tool Harness Communicator - MEL1566 . . . . . . . 10-60-3
Service Tool Harness Control - MEL1565 . . . . . . . . . . . . . 10-60-2

REMOTE START TOOL (SERVICE TOOL) KIT - 6689779 . . 10-61-1

Computer Service Tool Harness - 6689746 . . . . . . . . . . . . 10-61-4
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61-1
Loader Service Tool Harness - 6689747 . . . . . . . . . . . . . . 10-61-3
Remote Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-5
Remote Start Tool (Service Tool) - 6689778 . . . . . . . . . . . 10-61-2

SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1

SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . . . . . 10-170-1

Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1

STOPPING THE ENGINE AND LEAVING THE LOADER . . 10-200-1

Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-2
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1

TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
Rotating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

Continued On Next Page

10-02 S160 Service Manual

 SAFETY AND MAINTENANCE (CONT’D)

TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

TRANSPORTING THE LOADER ON A TRAILER . . . . . . . . . 10-40-1

Fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
Loading And Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1

TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE

STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SPEC
SECTION) UNLESS OTHERWISE SPECIFIED.

10-03 S160 Service Manual

LIFTING AND BLOCKING THE LOADER Figure 10-10-2

Figure 10-10-1

P-45481

B-7023A
Put a floor jack under the rear of the loader.

Lift the rear of the loader and install jackstands [Figure

10-10-2].
WARNING
Figure 10-10-3
Instructions are necessary before operating or
servicing machine. Read and understand the
Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or service.
Untrained operators and failure to follow instructions
can cause injury or death.
W-2003-0903

Procedure

Always park the loader on a level surface. P-45482

Put the floor jack under the front of the loader.

WARNING Lift the front of the loader and put jackstands under the
axle tubes [Figure 10-10-3].
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
NOTE: Make sure the jackstands do not touch the
Failure to use jackstands can allow the machine to
tires. Make sure tires clear the floor and any
fall or move and cause injury or death.
obstacles.
W-2017-0286

10-10-1 S160 Service Manual

LIFT ARM SUPPORT DEVICE Figure 10-20-2

Installing

WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
P-45252
Service lift arm support device if damaged or if parts
are missing. Using a damaged lift arm support or
with missing parts can cause lift arms to drop Lower the lift arm support device to the top of the lift
causing injury or death. cylinder. Hook the free end of the spring (Item 1) [Figure
W-2572-0407 10-20-2] to the lift arm support device so there will be no
interference with the support device engagement.

Sit in the operator’s seat, fasten the seat belt and lower
the seat bar. Start the engine.

Figure 10-20-3

Remove attachment from the loader. See BOB-TACH

(HAND LEVER) on Page 50-40-1. OR See BOB-TACH
(POWER) on Page 50-41-1.
1 2
Figure 10-20-1

2
P-54470A N-20524B

3 Raise the lift arms until the lift arm support device drops
onto the lift cylinder rod (Item 1) [Figure 10-20-3]

Lower the lift arms slowly until the support device is held
between the lift arm and the lift cylinder. Stop the engine.
1 Raise the seat bar and move both pedals until both
pedals lock.

P-43747 P-45251 Install pin (Item 2) [Figure 10-20-3] into the rear of the lift
arm support device below the cylinder rod.
Put jack stands under the rear corners of the loader
frame (Inset) [Figure 10-20-1].

Disconnect the spring (Item 1) from the lift arm support

device retaining pin. Support the lift arm support device
(Item 2) with your hand and remove the retaining pin
(Item 3) [Figure 10-20-1].

10-20-1 S160 Service Manual

LIFT ARM SUPPORT DEVICE (CONT’D) Figure 10-20-5

Removing

Remove the pin from the lift arm support device. 1

Figure 10-20-4

P-45251

Raise the lift arms a small amount. The spring will lift the
support device off the lift cylinder rod. Lower the lift arms.
Stop the engine.
P-45486
Raise the seat bar, disconnect the seat belt, move pedals
until both pedals lock and exit the cab.
Connect the spring (Item 1) [Figure 10-20-4] from the lift Disconnect the spring from the bracket.
arm support device to the bracket below the lift arms.
Raise the support device into storage position and insert
Sit in the operator’s seat fasten the seat belt and lower pin (Item 1) [Figure 10-20-5] through lift arm support
the seat bar. device and bracket. Connect the spring to the pin.

Start the engine. Remove the jack stands.

10-20-2 S160 Service Manual

OPERATOR CAB

Description

The Bobcat Loader has an operator cab (ROPS and

FOPS) as standard equipment to protect the operator
from rollover and falling objects. Check with your dealer if
the operator cab has been damaged. The seat belt must
be worn for rollover protection.

ROPS / FOPS - Roll Over protective Structure per ISO

3471, and Falling Object Protective Structure per SAE
J1043 and ISO 3449, Level I. Level II is available.

Level I
Protection from falling bricks, small concrete blocks,
and hand tools encountered in operations such as
highway maintenance, landscaping, and other
construction sites.

Level II
Protection from falling trees, rocks: for machines
involved in site clearing, overhead demolition or
forestry.

WARNING
Never modify operator cab by welding, grinding,
drilling holes or adding attachments unless
instructed to do so by Bobcat Company. Changes to
the cab can cause loss of operator protection from
rollover and falling objects, and result in injury or
death.
W-2069-0200

10-30-1 S160 Service Manual

OPERATOR CAB (CONT’D)

Raising

Always stop the engine before raising or lowering the

cab.

Stop the loader on a level surface. Lower the lift arms. If

the lift arms must be up while raising the operator cab,
install the lift arm support device. (See LIFT ARM
SUPPORT DEVICE on Page 10-20-1.)

Figure 10-30-1

NOTE: On Advanced Control System (ACS) equipped

machines, the steering levers could contact
the cab frame while raising or lowering the
operator cab. The engine MUST be stopped
before raising or lowering the cab.

Figure 10-30-3

P-43747

Install jackstands under the rear of the loader frame

[Figure 10-30-1].

Figure 10-30-2

P-45261

Lift on the grab handles and bottom of the operator cab

[Figure 10-30-3] slowly until the cab is all the way up and
the latching mechanism engages.

P-31288 P-31289

Remove the nuts and plates [Figure 10-30-2] (both

sides) at the front corners of the cab.

10-30-2 S160 Service Manual

OPERATOR CAB (CONT’D)

Lowering
Always stop the engine before raising or lowering the
WARNING
cab.
NOTE: Always use the grab handles to lower the cab. PINCH POINT CAN CAUSE INJURY
Figure 10-30-4 Remove your hand from the latching mechanism
when the cab is past the latch stop.
W-2469-0803

Figure 10-30-5

N-20120 P-45262

Pull down on the bottom of the operator cab until it stops

at the latching mechanism [Figure 10-30-4].
P-31288 P-31289
NOTE: The weight of the cab increases when
equipped with options and accessories such Install the plates and nuts (both sides) [Figure 10-30-5].
cab door, heater, air conditioning, etc. In
these cases, the cab may need to be raised Tighten the nuts to 40-45 ft.-lb. (54-61 N•m) torque.
slightly from the latch to be able to release the
latch.

NOTE: On Advanced Control System (ACS) equipped

machines, the steering levers could contact
the cab frame while raising or lowering the
operator cab. The engine MUST be stopped
before raising or lowering the cab.

Support the cab and release the latching mechanism

(Inset) [Figure 10-30-4]. Remove your hand from
latching mechanism when the cab is past the latch stop.
Use both hands to lower the cab all the way down.

10-30-3 S160 Service Manual

OPERATOR CAB (CONT’D) Special Applications Kit

Cab Door Sensor Figure 10-30-8

This machine may be equipped with a Cab Door Sensor.

Figure 10-30-6

S3999A

B-25286A

1
2 Available for special applications to restrict material from
entering cab openings. Kit includes 1/2 inch
P-68116
polycarbonate front door, top and rear windows. [Figure
P-68115 10-30-8].

See your Bobcat dealer for availability.

The cab door has a sensor (Item 1) [Figure 10-30-6]
installed which deactivates the lift and tilt valves when the Special Applications Kit Inspection And Maintenance
door is open.
• Inspect for cracks or damage. Replace if required.
A decal is located on the latch mechanism (Item 2)
• Pre-rinse with water to remove gritty materials.
[Figure 10-30-6].
• Wash with a mild household detergent and warm
The LIFT & TILT VALVE light (Item 3) [Figure 10-30-6] water.
will be OFF when the door is closed, the key switch is • Use a sponge or soft cloth. Rinse well with water and
turned to RUN or the RUN / ENTER button is pressed, dry with a clean soft cloth or rubber squeegee.
the seat bar is lowered and the PRESS TO OPERATE • Do not use abrasive or highly alkaline cleaners.
LOADER button is pressed. • Do not operate windshield wipers on a dry surface.
• Do not clean with metal blades or scrapers.
Figure 10-30-7

The LIFT & TILT VALVE light (Item 3) [Figure 10-30-7]

will be ON when the door is open, the key switch is
turned to RUN or the RUN / ENTER button is pressed,
the seat bar is lowered and the PRESS TO OPERATE
LOADER button is pressed.

[DOOR] will appear in the data display [Figure 10-30-7].

10-30-4 S160 Service Manual

TRANSPORTING THE LOADER ON A TRAILER Fastening

Loading And Unloading Figure 10-40-2

WARNING
AVOID SERIOUS INJURY OR DEATH
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can
break and cause personal injury.
P-31228 P-73276
W-2058-0807

Be sure the transport and towing vehicles are of

adequate size and capacity for weight of loader. (See
Performance on Page SPEC-10-2).

Figure 10-40-1

Alternate Front
Tie-Down

P-45989 P-45218C

Use the following procedure to fasten the Bobcat Loader

to the transport vehicle to prevent the loader from moving
during sudden stops or when going up or down slopes
[Figure 10-40-2].

• Lower the bucket or attachment to the floor.

1
• Stop the engine.
• Engage the parking brake.
P-43631 P-45215D • Install chains at the front and rear loader tie down
positions [Figure 10-40-2]
• Fasten each end of the chain to the transport vehicle.
A loader with an empty bucket or no attachment must be
loaded backward onto the transport vehicle [Figure 10-
40-1].

The rear of the trailer must be blocked or supported (Item

1) [Figure 10-40-1] when loading or unloading the loader
to prevent the front end of the trailer from raising up.

10-40-1 S160 Service Manual

TOWING THE LOADER

Procedure

Because of the design of the loader, there is not a

recommended towing procedure.

• The loader can be lifted onto a transport vehicle.

• The loader can be skidded a short distance to move

for service (EXAMPLE: Move onto a transport
vehicle.) without damage to the hydrostatic system.
(The tires will not turn.) There might be slight wear to
the tires when the loader is skidded.

The towing chain (or cable) must be rated at one and

one-half times the weight of the loader. (See
Performance on Page SPEC-10-2.)

10-50-1 S160 Service Manual

REMOTE START TOOL KIT -MEL1563 Figure 10-60-2

Remote Start Tool - MEL1563

Tools that will be needed to complete the following steps

are:
2
MEL1563 - Remote Start Tool 3
MEL1565 - Service Tool Harness Control 1
MEL1566 - Service Tool Harness Communicator
(Computer Interface)

Figure 10-60-1

P16117
1

The traction lock switch (Item 1) [Figure 10-60-2] is used

to turn traction lock ON or OFF. Push the switch to the
override position. The switch will illuminate to indicate
traction lock OVERRIDE, in this position the wheels are
able to turn.

The maximum flow/variable flow switch (Item 2) [Figure

10-60-2] is used to activate the auxiliary hydraulics.
Pressing the switch once will activate maximum flow.
P16114 Pressing the switch again will activate variable flow. The
switch will illuminate to indicate which flow rate is active.
Pressing the switch a third time will turn the flow OFF.
The remote start tool (Item 1) [Figure 10-60-1] is The switch is used when checking pressures and flow
required when the service technician is checking the rate.
hydraulic/hydrostatic system or adjusting the steering
linkage. The auxiliary pressure release (Item 3) [Figure 10-60-2]
is used to release hydraulic pressure to the front and/or
rear auxiliary couplers. To release pressure; push and
hold the switch for a few seconds.

NOTE: With the engine running; pushing and holding

the pressure release switch will cause the
engine to stop. To relieve the pressure; press
the switch until the engine stops.

10-60-1 S160 Service Manual

REMOTE START TOOL-MEL1563 (CONT'D) Service Tool Harness Control - MEL1565

Remote Start Tool - MEL1563 (Cont’d) Figure 10-60-5

Figure 10-60-3
2

1 1

P16114

P16116
The service tool harness control (Item 1) [Figure 10-60-
5] is used to connect the remote start tool (Item 2)
Figure 10-60-4 [Figure 10-60-5] to the electrical system on the loader.

1 Figure 10-60-6

P16120

N-19561
The 10-pin rectangular connector (Item 1) [Figure 10-60-
3] is used to update software in the Deluxe
Instrumentation Panel (Item 1) [Figure 10-60-4]. Remove the plug (Item 1) [Figure 10-60-6] from the
loader harness connector.
NOTE: The Service PC must be connected to the
remote start tool to update the deluxe panel Connect the service tool harness control to the loader
software. harness connector.

The panel must be removed from inside the operator cab

and plugged into this connector [Figure 10-60-3].

10-60-2 S160 Service Manual

REMOTE START TOOL-MEL1563 (CONT'D) Service Tool Harness Communicator - MEL1566

Service Tool Harness Control - MEL1565 (Cont’d) Figure 10-60-8

Figure 10-60-7 2

2
1

1
P16119

N-19631
The service tool harness communicator (Item 1) [Figure
10-60-8] is required to connect remote start tool to the
Loaders equipped with an attachment harness (Item 1) Service PC (Item 2) [Figure 10-60-8].
[Figure 10-60-7] must disconnect the attachment
harness from the loader harness (Item 2) [Figure 10-60-
7].

Connect the service tool harness to the ACD connector

and the loader harness connector.

NOTE: To monitor, diagnose or load new software

the Service PC must be connected to the
Remote Start Tool Switch.

10-60-3 S160 Service Manual

REMOTE START TOOL KIT-MEL1563 (CONT’D) Figure 10-60-11

Remote Start Procedure

The tool listed will be needed to do the following

procedure:

MEL1563: Remote Start Tool Kit

1
Figure 10-60-9

N-19150

Remove the plug (Item 1) [Figure 10-60-10] or

disconnect the attachment control harness (Item 1)
[Figure 10-60-11] if connected.

Figure 10-60-12

P16115

The remote start tool (Item 1) [Figure 10-60-9] is

required when the operator cab is in the raised position
for service and the service technician needs to turn the
key switch on or start the engine. Example: adjusting the
steering linkage.

Lift and block the loader.

Raise the lift arms (if required by the procedure) and
install an approved lift arm support device.
P13861
Raise the operator cab (if required by the procedure).

Open the rear door of the loader. Connect the remote start tool to the engine harness
connector [Figure 10-60-12].
Figure 10-60-10
NOTE: The key switch on the right-hand side
operator panel must be in the off position or
the Remote Start Kit will not operate.

WARNING
1
AVOID INJURY OR DEATH
With the 7-pin connector plugged into the loader and
the Remote Start Key Switch in the OFF position, the
loader can still be started from the operator panel
inside the cab. Placing the key switch of the remote
start tool in the run position disconnects the
operator panel key switch from the start circuit. If the
N-19151 service technician will be working in the engine area
it is important to remove the operator panel keys.
W-2357-0899

10-60-4 S160 Service Manual

REMOTE START TOOL KIT-MEL1563 (CONT'D) Figure 10-60-14

Remote Start Procedure (Cont'd)

Figure 10-60-13

2
3 1

P16118

The traction lock switch (Item 1) [Figure 10-60-14] is

P16116 used to turn traction lock on or off. Push the switch to the
override position. The switch will illuminate to indicate
traction lock OVERRIDE, in this position the wheels are
The remote start tool (Item 1) [Figure 10-60-13] has able to turn.
three rocker switches.
The maximum flow/variable flow switch (Item 2) [Figure
10-60-14] is used to activate the auxiliary hydraulics.
Pressing the switch once will activate variable flow.
Pressing the switch again will activate maximum flow.
The switch will illuminate to indicate which flow rate is
active. Pressing the switch a third time will turn the flow
OFF. The switch is used when checking pressures and
flow rate.

The auxiliary pressure release (Item 3) [Figure 10-60-14]

is used to release hydraulic pressure to the front and/or
rear auxiliary couplers. To release pressure; push and
hold the switch for three seconds.

NOTE: With the engine running; pushing and holding

the pressure release switch will cause the
engine to stop in three seconds. To relieve the
pressure; continue to press the switch after
the engine has stopped.

10-60-5 S160 Service Manual

REMOTE START TOOL KIT-MEL1563 (CONT'D)

Remote Start Procedure (Cont'd)

NOTE: With the engine running; pushing and holding

the pressure release switch will cause the
engine to stop in three seconds. To relieve the
pressure at the rear or right hand auxiliary, (If
so equipped.) continue to hold the switch for
three seconds after the engine has stopped.

Figure 10-60-15

P-34661

Push the couplers on the front auxiliary block toward the

block and hold for five seconds to release the front
auxiliary pressure [Figure 10-60-15].

10-60-6 S160 Service Manual

REMOTE START TOOL (SERVICE TOOL) KIT -
6689779

Description

The Remote Start Tool (Service Tool) Kit is a replacement

tool for MEL 1563 Remote Start Tool and MEL 1400B -
BOSS® Diagnostic Tool.

The Remote Start Tool (Service Tool) Kit, P/N 6689779,

can be used to service older loaders with the BOSS®
system using the supplied BOSS® Service Tool Harness
P/N 6689745.

The Remote Start Tool (Service Tool) Kit, P/N 6689779,

can be used to service newer loaders using the supplied
harness P/N 6689747.

A computer can be connected to the Remote Start Tool

(Service Tool) for diagnostics and software updates using
the computer harness P/N 6689746 in conjunction with
the loader harness.

10-61-1 S160 Service Manual

REMOTE START TOOL (SERVICE TOOL) KIT - Figure 10-61-17
6689779 (CONT'D)
2
Remote Start Tool (Service Tool) - 6689778

Tools that will be needed to complete the following steps

5 3
are:

Order from Bobcat Parts P/N: 6689779 - Remote Start 6 4

Tool (Service Tool) Kit
Kit Includes:
6689778 - Remote Start Tool (Service Tool) 1
6689747 - Loader Service Tool Harness
6689746 - Computer Service Tool Harness
6689745 - BOSS® Service Tool Harness
P-76439
Figure 10-61-16
The Remote Start Tool (Service Tool) (Item 1) [Figure 10-
61-17] has five buttons.

The STOP button (Item 2) [Figure 10-61-17] is used to

stop the Remote Start Tool (Service Tool) from
communicating and stop the loader engine.

The RUN button (Item 3) [Figure 10-61-17] is used to

turn the Remote Start Tool (Service Tool) on and
1 activates the loader ignition power. The button will
illuminate to indicate the service tool is active.

The START button (Item 4) [Figure 10-61-17] is used to

start the loader engine.
P-76678

The traction lock button (Item 5) [Figure 10-61-17] is

used to turn traction lock ON or OFF. Push the button and
The remote start tool (Item 1) [Figure 10-61-16] is the button will illuminate indicating the traction lock is
required when the service technician is checking the disabled in which the wheels or tracks are able to turn.
hydraulic / hydrostatic system or adjusting the steering
linkage. The auxiliary button (Item 6) [Figure 10-61-17] is used to
activate the auxiliary hydraulics. The button will illuminate
to indicate the auxiliary hydraulics are active. Pressing
the button a second time will turn the flow OFF. The
button is used when checking pressures and flow rate.

10-61-2 S160 Service Manual

REMOTE START TOOL (SERVICE TOOL) KIT - Figure 10-61-20
6689779 (CONT'D)

Loader Service Tool Harness - 6689747 2

Figure 10-61-18

P-76452
2

Loaders with an attachment control harness (7 pin or 14

pin), the attachment harness (Item 1) must be
P-76678 disconnected from the loader harness (Item 2) [Figure
10-61-20].

The loader service tool harness (Item 1) [Figure 10-61- When the remote start procedure is completed, replace
18] is used to connect the remote start tool (service tool) the loader connector cap (Item 1) [Figure 10-61-19] or
(Item 2) [Figure 10-61-18] to the electrical system on the reconnect the attachment control harness to the loader
loader. harness [Figure 10-61-20].

Figure 10-61-19

P-76451

Loaders without an attachment control harness, remove

the loader harness cap (Item 1) [Figure 10-61-19] and
connect the Loader Service Tool Harness from the
Remote Start Tool (Service Tool).

10-61-3 S160 Service Manual

REMOTE START TOOL (SERVICE TOOL) KIT - NOTE: The right instrument panel (Standard Key
6689779 (CONT'D) Panel or Deluxe Instrumentation Panel) must
be in the off position or the Remote Start Tool
Loader Service Tool Harness - 6689747 (Cont’d) (Service Tool) will not operate.

Figure 10-61-21

3
1
P-76454

P-76453
Computer Service Tool Harness - 6689746

NOTE: The Remote Start Tool (Service Tool) Figure 10-61-22

connection harness has two connectors (Item
1) and (Item 3). The main connector (Item 1)
[Figure 10-61-21] is always used for
connection to the loader harness. 1
The second connector (Item 3) [Figure 10-61-
21] is used for attachment ACD upgrades or
attachment operational diagnostics only. This
connector has a cap attached to it to prevent
damage or corrosion when not in use.

Connect the Remote Start Tool (Service Tool) connector

(Item 1) to the loader harness connector (Item 2) and the
other Remote Start Tool (Service Tool) connector to the 2
ACD harness connector (Item 3) [Figure 10-61-21]. P-76450

The computer service tool harness (Item 1) [Figure 10-

61-22] is required to connect remote start tool (service
tool) to the Service PC (Item 2) [Figure 10-61-22].

10-61-4 S160 Service Manual

REMOTE START TOOL (SERVICE TOOL) KIT - Figure 10-61-24
6689779 (CONT'D)

Remote Start Procedure

WARNING
AVOID INJURY OR DEATH
With the 7-pin connector plugged into the loader and
Remote Start Tool RUN button is not illuminated, the
loader can still be started from the operator panel
inside the cab.

Pressing the RUN button on the Remote Start Tool P-76451

disconnects the operator panel from the start circuit.

If the service technician will be working in the engine
Loaders without an attachment control harness, remove
area it is important to remove the operator panel key
the loader harness cap (Item 1) [Figure 10-61-24] and
or lock the keypad with a unique password.
W-2647-0707
connect the Loader Service Tool Harness from the
Remote Start Tool (Service Tool).

The tool listed will be needed to do the following Figure 10-61-25

procedure:

6689779: Remote Start Tool (Service Tool) Kit 2

Figure 10-61-23

1
1

P-76452

Loaders with an attachment control harness (7 pin or 14

pin), the attachment harness (Item 1) must be
P-76450 disconnected from the loader harness (Item 2) [Figure
10-61-25].

The Remote Start Tool (Service Tool) (Item 1) [Figure 10- When the remote start procedure is completed, replace
61-23] is required when the operator cab is in the raised the loader connector cap (Item 1) [Figure 10-61-25] or
position for service and the service technician needs to reconnect the attachment control harness to the loader
turn on the loader or start the engine. Example: adjusting harness [Figure 10-61-25].
the steering linkage.

Lift and block the loader.

Raise the lift arms (if required by the procedure) and
install an approved lift arm support device.
Raise the operator cab (if required by the procedure).

Open the rear door of the loader.

10-61-5 S160 Service Manual

REMOTE START TOOL (SERVICE TOOL) KIT - Figure 10-61-27
6689779 (CONT'D)
2
Remote Start Procedure (Cont'd)

Figure 10-61-26
5 3
2
6 4
1

P-76439

3
1 The Remote Start Tool (Service Tool) (Item 1) [Figure 10-
61-27] has five buttons.
P-76453
The STOP button (Item 2) [Figure 10-61-27] is used to
stop the Remote Start Tool (Service Tool) from
NOTE: The Remote Start Tool (Service Tool) communicating and stop the loader engine.
connection harness has two connectors (Item
1) and (Item 3). The main connector (Item 1) The RUN button (Item 3) [Figure 10-61-27] is used to
[Figure 10-61-26] is always used for turn the Remote Start Tool (Service Tool) on and
connection to the loader harness. activates the loader ignition power. The button will
illuminate to indicate the service tool is active.
The second connector (Item 3) [Figure 10-61-
26] is used for attachment ACD upgrades or The START button (Item 4) [Figure 10-61-27] is used to
attachment operational diagnostics only. This start the loader engine.
connector has a cap attached to it to prevent
damage or corrosion when not in use. The traction lock button (Item 5) [Figure 10-61-27] is
used to turn traction lock ON or OFF. Push the button and
Connect the Remote Start Tool (Service Tool) connector the button will illuminate indicating the traction lock is
(Item 1) to the loader harness connector (Item 2) and the disabled in which the wheels or tracks are able to turn.
other Remote Start Tool (Service Tool) connector to the
ACD harness connector (Item 3) [Figure 10-61-26]. The auxiliary button (Item 6) [Figure 10-61-27] is used to
activate the auxiliary hydraulics. The button will illuminate
NOTE: The right instrument panel (Standard Key to indicate the auxiliary hydraulics are active. Pressing
Panel or Deluxe Instrumentation Panel) must
the button a second time will turn the flow OFF. The
be in the off position or the Remote Start Tool
(Service Tool) will not operate. button is used when checking pressures and flow rate.

P-76454

10-61-6 S160 Service Manual

REMOTE START TOOL (SERVICE TOOL) KIT - Figure 10-61-29
6689779 (CONT'D)

Remote Start Procedure (Cont'd)

Figure 10-61-28

1 2

P-34661

Push the couplers on the front auxiliary block toward the

block and hold for five seconds to release the front
P-76441 auxiliary pressure [Figure 10-61-29].

The gear icon with the left facing arrows (Item 1) [Figure
10-61-28] will illuminate and blink when the RUN key is
pressed and the loader is communicating with the service
tool.

The computer icon with the right facing arrows (Item 2)

[Figure 10-61-28] will illuminate and blink when the
Remote Start Tool (Service Tool) is transmitting data to
and from the computer.

NOTE: To relieve the pressure at the rear or

secondary front auxiliary, (if equipped) press
the RUN button on the remote start tool. Then
press the auxiliary (AUX) hydraulics button on
the remote start tool and move the AUXILIARY
Hydraulic Switch on the to the right and left
several times.

10-61-7 S160 Service Manual

SERVICE SCHEDULE
Chart
Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The
service schedule is a guide for correct maintenance of the Bobcat Loader.
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
signs (decals) on machine. Follow warnings and instructions in the manuals
WARNING when making repairs, adjustments or servicing. Check for correct function
after adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0903

SERVICE SCHEDULE HOURS

■ ■ ■
ITEM SERVICE REQUIRED 8-10 50 100 250 500 1000
Engine Oil Check the oil level and add as needed. Do not overfill.
Engine Air Filter and Air System Check display panel. Service only when required. Check for leaks and
damaged components.
Engine Cooling System Clean debris from oil cooler, radiator and grill. Check coolant level COLD and
add premixed coolant as needed.
Fuel Filter Remove the trapped water.
Lift Arms, Cylinders, Bob-Tach Lubricate with multi-purpose lithium based grease.
Pivot Pins and Wedges
Tires Check for damaged tires and correct air pressure. Inflate to MAXIMUM
pressure shown on the sidewall of the tire.
Seat Bar, Control Interlocks, Seat Check the condition of seat belt. Clean or replace seat belt retractors as
Belt, Seat Belt Retractors needed. Check the seat bar and control interlocks for correct operation. Clean
dirt and debris from moving parts.
Bobcat Interlock Control Systems Check for correct function. Lift and Tilt functions MUST NOT operate with seat
(BICS) bar raised. See details in this Manual.
Safety Signs and Safety Treads Check for damaged signs (decals) and safety treads. Replace any signs or
safety treads that are damaged or worn.
Operator Cab Check the fastening bolts, washers and nuts. Check the condition of the cab.
Indicators and Lights Check for correct operation of all indicators and lights.
Heater and A/C Filters Clean or replace filters as needed.
(If Equipped)
Hydraulic Fluid, Hoses and Check fluid level and add as needed. Check for damage and leaks. Repair or
Tubelines replace as needed.
Final Drive Trans. (Chaincase), Check fluid level and add as needed.
Parking Brake, Foot Pedals, Check for correct operation. Repair or adjust as needed.
Hand Controls and Steering
Levers or Joysticks
Wheel Nuts Check for loose wheel nuts and tighten to correct torque. (See TIRE ❏
MAINTENANCE in this manual.)
Spark Arrestor Muffler Clean the spark chamber.
Battery Check cables, connections and electrolyte level. Add distilled water as needed.
Steering Lever Pivots Grease fittings.
Fuel Filter Replace filter element.
Engine / Hydro. Drive Belt Check for wear or damage. Check idler arm stop. ▲
Drive Belts (Alternator, air Check condition and tension. Adjust or replace as needed.
conditioning, water pump)
Bobcat Interlock Control System Check the function of the lift arm bypass control.
(BICS)
Engine Oil and Filter Replace oil and filter. ▲ ✶
Hydraulic / Hydrostatic Filter, Replace the hydraulic / hydrostatic filter, charge filter, and the reservoir ●
Charge Filter, Reservoir Breather breather.
Final Drive Trans. (Chaincase) Replace the fluid.
Hydraulic Reservoir Replace the fluid.
Case Drain Filters Replace the filters. ▲
Engine Valves Adjust the engine valves. ❍
Coolant Replace the coolant Every 2 years
■ Or every 12 months.
▲ Perform at first 50 hours, then as scheduled.
❏ Check every 8 - 10 hours for the first 24 hours, then at 50 hour intervals.
● Replace the hydraulic / hydrostatic filter element after the first 50 hours, then when service code [M0217] is displayed
or as scheduled.
✶ Change oil and filter every 100 hours when operating under severe conditions.
❍ Perform at first 500 hours, then as scheduled.

10-70-1 S160 Service Manual

AIR CLEANER SERVICE Outer Filter

Replacing Filter Elements Figure 10-80-3

Figure 10-80-1

3
1
1

P-76460G

P-31836

Figure 10-80-2
Remove the wing nut and remove the dust cover (Item 1)
[Figure 10-80-3].

Figure 10-80-4

B-15553M

It is important to change the air filter element only when

necessary. The Service indicator (Item 1) will FLASH and
P-48341
service code [M0117] (Air Filter Plugged) will show in the
Data Display (Item 2) when the Information button (Item
3) [Figure 10-80-1] is held for two seconds. Remove the wing nut and pull the outer filter element
(Item 1) [Figure 10-80-4] out and discard.
The Air Cleaner icon on the Deluxe Instrumentation
Panel, if equipped, will be ON (Item 1) [Figure 10-80-2]. NOTE: Make sure all sealing surfaces are free of dirt
and debris.
Replace the inner filter every third time the outer filter is
replaced or as indicated. Install new filter. Push all the way in until it contacts the
base of the housing. Install wing nut.

Install the dust cover and the wing nut [Figure 10-80-3].

10-80-1 S160 Service Manual

AIR CLEANER SERVICE (CONT’D)

Replacing Filter Elements (Cont’d)

Inner Filter

Only replace the inner filter element under the following

conditions:

• Replace the inner filter element every third time the

outer filter is replaced.
• After the outer element has been replaced, start the
engine and run at full RPM. If the HOURMETER /
CODE DISPLAY shows [M0117] (Air Filter Plugged),
replace the inner filter element.

Figure 10-80-5

P-48342

Remove the inner filter element (Item 1) [Figure 10-80-

5].

NOTE: Make sure all sealing surfaces are free of dirt

and debris.

Install the new inner element [Figure 10-80-5].

Install the outer element.

Install the dust cover and the wing nut.

10-80-2 S160 Service Manual

ENGINE COOLING SYSTEM Figure 10-90-2

Check the cooling system every day to prevent over-

heating, loss of performance or engine damage.
1

WARNING
AVOID INJURY OR DEATH
Wear safety glasses to prevent eye injury when any 2
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
P-76189
• Tools are being used.
W-2019-0907
NOTE: Be careful when raising and lowering the air
Cleaning conditioning condenser so that the air
conditioning condenser does not fall on the
Open the rear door and remove the rear grill. (See oil cooler and damage the fins.
Removal And Installation on Page 50-60-1.)
Raise the air conditioning condenser (Item 1) and use
Figure 10-90-1 low air pressure or water pressure to clean the top of the
oil cooler (Item 2) [Figure 10-90-2].

Figure 10-90-3
1

2
2

P-39459
1

Use low air pressure or water pressure to clean the top of P-76190

the air conditioning condenser (Item 1) [Figure 10-90-1],

if equipped. NOTE: Be careful when raising and lowering the oil
cooler so that the oil cooler does not fall on
Raise the overflow tank (Item 2) slightly and remove the the radiator and damage the fins.
two fasteners (Inset) [Figure 10-90-1].
Raise the oil cooler (Item 1) and use low air pressure or
water pressure to clean the top of the radiator (Item 2)
[Figure 10-90-3].

Lower the oil cooler.

Lower the air conditioning condenser, if equipped.

Install the fasteners and lower the overflow tank. Check

the cooling system for leaks.

Install the rear grill and close the rear door.

10-90-1 S160 Service Manual

ENGINE COOLING SYSTEM (CONT’D)

Checking Level

Open the rear door and raise the rear grill.

Check coolant level using the level markers (Item 3)

[Figure 10-90-5] on the tank. Coolant must be at the
bottom marker when the engine is cold; top marker when
hot.

Close the rear door before operating the loader.

IMPORTANT
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.

Too much antifreeze reduces cooling system

efficiency and may cause serious premature engine
damage.

Too little antifreeze reduces the additives which

protect the internal engine components; reduces the
boiling point and freeze protection of the system.

Always add a premixed solution. Adding full strength

concentrated coolant can cause serious premature
engine damage.
I-2124-0497

Figure 10-90-4

P-76782

NOTE: All access covers (Item 1) [Figure 10-90-4]

(both sides) must be in place to ensure
correct air flow through the oil cooler which
will ensure cooling for engine and hydraulic
system.

10-90-2 S160 Service Manual

ENGINE COOLING SYSTEM (CONT’D) Run the engine until it is at operating temperature. Stop
the engine. Check the coolant level when cool. Add
Removing And Replacing Coolant coolant as needed.

Open the rear door and remove the rear grill. Install the rear grill and close the rear door.

Figure 10-90-5 NOTE: When installing the coolant fill cap, the cap
must be tightened until it clicks.

Run the engine until it is at operating temperature. Stop

the engine. Check the coolant level in the recovery tank
when cool. Add coolant as needed.
1 2
Install the rear grill and close the rear door.

P-45245 P-45490

Remove the coolant fill cap (Item 1) [Figure 10-90-5].

Connect a hose to the engine block drain (Item 2)

[Figure 10-90-5]. Open the drain valve and drain the
coolant into a container.

After all the coolant is removed, close the drain valve and
remove the hose. Recycle or dispose of coolant in an
environmentally safe manner.

Mix new coolant in a separate container. (See Capacities

on Page SPEC-10-4.)

NOTE: The loader is factory filled with propylene

glycol coolant (purple color). DO NOT mix
propylene glycol with ethylene glycol.

Add premixed coolant, 47% water and 53% propylene

glycol to the recovery tank. (See Checking Level on Page
10-90-2.)

One gallon and one pint (4,3 L) of propylene glycol mixed

with one gallon (3,8 L) of water is the correct mixture of
coolant to provide a -34°F (-37°C) freeze protection.

Fill the tank until it is at the lower marker on the tank.

Use a refractometer to check the condition of propylene

glycol in your cooling system and replace the coolant fill
cap.

NOTE: When installing the coolant fill cap, the cap

must be tightened until it clicks.

10-90-3 S160 Service Manual

FUEL SYSTEM Biodiesel Blend Fuel

Fuel Specifications Biodiesel blend fuel has unique qualities that should be
considered before using in this machine:
Use only clean, high quality diesel fuel, Grade No. 2 or
Grade No. 1. • Cold weather conditions can lead to plugged fuel
system components and hard starting.
The following is one suggested blending guideline which
should prevent fuel gelling during cold temperatures: • Biodiesel blend fuel is an excellent medium for
microbial growth and contamination which can cause
TEMPERATURE F (C) NO. 2 NO. 1 corrosion and plugging of fuel system components.

+15° (9°) 100% 0% • Use of biodiesel blend fuel may result in premature
Down to -20° (-29°) 50% 50% failure of fuel system components, such as plugged
Below -20° (-29°) 0% 100% fuel filters and deteriorated fuel lines.

• Shorter maintenance intervals may be required, such

The following fuels may be used in this machine:
as cleaning the fuel system and replacing fuel filters
and fuel lines.
• Low Sulfur (500 ppm sulfur) Diesel Fuel.
• Using biodiesel blended fuels containing more than
• Ultra Low Sulfur (15 ppm sulfur) Diesel Fuel.
five percent biodiesel can affect engine life and cause
deterioration of hoses, tubelines, injectors, injector
• Biodiesel Blend Fuel - Must contain no more than five
pump and seals.
percent biodiesel mixed with low sulfur or ultra low
sulfur petroleum based diesel. This is commonly
Apply the following guidelines if biodiesel blend fuel is
marketed as B5 blended diesel fuel. B5 blended
used:
diesel fuel must meet ASTM D975 (US Standard) or
EN590 (EU Standard) specifications.
• Ensure the fuel tank is as full as possible at all times
to prevent moisture from collecting in the fuel tank.

• Ensure that the fuel tank cap is securely tightened.

• Biodiesel blend fuel can damage painted surfaces,

remove all spilled fuel from painted surfaces
immediately.

• Drain all water from the fuel filter daily before

operating the machine.

• Do not exceed engine oil change interval. Extended

oil change intervals can cause engine damage.

• Before vehicle storage; drain the fuel tank, refill with

100% petroleum diesel fuel, add fuel stabilizer and
run the engine for at least 30 minutes.

NOTE: Biodiesel blend fuel does not have long term

stability and should not be stored for more
than three months.

10-100-1 S160 Service Manual

FUEL SYSTEM (CONT’D) Figure 10-100-2

Filling The Fuel Tank WRONG

WARNING
AVOID INJURY OR DEATH
Stop and cool the engine before adding fuel. NO
SMOKING! Failure to obey warnings can cause an
explosion or fire.
W-2063-0807

Figure 10-100-1 B-15651

Use a clean, approved safety container to add fuel of the

1
correct specification. Add fuel only in an area that has
free movement of air and no open flames or sparks. NO
SMOKING! [Figure 10-100-2].

Install and tighten the fuel fill cap (Item 1) [Figure 10-
100-1].

WARNING
P-48468 AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Remove the fuel fill cap (Item 1) [Figure 10-100-1]. Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
W-2103-0807

10-100-2 S160 Service Manual

FUEL SYSTEM (CONT’D) Removing Air From The Fuel System

Fuel Filter After replacing the filter element or when the fuel tank
has run out of fuel, the air must be removed from the fuel
For the service interval for removing water from, or system before starting the engine.
replacing the fuel filter (See SERVICE SCHEDULE on
Page 10-70-1.)

Removing Water WARNING

Figure 10-100-3 AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807

Figure 10-100-4

2
1
P-48469

Loosen the drain (Item 1) [Figure 10-100-3] at the

bottom of the filter element to remove water from the
filter. 1
2
Replacing Element

Remove the filter element (Item 2) [Figure 10-100-3].

Clean the area around the filter housing. Put clean oil on
the seal of the new filter element. Install the fuel filter, and P-48469
hand tighten.

Remove air from the fuel system. (See Removing Air

From The Fuel System below.) Open the vent (Item 1) [Figure 10-100-4] on the fuel filter
housing.

Squeeze the hand pump (priming bulb) (Item 2) [Figure

WARNING 10-100-4] until fuel flows from the vent with no air
bubbles.
AVOID INJURY OR DEATH Close the vent (Item 1) [Figure 10-100-4].
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
W-2103-0807

10-100-3 S160 Service Manual

ENGINE LUBRICATION SYSTEM Engine Oil Chart

Checking And Adding Engine Oil Figure 10-110-2

Check the engine oil level every day before starting the
engine for the work shift.

Figure 10-110-1

1
2

B-16320C

P-48472
Use a good quality motor oil that meets API Service
Classification of CI-4 or better See Oil Chart [Figure 10-
Park the machine on level ground. Open the rear door 110-2].
and remove the dipstick (Item 1) [Figure 10-110-1].

Keep the oil level between the marks on the dipstick.

10-110-1 S160 Service Manual

ENGINE LUBRICATION SYSTEM (CONT’D)

Removing And Replacing Oil And Filter

WARNING
For the service interval for replacing the engine oil and
filter. (See SERVICE SCHEDULE on Page 10-70-1.)
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
Run the engine until it is at operating temperature. Stop
the engine. sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
Open the rear door and remove the drain hose from its explosion or fire which can result in injury or death.
storage position (Item 4) [Figure 10-110-1]. W-2103-0807

Figure 10-110-3

P-24679

Remove the drain plug (Item 1) [Figure 10-110-3] and

drain the oil into a container and recycle or dispose of
used oil in an environmentally safe manner.

Reinstall the drain plug.

Remove the oil filter (Item 3) [Figure 10-110-1] and clean
the filter housing surface.

Use genuine Bobcat filter only.

Put oil on the new filter gasket, install the filter and hand
tighten.
Remove the fill cap (Item 3) [Figure 10-110-1].

Put oil in the engine. For the correct quantity (See

Capacities on Page SPEC-10-4). Do not overfill.

Start the engine and let it run for several minutes. Stop
the engine and check for leaks at the filter.
Remove the dipstick (Item 1) [Figure 10-110-1] and
check the oil level. Add oil as needed if it is not at the top
mark on the dipstick.

Install the dipstick and close the rear door.

10-110-2 S160 Service Manual

HYDRAULIC / HYDROSTATIC SYSTEM Hydraulic / Hydrostatic Fluid Chart

Checking And Adding Fluid Figure 10-120-2

Put the loader on a level surface, lower the lift arms and
tilt the Bob-Tach fully back.

Stop the engine.

Figure 10-120-1

1
1
2
P-64023A

Use only recommended fluid in the hydraulic system

[Figure 10-120-2]. (See Hydraulic System on Page
SPEC-10-3.)

P-45224A
P-45224C P-48011

Check the fluid level in the sight gauge (Item 1) [Figure 10-
120-1].

Open the rear door and raise the rear grill. Remove the
fill cap (Item 2) [Figure 10-120-1].

Add fluid [Figure 10-120-2] as needed to bring the level

to the center of the sight gauge. Install the fill cap (Item 2)
[Figure 10-120-1].

Lower the rear grill and close the rear door.

10-120-1 S160 Service Manual

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Removing And Replacing Hydraulic / Hydrostatic
Filter
Removing And Replacing Hydraulic Fluid
For the correct service interval (See SERVICE
See the SERVICE SCHEDULE for the service interval. SCHEDULE on Page 10-70-1.)
(See SERVICE SCHEDULE on Page 10-70-1.)
Replace the fluid if it becomes contaminated or after Open the rear door.
major repair.
Figure 10-120-4
Always replace the hydraulic / hydrostatic filter, the
hydraulic case drain filters and the hydraulic charge filter
whenever the hydraulic fluid is replaced. (See Removing
And Replacing Hydraulic / Hydrostatic Filter on Page 10-
120-2.)
Open the rear door and raise the rear grill. Remove the
fill cap.
Raise the operator cab. (See Raising on Page 10-30-2.) 1
Figure 10-120-3

1 P-48470

Remove the filter (Item 1) [Figure 10-120-4].

Clean the surface of the filter housing where the filter

seal contacts the housing.

Put clean oil on the seal of the new filter element. Install
P-24751
and hand tighten the filter element.

Remove the plug from the top of the reservoir (Item 1)

[Figure 10-120-3]. Pump the fluid out of the reservoir
and into a container. WARNING
Recycle or dispose of the used fluid in an
environmentally safe manner. AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
WARNING explosion or fire which can result in injury or death.
W-2103-0807

AVOID INJURY OR DEATH

Always clean up spilled fuel or oil. Keep heat, flames, Close the rear door before operating the loader.
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause Start the engine and operate the loader hydraulic
explosion or fire which can result in injury or death. controls.
W-2103-0807
Stop the engine and check for leaks at the filter.
Lower the operator cab. (See Lowering on Page 10-30-
3.) Check the fluid level in the reservoir and add as needed.
(See Checking And Adding Fluid on Page 10-30-1.)
Add the correct fluid to the reservoir until the fluid level is
at the center of the sight gauge. (See Checking And
Adding Fluid on Page 10-30-1.)

10-120-2 S160 Service Manual

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Figure 10-120-6

Removing And Replacing Hydraulic Case Drain

Filters (Single Speed Loaders)
1
See the SERVICE SCHEDULE for the service interval.
(See SERVICE SCHEDULE on Page 10-70-1.)

Figure 10-120-5
Left Side Shown

P-45499 P-45493

Remove the case drain filter assemblies (Item 1) [Figure

10-120-6] near the hydrostatic motors. Install the fittings
from the old filter assembly onto the new filter assembly.
Install new filter assemblies. Install motor covers.

Recycle or dispose of used fluid in an environmentally

P-45492 safe manner.
Start the engine and operate the loader hydraulic
Remove both hydrostatic motor covers (Item 1) [Figure
controls.
10-120-5].
Stop the engine and check for leaks at the filter
assemblies.
Check the fluid level in the reservoir and add as needed.
(See Checking And Adding Fluid on Page 10-30-1.)

10-120-3 S160 Service Manual

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Figure 10-120-8

Removing And Replacing Hydraulic Case Drain

Filters (Two-Speed Loaders)

Raise the lift arms. (See LIFT ARM SUPPORT DEVICE

on Page 10-20-1.) 1

P-76168

Raise the operator cab. (See Raising on Page 10-30-2.) Remove the case drain filter assembly (Item 1) [Figure
10-120-8]. Install the fittings from the old filter assembly
Figure 10-120-7 onto the new filter assembly.

Install new case drain filter assembly and replace the

side access cover.

Recycle or dispose of used fluid in an environmentally

1 safe manner.

SJC equipped machines skip ahead to [Figure 10-120-

10].

Figure 10-120-9

P-76171

Remove the left side access cover (Item 1) [Figure 10- 2 2

120-7] near the rear tire.

1
1

P-76174

Scribe a mark across the top of the steering linkage bars

(Item 1) [Figure 10-120-9] which are connected to the
steering shaft on the control panel.

Remove the four steering linkage mounting bolts (Item 2)

[Figure 10-120-9].

10-120-4 S160 Service Manual

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D)

Removing And Replacing Hydraulic Case Drain

Filters (Two-Speed Loaders) (Cont’d) WARNING
Figure 10-120-10 AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
1 Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807

Stop the engine and check for leaks at the filter

assemblies.

Check the fluid level in the reservoir and add as needed.

(See Checking And Adding Fluid on Page 10-120-1.)
P-76160

Remove the case drain filter assembly (Item 1) [Figure

10-120-10]. Install the fittings from the old filter assembly
onto the new filter assembly.

Install new case drain filter assembly.

WARNING
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
W-2103-0807

Standard Controls and ACS only: Align the marks on the

steering linkage bars. Install the steering linkage
mounting bolts (Item 2) [Figure 10-120-9] in the proper
orientation (two bolts facing up and two bolts facing
down). Tighten the steering linkage mounting bolts to 35-
40 ft.-lb. (47,5-54,2 N•m).

Recycle or dispose of the used fluid in an

environmentally safe manner.

Lower the cab. (See Lowering on Page 10-30-3.)

Remove the lift arm support device and lower the lift arms
(See LIFT ARM SUPPORT DEVICE on Page 10-20-1.)

Start the engine and operate the loader hydraulic

controls.

10-120-5 S160 Service Manual

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D)

Removing And Replacing Hydraulic Charge Filter

WARNING
See the SERVICE SCHEDULE for the service interval.
(See SERVICE SCHEDULE on Page 10-70-1.) AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
Raise the operator cab. (See Raising on Page 10-30-2.)
penetrate skin or eyes, causing serious injury or
Figure 10-120-11 death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807

Stop the engine and check for leaks at the filter.

1 Check the fluid level in the reservoir and add as needed.

(See Checking And Adding Fluid on Page 10-120-1.)

P-64239

Remove the filter (Item 1) [Figure 10-120-11].

Clean the surface of the filter housing where the filter

seal contacts the housing.

Put clean oil on the seal of the new filter.

Install and hand tighten the new filter.

WARNING
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
W-2103-0807

Lower the operator cab. (See Lowering on Page 10-30-

3.)

Start the engine and operate the loader.

10-120-6 S160 Service Manual

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D)

Breather Cap

See the SERVICE SCHEDULE for the correct

replacement interval. (See SERVICE SCHEDULE on
Page 10-70-1.)

Raise the operator cab. (See Raising on Page 10-30-2.)

Figure 10-120-12

P-76673

Remove the breather cap (Item 1) [Figure 10-120-12]

and discard. (Blower housing removed for clarity.).

Install new breather.

Lower the operator cab. (See Lowering on Page 10-30-

3.)

10-120-7 S160 Service Manual

FINAL DRIVE TRANSMISSION (CHAINCASE) Removing And Replacing Oil

Checking And Adding Oil Figure 10-130-2

The chaincase contains the final drive sprockets and

chains and uses the same type of oil as the hydraulic /
hydrostatic system (See Hydraulic System on Page
SPEC-10-3.)
1
Stop the loader on a level surface and stop the engine.

Figure 10-130-1

1
P-76684

Remove the check plug (Item 1) [Figure 10-130-2] from

the front of the chaincase housing.

Figure 10-130-3

P-31287

Remove the drain plug (Item 1) [Figure 10-130-1] from

the front of the chaincase housing.

If oil can be reached with the tip of the your finger through
the hole, the oil level is correct.

If the level is low, add oil through the check plug hole until
the oil flows from the hole.

P-31287A

Remove the oil from the chaincase [Figure 10-130-3].

Recycle or dispose of the used oil in an environmentally

safe manner.

Add oil through the check plug hole until the oil flows from
the hole.

WARNING
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
W-2103-0807

10-130-1 S160 Service Manual

BOB-TACH (HAND LEVER) The spring loaded wedge (Item 1) [Figure 10-140-2]
must contact the lower edge of the hole in the attachment
Inspection And Maintenance (Item 2) [Figure 10-140-2].

Figure 10-140-1 If the wedge does not contact the lower edge of the hole
[Figure 10-140-2], the attachment will be loose and can
come off the Bob-Tach.

Figure 10-140-3

P-31693

Move the Bob-Tach levers to engage the wedges [Figure

10-140-1].

The levers and wedges must move freely.

WARNING
Bob-Tach wedges must extend through the holes in
attachment. Lever(s) must be fully down and locked.
Failure to secure wedges can allow attachment to
come off and cause injury or death.
W-2102-0497

Figure 10-140-2

2 B-17460

Inspect the mounting frame on the attachment and Bob-

Tach, linkages and wedges for excessive wear or
Wedge must contact damage [Figure 10-140-3]. Replace any parts that are
lower edge of hole in the damaged, bent or missing. Keep all fasteners tight.
attachment.
Look for cracked welds. Contact your Bobcat dealer for
P-31233 B-15177 repair or replacement parts.

Lubricate the wedges. (See SERVICE SCHEDULE on

The wedges (Item 1) [Figure 10-140-1] must extend Page 10-70-1) and (See LUBRICATING THE LOADER
through the holes in the attachment mounting frame. on Page 10-150-1).

10-140-1 S160 Service Manual

BOB-TACH (POWER) The spring loaded wedge (Item 1) must contact the lower
edge of the hole in the attachment (Item 2) [Figure 10-
This machine may be equipped with a Power Bob-Tach. 141-2].

Inspection And Maintenance If the wedge does not contact the lower edge of the hole
[Figure 10-141-2], the attachment will be loose and can
Figure 10-141-1 come off the Bob-Tach.

.B-15993Q

Push and hold the BOB-TACH "WEDGES UP" switch

(Item 1) until wedges are fully raised. Push and hold the
BOB-TACH "WEDGES DOWN" switch (Item 2) [Figure
10-141-1] until the wedges are fully down.

The levers and wedges must move freely.

WARNING
Bob-Tach wedges must extend through the holes in
attachment. Lever(s) must be fully down and locked.
Failure to secure wedges can allow attachment to
come off and cause injury or death.
W-2102-0497

Figure 10-141-2

Wedge must contact

lower edge of hole in the
attachment.

P-31233 B-15177

The wedges (Item 1) [Figure 10-141-2] must extend

through the holes in the attachment mounting frame .

10-141-1 S160 Service Manual

BOB-TACH (POWER) (CONT’D)

Inspection And Maintenance (Cont’d)

Figure 10-141-3

B-17460

Inspect the mounting frame on the attachment and the

Bob-Tach, linkages and wedges for excessive wear or
damage [Figure 10-141-3]. Replace any parts that are
damaged, bent, or missing. Keep all fasteners tight.

Look for cracked welds. Contact your Bobcat dealer for

repair or replacement parts.

Lubricate the wedges. (See SERVICE SCHEDULE on

Page 10-70-1) and (See LUBRICATING THE LOADER
on Page 10-150-1).

10-141-2 S160 Service Manual

LUBRICATING THE LOADER Figure 10-150-6

Lubrication Locations

Lubricate the loader as specified for the best

performance of the loader. (See SERVICE SCHEDULE
on Page 10-70-1.) 3

Record the operating hours each time you lubricate the

Bobcat Loader.

Always use a good quality lithium based multi-purpose

grease when you lubricate the loader. Apply the lubricant
until extra grease shows.

Lubricate the following locations on the loader: P-43784

Figure 10-150-4
3. Lift Arm Pivot Pin (Both Sides) (2) [Figure 10-150-6].

Figure 10-150-7

P-43782

1. Rod End Lift Cylinder (Both Sides) (2) [Figure 10-

N-18510
150-4].

Figure 10-150-5 4. Base End Tilt Cylinder (Both Sides) (2) [Figure 10-
150-7].

2
P-45257A

2. Base End Lift Cylinder (Both Sides) (2) [Figure 10-

150-5].

10-150-1 S160 Service Manual

LUBRICATING THE LOADER (CONT’D) Figure 10-150-10

Lubrication Locations (Cont’d)

Figure 10-150-8
9

5
6

P-45497

9. 250 Hours: Steering Lever Shaft (2) [Figure 10-150-

N-18509 10].

5. Rod End Tilt Cylinder (Both Sides) (2) [Figure 10-

150-8].

6. Bob-Tach Pivot Pin (Both Sides) (2) [Figure 10-150-

8].

Figure 10-150-9

P-24699

P-16045

7. Bob-Tach Wedge (Both Sides) (2) [Figure 10-150-9].

8. Power Bob-Tach linkage (Both Sides) (2) [Figure 10-

150-9].

10-150-2 S160 Service Manual

TIRE MAINTENANCE It is important to keep the same size tires on each side of
the loader. If different sizes are used, each tire will be
Wheel Nuts turning at a different rate and cause excessive wear. The
tread bars of all the tires must face the same direction.
Figure 10-160-1
Recommended tire pressure must be maintained to avoid
excessive tire wear and loss of stability and handling
capability. Check for correct pressure before operating
the loader.

Mounting

Tires are to be repaired only by an authorized person

using the proper procedures and safe equipment.

Tires and rims must always be checked for correct size

before mounting. Check rim and tire bead for damage.

P-54291 The rim flange must be cleaned and free of rust.

The tire bead and rim flange must be lubricated with a

See the SERVICE SCHEDULE for the service interval to rubber lubricant before mounting the tire.
check the wheel nuts [Figure 10-160-1]. (See SERVICE
SCHEDULE on Page 10-70-1.)
Avoid excessive pressure which can rupture the tire and
When installing wheel nuts, tighten to 160 ft.-lb. (217 cause serious injury or death.
N•m) torque.
During inflation of the tire, check the tire pressure
When checking wheel nut torque, set the torque wrench frequently to avoid over inflation.
to 140 ft.-lb. (190 N•m) to prevent over-tightening.

Rotating
WARNING
Check the tires regularly for wear, damage and pressure.
Inflate tires to the maximum pressure shown on the AVOID INJURY OR DEATH
sidewall of the tire.
Do not inflate tires above specified pressure. Failure
Figure 10-160-2 to use correct tire mounting procedure can cause an
explosion which can result in injury or death.
W-2078-1007

IMPORTANT
Inflate tires to the MAXIMUM pressure shown on the
sidewall of the tire. DO NOT mix brands of tires used
on the same loader.
I-2057-0794

B-9976

Rear tires usually wear faster than front tires. To keep tire
wear even, move the front tires to the rear and rear tires
to the front [Figure 10-160-2].

10-160-1 S160 Service Manual

SPARK ARRESTOR MUFFLER

Cleaning Procedure WARNING

Use the correct service interval for cleaning the spark
arrestor muffler. (See SERVICE SCHEDULE on Page When the engine is running during service, the
10-70-1.) steering levers must be in neutral and the parking
brake engaged. Failure to do so can cause injury or
Do not operate the loader with a defective exhaust death.
system. W-2006-0284

Start the engine and run for about 10 seconds while a

second person, wearing safety goggles, holds a piece of
wood over the outlet of the muffler.
IMPORTANT
This will force contaminants out through the cleanout
This loader is factory equipped with a U.S.D.A. hole.
Forestry Service approved spark arrestor muffler. It
is necessary to do maintenance on this spark Stop the engine.
arrestor muffler to keep it in working condition. The
spark arrestor muffler must be serviced by dumping Install and tighten the plug.
the spark chamber every 100 hours of operation.
Close the rear door.
If this machine is operated on flammable forest,
brush or grass covered land, it must be equipped
with a spark arrestor attached to the exhaust system
and maintained in working order. Failure to do so will WARNING
be in violation of California State Law, Section 4442
PRC. AVOID INJURY OR DEATH
When an engine is running in an enclosed area, fresh
Consult local laws and regulations for spark arrestor air must be added to avoid concentration of exhaust
requirements fumes. If the engine is stationary, vent the exhaust
I-2022-0807
outside. Exhaust fumes contain odorless, invisible
gases which can kill without warning.
Stop the engine and open the rear door. W-2050-0807

Figure 10-170-1

WARNING
1
Stop engine and allow the muffler to cool before
cleaning the spark chamber. Wear safety goggles.
Failure to obey can cause serious injury.
W-2011-1285

WARNING
P-45498
Never use machine in atmosphere with explosive
dust or gases or where exhaust can contact
Remove the plug (Item 1) [Figure 10-170-1] from the
flammable material. Failure to obey warnings can
bottom of the muffler.
cause injury or death.
W-2068-1285

10-170-1 S160 Service Manual

PIVOT PINS
Inspection And Maintenance
Figure 10-180-1

P-43783

All lift arm and cylinder pivots have a large pin held in
position with a retainer bolt and lock nut (Item 1) [Figure
10-180-1].

Check that the lock nuts are tightened to 35-40 ft.-lb. (48-
54 N•m) torque.

10-180-1 S160 Service Manual

LOADER STORAGE AND RETURN TO SERVICE Return to Service

Storage After the Bobcat Loader has been in storage, it is

necessary to follow a list of items to return the loader to
Sometimes it may be necessary to store your Bobcat service.
Loader for an extend period of time. Below is a list of
items to perform before storage. • Check the engine and hydraulic oil levels; check
coolant level.
• Thoroughly clean the loader including the engine
• Install a fully charged battery.
compartment.
• Remove grease from exposed cylinder rods.
• Lubricate the loader.
• Check all belt tensions.
• Replace worn or damaged parts.
• Be sure all shields and guards are in place.
• Park the loader in a dry protected shelter.
• Lubricate the loader.
• Lower the lift arms all the way and put the bucket flat
on the ground. • Check tire inflation and remove blocks from under
frame.
• Put blocks under the frame to remove weight from the • Remove cover from exhaust pipe opening.
tires.
• Start the engine and let run for a few minutes while
• Put grease on any exposed cylinder rods. observing the instrument panels and systems for
correct operation.
• Put fuel stabilizer in the fuel tank and run the engine
• Operate machine, check for correct function.
a few minutes to circulate the stabilizer to the pump
and fuel injectors. • Stop the engine and check for leaks. Repair as
needed.
If biodiesel blend fuel has been used, perform the
following:

Drain the fuel tank, refill with 100% petroleum diesel

fuel, add fuel stabilizer and run the engine for at least
30 minutes.

• Drain and flush the cooling system. Refill with

premixed coolant.

• Replace all fluids and filters (engine, hyd. / hydro.).

• Replace air cleaner, heater and air conditioning filters.
• Put all controls in neutral position.
• Remove the battery. Be sure the electrolyte level is
correct then charge the battery. Store it in a cool dry
place above freezing temperatures and charge it
periodically during storage.
• Cover the exhaust pipe opening.
• Tag the machine to indicate that it is in storage
condition.

10-190-1 S160 Service Manual

STOPPING THE ENGINE AND LEAVING THE NOTE: Activating the Password Lockout Feature on
LOADER machines with the Deluxe Instrumentation
Panel allows operation of the loader without
Procedure
using a password. (See Password Lockout
Stop the loader on level ground. Feature on Page 60-190-2.)

Fully lower the lift arms and put the attachment flat on the Figure 10-200-3
ground.

Figure 10-200-1

P-66667 P-66668

Exit the loader using grab handles, safety tread and

P-31864
steps (maintaining a 3-point contact) [Figure 10-200-2].

Pull the engine speed control fully backward [Figure 10-

200-1] to decrease the engine speed.

Engage the parking brake.

WARNING
Figure 10-200-2 Before you leave the operator’s seat:
• Lower the lift arms, put the attachment flat on the
ground.
• Stop the engine.
1 • Engage the parking brake.
• Raise seat bar.
• (Foot Pedal Controls) Move pedals until both
lock.
• (Advanced Control System-ACS) Move the
hydraulic controls to the NEUTRAL POSITION to
2 make sure that both lift and tilt functions are
deactivated.
The seat bar system must deactivate the lift and
P-76603 B-15553L tilt control functions when the seat bar is up.
Service the system if hand controls do not
deactivate.
Turn the key switch to the STOP position (Item 1) • (Selectable Joystick Controls-SJC) Move the
(Standard Key Panel) or press the STOP button (Item 2) joysticks to the NEUTRAL POSITION to make
(Deluxe Instrumentation Panel) [Figure 10-200-2]. sure that travel and hydraulic functions are
deactivated.
Lift the seat bar and make sure the lift and tilt functions The seat bar system must deactivate these
functions when the seat bar is up. Service the
are deactivated.
system if controls do not deactivate.
W-2463-0603
Unbuckle the seat belt.
Remove the key from the switch (Standard Key Panel) to
prevent operation of the loader by unauthorized
personnel.

10-200-1 S160 Service Manual

STOPPING THE ENGINE AND LEAVING THE Front Door (If Equipped)
LOADER (CONT’D)
NOTE: When an Operator Cab Enclosure Kit is
Emergency Exit installed, the window of the front door can be
used as an emergency exit. [Figure 10-200-6]
The front opening on the operator cab and rear window
provide exits. NOTE: If the loader has a Special Application Door
Kit installed, the window of the front door is
Rear Window (If Equipped) NOT an emergency exit.

Figure 10-200-4 Figure 10-200-6

P-64994 N-20171

Pull on the tag on the top of the rear window to remove Pull the plastic loop at the top of the window in the front
the rubber cord [Figure 10-200-4]. door to remove the rubber cord [Figure 10-200-6].

Push the rear window out of the rear of the operator cab. Figure 10-200-7

Figure 10-200-5

X X

X X

S0363

P-45260
Push the window out with your foot [Figure 10-200-7] at
any corner of the window.
Exit through the rear of the operator cab [Figure 10-200-
5]. Exit through the front door.

10-200-2 S160 Service Manual

 HYDRAULIC SYSTEM

BOB-TACH (POWER) BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1 HYDRAULIC
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-3 SAFETY
SYSTEM &
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1

BUCKET POSITION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-3
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1
Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-2 DRIVE
SYSTEM
CYLINDER (BOB-TACH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-4
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-2
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1

CYLINDER (LIFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1 ELECTRICAL

Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-4 SYSTEM &
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-3 ANALYSIS
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-2
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
ENGINE
CYLINDER (TILT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1 SERVICE
Base End Pivot Pin Removal and Installation . . . . . . . . . . . . . . . . . 20-21-3
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-6
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-5
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-2 SPECIFICATIONS
Rod End Pivot Pin Bushing And Seal Removal And Installation . . . 20-21-4
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1

FRONT AUXILIARY HYDRAULIC COUPLER BLOCK. . . . . . . . . . . . 20-140-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-1
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-1

HIGH FLOW VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-5
High Flow Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 20-150-2
High Flow Relief Valve Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-4
Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-3

Continued On Next Page

20-01 S160 Service Manual

 HYDRAULIC SYSTEM (CONT’D)

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) . . . . . . . . . . . . . . . . . . . . . . . . .20-41-1

Actuator Removal And Installation (Out of Loader) . . . . . . . . . . . . . . . . . . . . . .20-41-6
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) . . . . . . . . . . . .20-41-12
Auxiliary Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-25
Auxiliary Spool Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-24
Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-32
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
End Cap Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-16
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-9
Lift Arm Bypass Orifice Removal And Installation . . . . . . . . . . . . . . . . . . . . . .20-41-30
Lift Load Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . .20-41-10
Lift Spool And Detent Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 20-41-17
Load Check Valve Removal And Installation (Tilt & Auxiliary) . . . . . . . . . . . . . 20-41-11
Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-28
Main Relief Valve Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-31
Mount Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-10
Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-15
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) . 20-41-13
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) .20-41-13
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) . .20-41-14
Port Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-14
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-1
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-26
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-22

HYDRAULIC CONTROL VALVE (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-1

Anti-Cavitation Valve Removal And Installation (Lift, Rod End) . . . . . . . . . . . . .20-40-9
Auxiliary Spool Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-27
Auxiliary Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-28
Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-34
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
End Cap / Spool Lock Block Removal And Installation . . . . . . . . . . . . . . . . . .20-40-14
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-6
Lift Arm Bypass Orifice Removal And Installation . . . . . . . . . . . . . . . . . . . . . .20-40-33
Lift Load Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . .20-40-7
Lift Spool And Detent Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 20-40-15
Load Check Valve Removal And Installation (Tilt & Auxiliary) . . . . . . . . . . . . . .20-40-8
Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-31
Main Relief Valve Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-33
Mount Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-7
Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-12
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) .20-40-10
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) .20-40-10
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) . . 20-40-11
Port Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-11
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-1
Rubber Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-13
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-29
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-25

Continued On Next Page

20-02 S160 Service Manual

 HYDRAULIC SYSTEM (CONT’D)

HYDRAULIC/HYDROSTATIC FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
Charge Filter Housing Removal And Installation . . . . . . . . . . . . . . . . . . . 20-80-3
Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1

HYDRAULIC FLUID RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1
Hydraulic Fluid Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1

HYDRAULIC PUMP (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Direct Pump Test (Charge Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-4
Direct Pump Test (Standard Section). . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-2
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-10
Hydraulic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-8
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-9
Pump Test at Quick Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-6

HYDRAULIC PUMP (STANDARD) (HIGH FLOW) . . . . . . . . . . . . . . . . . . . . 20-61-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1
Direct Pump Test (Charge Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-4
Direct Pump Test (High Flow Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-6
Direct Pump Test (Standard Section). . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-2
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-12
Hydraulic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-10
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-11
Pump Test At Quick Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-8

HYDRAULIC PUMP (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
Direct Pump Test (Charge Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-4
Direct Pump Test (Standard Section). . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-2
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-10
Hydraulic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-8
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-9
Pump Test At Quick Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-6
Continued On Next Page

20-03 S160 Service Manual

 HYDRAULIC SYSTEM (CONT’D)

HYDRAULIC PUMP (SJC) (HIGH FLOW) . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71-1
Direct Pump Test (Charge Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71-4
Direct Pump Test (High Flow Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71-6
Direct Pump Test (Standard Section). . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71-2
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71-12
Hydraulic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71-10
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71-11
Pump Test At Quick Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71-8

HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1

Glossary Of Hydraulic / Hydrostatic Symbols . . . . . . . . . . . . . . . . . . . . . 20-10-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5

LIFT ARM BYPASS CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-2
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1

MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-4
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-2

OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1

REAR AUXILIARY DIVERTER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-5
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-2
Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1

TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD

TORQUE SPECIFICATIONS FOR BOLTS, SPEC SECTION) UNLESS
OTHERWISE SPECIFIED.

20-04 S160 Service Manual

Thank you very much
for your reading.
Please Click Here
Then Get More
Information.