PDF Operation & Maintenance Manual Bobcat S160 Skid Steer Loader - 885 KB
Get the most out of your Bobcat S160 Skid Steer Loader with the official Operation & Maintenance Manual.
This guide provides essential information on daily checks, safe operating procedures, and routine maintenance tasks.
It's designed to help operators work efficiently and safely while keeping the machine in top condition.
Every owner and operator should have this manual on hand.
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Operation & Maintenance Manual
S160 Skid-Steer Loader
S/N AHWA11001 & Above
S/N A15111001 & Above
EQUIPPED WITH
BOBCAT INTERLOCK
CONTROL SYSTEM (BICS™)
6989453 (8-12) Revised (2-13) (6) Printed in U.S.A. © Bobcat Company 2013
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LOADER IDENTIFICATION
FRONT OPERATION &
LIGHTS MAINTENANCE
MANUAL AND
GRAB OPERATOR’S
HANDLES HANDBOOK
OPERATOR SEAT
with SEAT BELT
AND SEAT BAR
TILT
CYLINDERS
FRONT AUXILIARY
QUICK COUPLERS
†BUCKET
STEP
BUCKET
STEPS
â—Ź OPERATOR CAB
LIFT (ROPS AND FOPS)
CYLINDER LIFT ARM
SUPPORT DEVICE
REAR
GRILLE
LIFT ARM
BACK-UP
ALARM
REAR
LIGHT
REAR
TAIL LIGHT * TIRES B-19876A
DOOR B-19877A
* TIRES - The Bobcat loader is factory equipped with standard tires.
†BUCKETS - Several different buckets and other attachments are available for the Bobcat loader.
â—Ź ROPS - Roll-Over Protective Structure per ISO 3471 and FOPS - Falling-Object Protective Structure per ISO 3449,
Level I. Level II is available.
9 S160 Operation & Maintenance Manual
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PUBLICATIONS AND TRAINING RESOURCES
The following publications are also available for your
Bobcat loader. You can order them from your Bobcat
dealer. OPERATOR’S
HANDBOOK
For the latest information on Bobcat products and the
Bobcat Company, visit our web site at 6986651
training.bobcat.com or www.bobcat.com.
Gives basic operation instructions and safety warnings.
OPERATION &
MAINTENANCE
SKID-STEER
MANUAL
LOADER
OPERATOR
6989453
TRAINING COURSE
6901726
Complete instructions on the correct operation and the
routine maintenance of the Bobcat loader.
Introduces operator to step-by-step basics of skid-steer
loader operation. Also available in Spanish P/N 6902289.
OPERATOR SAFETY
VIDEO
S160 SERVICE
MANUAL
6902176
6987034
OPERATOR SAFETY
DVD (English &
Spanish)
6904762
Complete maintenance instructions for your Bobcat loader.
Provides basic safety instructions contained in all Bobcat
safety videos in both English and Spanish.
SKID-STEER
LOADER SERVICE
SAFETY
TRAINING COURSE
SAFETY MANUAL
(English & Spanish) 6900641
6556500
Introduces service technicians to step-by-step basics of
Provides basic safety procedures and warnings for your proper and safe skid-steer loader maintenance and servicing
Bobcat loader in both English and Spanish. procedures.
19 S160 Operation & Maintenance Manual
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INSTRUMENT PANEL IDENTIFICATION (CONT’D)
Left Panel (Cont’d)
REF.
DESCRIPTION FUNCTION / OPERATION
NO.
1 ENGINE TEMPERATURE GAUGE Shows the engine coolant temperature.
2 LEFT TURN SIGNAL (Option) Indicates left turn signals are ON.
3 GENERAL WARNING Malfunction with one or more machine functions. (See Service Codes*)
4 TWO-SPEED (Option) High range selected.
5 ENGINE MALFUNCTION Engine malfunction or failure. (See Service Codes*)
6 ENGINE COOLANT TEMPERATURE Engine coolant temperature high or sensor error.
7 DISPLAY SCREEN Displays information. (See Display Screen in this manual.)
8 SEAT BELT Instructs operator to fasten seat belt. Remains lit for 45 seconds.
9 SEAT BAR The light comes on when the seat bar is UP.
10 LIFT & TILT VALVE The light comes on when the lift and tilt functions cannot be operated.
11 PARKING BRAKE The light comes on when the loader cannot be driven.
12 RIGHT TURN SIGNAL (Option) Indicates right turn signals are ON.
13 SHOULDER BELT (Option) Instructs operator to fasten shoulder belt when operating in high range.
Remains lit while in high range.
14 HYDRAULIC SYSTEM MALFUNCTION Hydraulic system malfunction or failure. (See Service Codes*)
15 FUEL Fuel level low or sensor error.
16 FUEL GAUGE Shows the amount of fuel in the tank.
17 LIGHTS Press once for FRONT work lights and REAR taillights. (Left green LED
will light.) Press a second time to add REAR work lights. (Left and right
green LEDs will light.) Press a third time to turn all lights off. (Left and
right green LEDs will be off.)
Press and hold five seconds to display software version in display
screen.
18 HIGH-FLOW (Option) Press once to engage the HIGH-FLOW auxiliary hydraulics. (Left green
LED will light.) Press a second time to disengage.
19 AUXILIARY HYDRAULICS Press once to engage the auxiliary hydraulics. (Left green LED will
light.) Press a second time to disengage.
20 INFORMATION Cycles through (after each button press):
• Hourmeter (On start up)
• Engine rpm
• Battery voltage
• Maintenance clock (Press and hold for seven seconds when
displayed to reset the maintenance clock.
• Service codes*
21 TRACTION LOCK OVERRIDE Functions only when the seat bar is raised and the engine is running.
Press once to unlock the brakes. Allows you to use the steering levers
or joystick(s) to move the loader forward or backward when using the
backhoe attachment. (See TRACTION LOCK OVERRIDE in this
manual.) Press a second time to lock the brakes.
22 PRESS TO OPERATE LOADER Press to activate the BICS™ when the seat bar is down and operator is
seated in operating position. Button will light.
Press and hold three seconds to engage Drive Response and
Steering Drift Compensation. (See DRIVE RESPONSE and
STEERING DRIFT COMPENSATION in this manual.)
23 ALARM The alarm beeps when Error, Warning or Shutdown conditions exist.
* See SYSTEM SETUP & ANALYSIS for Service Code description. (See DIAGNOSTIC SERVICE CODES on Page 149.)
29 S160 Operation & Maintenance Manual
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LIFT ARM BYPASS CONTROL TRACTION LOCK OVERRIDE
Operation Operation
Figure 23 Figure 25
1
2
1
P-54406
P-76683
The lift arm bypass control (Item 1) [Figure 23] is used to (Functions Only When The Seat Bar Is Raised And The
lower the lift arms if the lift arms cannot be lowered Engine Is Running) There is a TRACTION LOCK
during normal operations. OVERRIDE button (Item 1) [Figure 25] on the left
instrument panel which will allow you to use the steering
1. Sit in the operator's seat. levers to move the loader forward and backward when
2. Fasten the seat belt and lower the seat bar. using the backhoe attachment.
3. Turn the knob (Item 1) [Figure 23] clockwise 1/4 turn.
4. Pull up and hold the knob until the lift arms lower. • Press the TRACTION LOCK OVERRIDE button once
to unlock traction drive. The PARKING BRAKE light
PARKING BRAKE (Item 2) [Figure 25] will be OFF.
Operation • Press the button a second time to lock the traction
drive. The PARKING BRAKE light (Item 2)
Figure 24 [Figure 25] will be ON.
1 NOTE: The TRACTION LOCK OVERRIDE button will
unlock the traction drive when the seat bar is
raised and the engine is running.
NOTE: The TRACTION LOCK OVERRIDE button will
function if the parking brake is in the engaged
2 B-15993Q
or disengaged position and the engine is
running. If the parking brake switch is turned
Press the top of the switch (Item 1) [Figure 24] to ON, the red light in the parking brake switch
engage the parking brake. The red light in the switch will will turn OFF when TRACTION LOCK
turn on. The traction drive system will be locked. OVERRIDE is engaged.
Press the bottom of the switch (Item 2) [Figure 24] to
disengage the parking brake. The red light in the switch
will turn off. The traction drive system will be unlocked.
NOTE: The PARKING BRAKE light on the left
instrument panel will remain ON until the
engine is started, the PRESS TO OPERATE
LOADER button is pressed and the parking
brake is disengaged.
39 S160 Operation & Maintenance Manual
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DRIVE RESPONSE Operation
Drive Response is available on SJC equipped machines. NOTE: Changes CANNOT be performed until the seat
bar is lowered, the engine is started and the
NOTE: An upgrade to the loader’s software may be PRESS TO OPERATE LOADER button is
required if this feature does not function as pressed to activate the BICS™.
described in this manual. See your Bobcat
dealer to update your machine’s software Perform pre-starting and starting procedures:
version if necessary.
1. Fasten seat belt.
Description
2. Lower seat bar.
Drive Response changes how responsive (more or less)
the loader’s drive and steering systems are when the 3. Place joysticks in neutral position.
operator moves the joystick(s).
4. Start the engine.
Drive Response can be changed by the operator for
different drive response preferences and various job 5. Press the PRESS TO OPERATE LOADER button.
conditions and attachment use.
6. Current drive response setting will be displayed briefly
NOTE: Changes to drive response do not affect in the data display.
braking or stopping the loader.
NOTE: Raising the seat bar or changing control
There are three drive response settings: mode (ISO / H) will cause the machine to
disengage from drive response. The last
• [DR-1] provides a smooth responsive reaction to displayed setting will remain in effect until the
joystick movement. (Drive only) STOP button is pressed or the key is turned
OFF.
• [DR-2] is the default setting and provides a normal
responsive reaction to joystick movement. (Drive
only)
• [DR-3] provides a quick responsive reaction to
joystick movement. (Drive only)
49 S160 Operation & Maintenance Manual
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HYDRAULIC CONTROLS (CONT’D) Standard And ACS (If Equipped)
FRONT Auxiliary Hydraulics Operation Figure 65
Figure 64
1
P16537B P-31833A
SJC (If Equipped)
2 1 Figure 66
P-76460C
1
Press the auxiliary hydraulics button (Item 1) [Figure 64]
once to engage auxiliary hydraulics.
The light (Item 2) [Figure 64] will be ON.
P-27820A P-24802A
Move the front auxiliary hydraulic switch (Item 1)
[Figure 65] or [Figure 66] to the right or left to change
the fluid flow direction of the front quick couplers. If you
move the switch half-way, the auxiliary functions move at
approximately one-half speed; release the switch to stop
auxiliary functions. (EXAMPLE: Open and close grapple
teeth.)
To disengage, press the auxiliary hydraulics button (Item
1) [Figure 64] again.
The light (Item 2) [Figure 64] will be OFF.
NOTE: When the operator is seated and raises the
seat bar, the Auxiliary Hydraulic System
(Front and Rear) will deactivate.
59 S160 Operation & Maintenance Manual
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PRE-STARTING PROCEDURE (CONT’D)
Seat Belt Adjustment
Figure 91
IMPORTANT
Check the seat belt and shoulder belt retractors for
correct operation.
Keep retractors clean and replace as necessary.
I-2199-0200
P-16041 Seat Bar
Figure 93
P-16038
Squeeze both seat belt adjusters to release and lengthen
each half of the seat belt [Figure 91].
Fasten the seat belt.
Pull the ends of the belt through the belt adjusters so that
the seat belt is snug and the buckle is centered between
your hips [Figure 91]. P-45114
Figure 92
Lower the seat bar and engage the parking brake
2 [Figure 93].
Put the foot pedals or hand controls in neutral position.
NOTE: Keep your hands on the steering levers and
your feet on the foot pedals (or footrests)
1 while operating the loader.
N-21774
WARNING
AVOID INJURY OR DEATH
When operating the machine:
• Keep the seat belt fastened snugly.
• The seat bar must be lowered.
N-21773
• Keep your feet on the pedal controls or footrests
and hands on the controls.
W-2261-0909
3-Point Restraint - (Option and Loaders with Two-Speed)
Connect the shoulder belt to the lap belt (Item 1)
[Figure 92]. Pull the lap belt across to the left side of the
seat (Item 2) [Figure 92] and fasten.
The shoulder belt must be positioned over your right
shoulder and lap belt over your lower hips [Figure 92].
69 S160 Operation & Maintenance Manual
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STOPPING THE ENGINE AND LEAVING THE LOADER NOTE: Activating the Password Lockout Feature on
machines with the Keyless Start Panel or the
Procedure Deluxe Instrumentation Panel allows
operation of the loader without using a
Stop the loader on level ground. password. (See Password Lockout Feature on
Page 157.) or (See Password Lockout Feature
Fully lower the lift arms and put the attachment flat on the on Page 159.)
ground.
Figure 115
Figure 113
P-31864 P-66667 P-66668
Pull the engine speed control fully backward Exit the loader using grab handles, safety tread and steps
[Figure 113] to decrease the engine speed. (maintaining a 3-point contact) [Figure 115].
Engage the parking brake.
Figure 114 WARNING
1 2
AVOID INJURY OR DEATH
Before you leave the operator’s seat:
• Lower the lift arms and put the attachment flat on
the ground.
2 • Stop the engine.
P-76603 B-15553L
• Engage the parking brake.
P-90809A
• Raise the seat bar.
• Move all controls to the NEUTRAL / LOCKED
Turn the key switch to the STOP position (Item 1) or position to make sure the lift, tilt and traction
press the STOP button (Item 2) [Figure 114]. drive functions are deactivated.
NOTE: If the loader lights are ON, they will remain ON The seat bar system must deactivate these functions
for approximately 90 seconds after turning when the seat bar is up. See your Bobcat dealer for
the loader OFF. service if controls do not deactivate.
W-2463-1110
Raise the seat bar and make sure the lift and tilt functions
are deactivated.
Unbuckle the seat belt.
Remove the key from the switch (Standard Key Panel) to
prevent operation of the loader by unauthorized
personnel.
79 S160 Operation & Maintenance Manual
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OPERATING PROCEDURE (CONT’D) Emptying
Filling And Emptying The Bucket (Foot Pedals) Figure 136
Filling
Figure 134 2
1
1 2
B-15595 B-15973
Keep the bucket low when moving to the area where you
B-15585 B-15973 want to empty the bucket.
Raise the lift arms (Item 1) [Figure 136]. Level the bucket
Figure 135 (Item 2) [Figure 136] while raising the lift arms to help
prevent material from falling off the back of the bucket.
Drive forward slowly until the bucket is over the top of the
truck box or bin.
Empty the bucket (Item 2) [Figure 136]. If all the material
1 is near the side of the truck or bin, use the bucket tilt to
move it to the other side.
B-15586 B-15973
WARNING
Lower the lift arms all the way (Item 1) [Figure 134].
Never dump over an obstruction, such as a post, that
Tilt the bucket forward (Item 2) [Figure 134] until the can enter the operator cab. The machine could tip
cutting edge of the bucket is on the ground. forward and cause injury or death.
W-2057-0694
Drive slowly forward into the material. Tilt the bucket
backward (Item 1) [Figure 135] all the way when the
bucket is full.
Drive backward away from the material.
WARNING
Load, unload and turn on flat level ground. Do not
exceed Rated Operating Capacity (ROC) shown on
sign (decal) in cab. Failure to obey warnings can
cause the machine to tip or rollover and cause injury
or death.
W-2056-1112
89 S160 Operation & Maintenance Manual
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PREVENTIVE MAINTENANCE
MAINTENANCE SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Inspecting The BICS™ (Engine STOPPED - Key ON) . . . . . . . . . . . . . . . . . . . . . . . . . . .106
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Inspecting The Seat Bar Sensor (Engine RUNNING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Inspecting The Traction Lock (Engine RUNNING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
Inspecting The Lift Arm Bypass Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC) . . . . . . . . . . . . . . . . . . 106
SEAT BAR RESTRAINT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Maintaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
BACK-UP ALARM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Adjusting Switch Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
Cab Door Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
REAR DOOR (TAILGATE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Opening And Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
REAR GRILLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
99 S160 Operation & Maintenance Manual
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LIFT ARM SUPPORT DEVICE Figure 161
Installing
2