Description

Bobcat S160 2008 Service Manual

I’ve lost count of how many times I’ve seen a skid-steer come into my shop with a cracked block or a blown seal because someone used a generic manual. You avoid that by pulling the Bobcat S160 2008 Service Manual – 996 pages of factory-printed, dealer-level documentation. Page 1 starts with the safety warnings that most guys skip, and that’s where you learn why the BICS system shuts you down if you try a shortcut. This isn’t a reprint from some third-party scanner. It’s the actual OEM PDF Bobcat dealers used in 2008.

996 Pages of Factory Procedure

The manual is broken into real chapters, not a shuffled mess. You get the full FOREWORD, SAFETY INSTRUCTIONS, FIRE PREVENTION (including a sub-section on Electrical hazards that covers arc flash risk when working near the battery), SERIAL NUMBER LOCATIONS, and the DELIVERY REPORT so you can confirm the machine’s history. Then the SAFETY AND MAINTENANCE section runs through lifting, blocking, cab handling, and the exact procedure for installing the lift arm support device. I don’t care how fast you think you are – never go under the arms without that device. The manual tells you the inspection intervals and part numbers for the support.

Hydraulic System: Relief Valve Testing and Adjustment

Skid-steer hydraulics kill billable hours when you guess. The HYDRAULIC SYSTEM section gives you the glossary of hydraulic symbols, troubleshooting flowcharts, and then gets into the cylinder work. You get CYLINDER (LIFT), CYLINDER (TILT), and CYLINDER (BOB-TACH) – each with testing, removal and installation, and a parts identification diagram. The MAIN RELIEF VALVE section has a description, testing procedure, adjustment specs, and removal/installation steps. You won’t find that in a $20 aftermarket access. If you need the earlier model, check the Bobcat S150 S160 2006 Service Manual – the hydraulic setup changed slightly.

Engine Overhaul Information

The manual covers the Engine through the SERVICE SCHEDULE, AIR CLEANER SERVICE, ENGINE COOLING SYSTEM (cleaning, checking coolant level, removal and replacement), FUEL SYSTEM (including biodiesel blend fuel specifications and the exact procedure for removing air from the fuel system), and the ENGINE LUBRICATION SYSTEM with oil charts, checking and adding, filter changes. For the lubricant specs, see the Bobcat S150 S160 2006 Service Manual – Section: Engine – the 2008 version carries the same viscosity recommendations. The Bobcat S150 S160 2008 Service Manual – Section: Engine Lubrication System gives you the drain interval and capacity in quarts, not liters.

3 Critical Safety Procedures You Must Follow

First: never disconnect hydraulic lines without relieving system pressure – the manual shows the depressurization sequence. Second: the lift arm support device must be inspected before each use; the manual lists the part number and replacement criteria. Third: when using the remote start tool kits (MEL1563 and 6689779), follow the exact harness connections – the manual provides pinout diagrams for both the Service Tool Harness Control (MEL1565) and the Communicator (MEL1566). Skip those steps and you’re looking at a fried ECU.

Does This Manual Cover the Fuel System?

Yes, and it’s not just a diagram. The FUEL SYSTEM chapter tells you the fuel specifications, how to handle biodiesel blends, the correct way to fill the tank to avoid air ingestion, the filter part numbers, and the step-by-step bleeding procedure. That’s the difference between a machine that starts on the first crank and one that sputters for ten minutes. The manual also covers the Spark Arrestor Exhaust System cleaning, which is a regular maintenance item in Texas fire season.

Get the Right Torque Data

Torque is not “feel” – it’s a spec. The manual includes torque values for wheel nuts, pivot pin hardware, hydraulic fittings, and engine fasteners. I’ve seen guys strip the Bob-Tach hand lever bolts because they grabbed a generic torque chart. Don’t do that. The manual also details the FINAL DRIVE TRANSMISSION (CHAINCASE) oil checks and changes – unlike a Manual Transmission, the chaincase uses a specific grade of gear lube, and the fill level needs to be checked with the machine level. For general transmission theory, you can read about a Manual Transmission online, but for a skid-steer hydrostatic, stick to the OEM doc.

FAQ

Can I use this manual on a Bobcat S150?

Most sections are identical for the S150 and S160. The main differences are in the hydraulic pump and driveline. This manual covers S160 serial numbers A3L311001 & Above and A3L411001 & Above. For an S150, get the matching year manual.

Does the PDF include wiring diagrams?

Short answer: yes.

How do I access the manual after purchase?

You get a direct access link immediately after payment. The file is a searchable PDF, about 150 MB. You can view it on a tablet or computer. We do not mail CDs. Save it to your shop tablet before you start the job because the hydraulic schematic alone is worth the price.

Is this the same manual a Bobcat dealer uses?

Yes. This is a scanned copy of the official Bobcat Company Service Manual, part number 6987048 (8-08). The cover says “Dealer Copy – Not for Resale.” It has the same content as the paper manual that cost $400 from the dealer. We offer it as a digital access for a fraction of that.

Your time is money. Your machine is expensive. Don’t waste either on guesswork. Access the Factory Manual and have the specs, schematics, and torque values on your workbench in the next five minutes. This is the PDF that keeps skid-steers running straight and safe.