2006 ASV RC-85 & RC-100 Track Loader Manual Set (P/N 0201-669)

The operating guide supports routine care, while the service volume and matching parts catalog support RC-100 repair planning. Engine-specific filter listings and different track-tensioner assemblies help distinguish the parts information that applies to your machine.

Coverage distinction: RC-85 coverage is operation and maintenance; the service procedures, separate schematics, and parts catalogs cover the RC-100. Engine content covers specifications, routine service, and parts identification rather than internal engine overhaul.

PDF Search, Bookmarks, and Drawing Detail

Search and drawing access: Text search works across the manuals, parts tables, and separate schematics, but some labels within the service manual’s system illustrations are not searchable. Embedded bookmarks link to each publication and detailed service sections; small schematic labels require zooming, and some parts drawings have faint linework.

All six publications are combined in one printable, 156-page PDF. The total includes six cover/back-cover pages, four additional contents pages, and one service-log page.

Loader Hydraulics, Track Service, and Parts Identification

These selected content highlights show the main workshop areas rather than the complete contents; additional topics include electric attachment controls and forestry-package ROPS access.

• Hydrostatic pumps: Charge and auxiliary pump removal, tandem pump removal and installation, and hydraulic reservoir clean-out after pump failure.

• Undercarriage repair: Step-by-step track removal and installation, sprocket roller replacement, drive motor removal, wheel replacement, and keeper-plate adjustment.

• Hydraulic diagnosis: Charge and auxiliary pressure checks, test-port identification, and troubleshooting for disabled hydraulics, drive faults, and lift-arm problems.

• Electrical systems: Wiring schematics, operator-presence interlocks, starting and charging fault diagnosis, and loader float-magnet troubleshooting.

• Operator enclosure and cooling: Light bar, ignition switch, gauge panel, and lap bar gas-assist spring service, plus fuel tank and radiator/oil cooler removal.

• Maintenance and parts: Fluid and filter service, track-tension checks, lubrication schedules, and illustrated component lists with reference numbers and quantities.

The repair sections suit technicians familiar with hydraulic systems and component removal; pressure testing requires a gauge, and the manual calls for manufacturer assistance before those checks.

RC-100 Pump Service and Fault Isolation

The pump chapter documents component removal and installation rather than internal pump rebuilding. Its reservoir clean-out section addresses contamination after pump failure, extending the work beyond replacing the failed assembly.

Hydraulic pressure-check pages identify separate filter-side and pump-side charge test locations. These references help technicians compare readings at the correct location when tracing hydraulic faults.

Troubleshooting distinguishes a machine that will not crank from one that cranks without starting. Separate scenarios address hydraulic lockout, tracks or lift arms that will not operate, auxiliary-flow faults, charging problems, and overheating.

Circuit Views and Component Service

The Hydraulic Charge System, Auxiliary Circuit System, and Drive Loop System drawings show component connections and hydraulic routing. Loader Valve, Solenoid Block, and Electrical Attachment Outlet views identify ports, solenoid functions, and attachment connections.

The service specifications identify the Husko load-sense loader valve. Separate electrical and hydraulic schematic sheets provide broader circuit references, including connector identifiers, wire codes, and hydraulic symbols.

Fuel-system procedures cover the sending unit, crossover tube, and fuel tanks. Cooling-system work includes fan guard, optional A/C condenser, fan, and radiator/oil cooler removal.

Track Installation and Serial-Specific Parts

The track installation procedure requires tool P/N 0703-138, which also appears in the parts catalogs. The catalogs illustrate different tensioning arrangements: a turnbuckle assembly in the later catalog and hydraulic tension cylinders in the earlier version.

Illustrated lists cover axle mountings, 10- and 14-inch wheel assemblies, drive sprockets, and suspension components. They also break down the pilot control manifold, hydraulic reservoir, lap bar, and quick attach assembly for parts identification.

Running tracks too tight can cause track stretch and bearing failure; excessive slack can cause misfeeding and track damage. The service instructions also warn that drive-sprocket misalignment can cause derailment or abnormal wear.

Heavy equipment maintenance involves high-pressure hydraulics and significant mechanical forces. Always review the integrated product safety chapters before starting major disassembly, particularly work involving raised lift arms or heavy components.

Examples of Track-Tension and Fastener Specifications

The RC-100 track-adjustment section specifies 0.75–1 inch of deflection under 90 pounds of downward force at the midpoint between the sprocket and front idler, measured against a straightedge.

The critical torque table lists 85 ft-lb with Blue Loctite for transmission mounting bolts and 160 ft-lb dry for drive sprocket lug nuts.