2004–2005 ASV RC-85 Track Loader Service & Parts Manuals with RC-85 / RC-100 Operation & Maintenance (P/N 2015-041)

For 2004–2005 ASV RC-85 and RC-100 Posi-Track rubber track loaders, this R-Series collection combines the RC-85 Service Manual (P/N 2015-041, May 2004 cover date) with two RC-85 parts catalogs and a shared operation and maintenance guide. RC-100 coverage consists of operation, maintenance, and the shared electrical schematic; the service manual and parts catalogs are for the RC-85.

• Hydraulics: Charge and auxiliary pressure checks, charge and auxiliary piston pump removal, tandem hydrostatic pump removal and installation, and hydraulic reservoir clean-out.

• Undercarriage: Track removal and installation, sprocket roller and wheel replacement, Rexroth MCR 5 drive motor removal, and track-tension adjustment.

• Fuel and cooling: Fuel tank, cross-over tube, and sending-unit removal, plus fan, optional A/C condenser, and radiator/oil cooler removal procedures.

• Cab controls: Light-bar access, ignition-switch and gauge-panel replacement, lap-bar gas assist spring replacement, joystick removal, and loader float magnet service.

• Fault tracing: Symptom-based troubleshooting for starting, charging, hydraulic lockout, travel, lift, float, and overheating, supported by hydraulic diagrams and electrical schematics.

• Parts identification: Serial-specific exploded views and numbered parts lists for the engine installation, suspension, drive tables, loader, hydraulic plumbing, and quick attach.

• Operation and maintenance: Standard and optional joystick patterns, attachment controls, ROPS canopy access, fluid and filter service, and scheduled maintenance.

The repair sections suit mechanics familiar with hydrostatic systems, pressure gauges, and safely supporting heavy loader components; the operation guide also addresses routine use and upkeep.

Serial Coverage and Engine Identification

Parts manual 2015-021 lists RC-85 serial numbers RSF00101 and up, while 2015-047 lists RSF00489 and up. The earlier catalog identifies the Cat 3054C; the later catalog identifies the Perkins 1104C-44. The operation guide also lists the RC-100's Perkins 1104C-44T.

These separate engine and service-filter listings help match replacement parts to the machine configuration. The later loader-assembly illustration identifies an earlier loader-stop arrangement for RSF00101–RSF00556.

Engine scope: Specifications, routine maintenance, and engine-installation parts views are included. Engine removal and internal engine overhaul procedures are not included.

Hydraulic Diagnosis and System Diagrams

The hydraulic sections identify the Cat AA20VG45T tandem transmission and Husko load-sensing loader valve. Pump procedures cover removal, tandem-pump reinstallation, and cleanup after pump failure; they do not cover internal pump rebuilding. The pressure-check chapter calls for manufacturer assistance.

Hydraulic Charge System, Auxiliary Circuit System, Drive Loop System, Loader Valve, and Solenoid Block views support fault tracing. The appended schematics add the RC-85 hydraulic circuit and RC-100/85 wiring, including connector pins, wire-color codes, fuses, and relays.

The troubleshooting section connects hydraulic lockout symptoms with seat, lap-bar, and door switches, safety relays, solenoids, and charge pressure. This helps separate an operator-presence circuit fault from a hydraulic supply problem before components are removed.

Track, Fuel and Cooling Service

Track installation specifies tool P/N 0703-138. Undercarriage procedures also address sprocket-bearing removal, drive-table alignment, and wheel keeper-plate repositioning.

The track-tension section warns that excessive tension can damage tracks and bearings, while a misaligned drive sprocket can cause derailment. Fuel-sender removal carries a separate warning about damaging the float mechanism.

Cooling-system coverage includes fan-guard access and removal of the combined radiator/oil cooler. The operation guide adds cleaning guidance for the cooler, engine compartment, and chassis.

Control Variants and Routine Upkeep

The operation guide distinguishes the optional Case-type joystick pattern from the standard controls and explains the RC-100's two-speed drive and power quick attach. ROPS canopy access includes additional preparation for Forestry Package machines.

Maintenance coverage separates normal and severe-service engine oil intervals and includes hydraulic filtration, fuel/water separator draining, air-cleaner care, and grease-fitting locations.

Follow the manual's hydraulic pressure-relief and raised-lift-arm support precautions before service.

Sample Pressure, Temperature and Track-Tension Data

These figures are a small selection of the service specifications in the collection. RC-85 specifications list auxiliary-pump relief pressure at 3,300 psi and average water/thermostat temperature at 190°F (87.8°C).

The track-tension check specifies 0.75–1 inch of deflection under a 90 lb load at the midpoint between the drive sprocket and front idler. Both the RC-85 service manual and the shared operation guide describe this check.

PDF Navigation, Diagram Detail and Included Documents

Search and diagram detail: Manual text, parts listings, and appended schematic labels are searchable, but some labels within illustrations are not. Bookmarks link to the documents and detailed service sections. Small schematic labels require zooming; some chapter diagrams have blurred labels, and several parts drawings have faint lines.

One printable English PDF contains 154 pages total: RC-85 service manual, 61; operation and maintenance guide (ASVRC2OM-05), 28; earlier RC-85 parts catalog, 29; later RC-85 parts catalog, 33; hydraulic schematic (P/N 2015-037), 1; electrical schematic (P/N 0201-217), 1; and one introductory supplementary page. All covers and the supplementary page are already included in that total.