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

Use the service procedures and circuit diagrams to trace a fault, then check the relevant parts catalog against the machine’s serial number and engine configuration.

RC-100 coverage is limited to the shared operation and maintenance guide and electrical schematic. The workshop procedures, parts catalogs, and separate hydraulic schematic cover the RC-85.

PDF Search, Bookmarks, and Drawing Detail

Text search and diagrams: Manual text, parts lists, and labels on the two standalone schematics are searchable. Some illustration labels are outside the search layer. Bookmarks open the included documents and service sections. Small connector pins and wire codes are legible when zoomed in. Some service diagrams have soft labels or faint lines, and several parts illustrations are faint. The PDF restricts text copying.

One printable English PDF contains 154 pages, including the original covers and one introductory supplementary page.

Hydrostatic Service, Track Work, and Parts Identification

The following are selected topics. The operation guide also includes a pre-start inspection checklist and a service log.

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

• Undercarriage: Step-by-step instructions for track removal and installation, plus 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 removal procedures for the fan, optional A/C condenser, and combined radiator/oil cooler.

• Cab controls: Light-bar access, ignition-switch and gauge-panel replacement, lap-bar gas assist spring replacement, joystick removal and installation, 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 RC-85 service procedures are written for mechanics familiar with hydrostatic systems, pressure gauges, and safely supporting heavy loader components. The operation guide also covers routine use and upkeep for operators.

RC-85 Engine and Parts Identification

The January 2004 parts catalog lists the Cat 3054C from RSF00101 and up. The January 2005 catalog lists the Perkins 1104C-44 from RSF00489 and up. The separate engine and filter listings help match service parts to the machine. The later catalog also illustrates the earlier loader-stop arrangement.

Engine coverage is limited to specifications, routine maintenance, and engine-installation parts views. The operation guide identifies the RC-100 engine as the Perkins 1104C-44T.

Hydraulic Pressure Checks and Electrical Fault Tracing

The service manual identifies the Cat AA20VG45T tandem transmission and the Husko load-sensing loader valve. Pump work covers removal, tandem-pump reinstallation, and cleanup after a failure. The pressure-check chapter shows the gauge connections and calls for manufacturer assistance before beginning the checks.

The charge, auxiliary, and drive-loop diagrams show how the hydraulic circuits are routed. Separate views identify the loader valve, solenoid block, and electrical attachment outlet. The shared wiring schematic identifies connector pins, wire-color codes, fuses, and relays.

For a hydraulic lockout, the troubleshooting section helps distinguish seat, lap-bar, or door interlock faults from safety relay, solenoid, and low charge-pressure faults before components are removed.

Track, Fuel, and Cooling Service

Track installation specifies tool P/N 0703-138. The undercarriage chapter also covers sprocket bearing removal, drive-table alignment, and wheel keeper-plate repositioning. The manual explains how excessive tension can damage tracks and bearings and how sprocket misalignment can derail a track.

The fuel-system chapter cautions against damaging the float mechanism during sending-unit removal. Cooling coverage includes fan-guard access, and the operation guide explains how to clean the radiator/oil cooler, engine compartment, and chassis.

Control Options and Routine Upkeep

The operation guide explains the optional Case-type joystick pattern and the RC-100’s two-speed drive and power quick attach. The tilt-up ROPS instructions identify the additional preparation required for Forestry Package machines.

Maintenance coverage distinguishes 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 Hydraulic, Cooling, and Track-Tension Specs

The RC-85 service manual specifies 3,300 psi for auxiliary-pump relief and gives the same target for the auxiliary pressure check. For the Cat 3054C, it lists an average water/thermostat temperature of 190°F (87.8°C).

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