2004–2006 ASV RC-100 Rubber Track Loader Service, Operation & Parts Manual Set (P/N 0201-669)

For the 2004–2006 ASV RC-100 rubber track loader, this set combines Service Manual P/N 0201-669 (July 2004), operation and maintenance guide ASVRC2OM-05 (December 2006), and Master Parts Manual P/N 0201-993 (September 2007). The operation guide also covers the RC-85; repair procedures and the parts catalog focus on the RC-100.

Text search and schematic detail: Manual text and parts lists are searchable; some diagram labels and the appended electrical schematic are not. No embedded PDF bookmarks. Small labels in the appended schematics need zooming; some service-manual system-view labels remain pixelated.

• Hydrostatic and auxiliary pumps: Charge and auxiliary pump removal, tandem pump replacement, hydraulic reservoir clean-out after pump failure, and charge/auxiliary pressure checks.

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

• Controls and electrical diagnosis: Joystick and loader float magnet service, starting and charging troubleshooting, operator-presence interlocks, and electrical attachment connections.

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

• Routine maintenance: Engine oil, hydraulic fluid, filters, fuel-water separator, air cleaner and lubrication service, with schedules and fluid-capacity specifications.

• Parts identification: Exploded assemblies, cylinder service parts, and serial-specific component changes, including optional enclosed cab, air conditioning, and forestry equipment.

The repair sections suit mechanics familiar with hydrostatic equipment and equipped for pressure testing and heavy-component handling; the operation guide addresses operators and routine maintenance.

Drivetrain & Hydraulic System Breakdown

Specifications identify the Cat AA20VG38.5 (Rexroth) tandem pump, Rexroth MCR 5 drive motors and Rexroth variable-load-sense auxiliary pump. Separate charge-pressure test locations help keep pump readings from being compared with filter-port specifications.

Hydraulic Charge System, Auxiliary Circuit System and Drive Loop System diagrams show circuit routing; Loader Valve and Solenoid Block views identify connections. The pressure chapter covers charge and auxiliary-valve checks; the drive-pressure adjustment pages listed in the contents are not included.

Electrical Diagnosis and Operator Controls

The Electrical Attachment Outlet view links joystick buttons to receptacle terminals. The separate RC-100/85/RCV electrical schematic identifies connector pins, wire colors, fuses and relays.

The troubleshooting section separates starting and charging faults from drive, lift-arm, auxiliary-flow and float-detent problems. Operator-enclosure procedures cover the light bar, ignition switch, console gauge/warning panel and lap bar gas assist springs.

Component Teardown & Routine Maintenance

Undercarriage repair: Track installation specifies tool P/N 0703-138. The procedures cover sprocket-bearing removal and split center-wheel replacement, plus keeper-plate repositioning when the standard track adjustment range is exhausted.

The track-tension guidance explains how excessive tension can damage bearings and tracks, while a misaligned drive sprocket can cause derailment or abnormal wear.

Fuel and cooling: Twin-tank removal includes the connecting cross-over tube. The fuel sender instructions flag possible float damage during removal; cooling coverage extends to the optional A/C condenser.

Working with pressurized systems and hot fluids presents serious shop hazards. The manual contains safety messages within the fluid-handling sections that must be reviewed before opening lines or valves.

Engine Variants, Specifications and Parts Coverage

The service specifications describe the Cat 3054CT turbo, while the RC-100 operation guide and later parts coverage identify the Perkins 1104C-44T. Engine material covers maintenance and basic specifications, not a full internal overhaul.

Critical torque references cover transmission mounting bolts and drive sprocket lug nuts.

Serial-specific parts: Caterpillar engine service items cover RSD 00101–1031; the Perkins assembly starts at RSD 01032. Parts changes include the chassis at RSD 01556, quick-attach at RSD 02212, lift-arm control valve at RSD 02369 and radiator/oil cooler at RSD 02646.

These illustrated breaks help match replacement assemblies to the machine's serial number. “Current” in the catalog means production at its September 2007 printing. Cylinder service notes also distinguish earlier and current designs, including matched-pair replacement requirements.

PDF Manual Set and Page Breakdown

One printable, English-language 129-page PDF contains the RC-100 Service Manual (60 pages), RC-85/RC-100 operation and maintenance guide (28 pages), and RC-100 Master Parts Manual (38 pages). The total also includes one combined-file cover, one hydraulic schematic sheet (0201-222) and one electrical schematic sheet (0201-217).