This ASV RC-85, RC-100 Service Manual (OEM #ASVRC2OM-05) runs 156 pages and covers both machines end to end: owner maintenance up front, then a full service repair section with system diagrams and step-by-step disassembly and assembly for the hydrostatic and auxiliary pump, undercarriage, loader, and transmission controls, plus hydraulic pressure check and adjustment. The electrical schematic maps the complete fuse panel, solenoid block, and pilot generation circuit; the hydraulic schematic traces the loader valve, two-speed system, and load-sense routing. Need to button up the undercarriage? Torque the RC-100 drive sprocket lug nuts to 160 ft-lb., and set track deflection between .75 and 1 inch under a 90-pound load. When your machine is down and the forum threads dead-end, this PDF searches by keyword and opens on any device in the shop.
What's Inside This ASV RC-85, RC-100 Manual
| System | Pages | Key Topics |
|---|---|---|
| Owner's & Maintenance Manual | 1-28 | Specifications, Safety Warnings, Machine Controls, Machine Operation, Machine Maintenance, ROPS Canopy Tilt-Up Access |
| Service & Repair Manual | 29-89 | Table of Contents, Product Safety, Technical Specifications, System Diagrams, Machine Controls and Instrumentation, Dash & Lap Bar Disassembly and Assembly |
| Electrical Schematic | 90 | Fuse Panel, Engine, Battery, Solenoid Block, Pilot Generation, Control Handle |
| Hydraulic Schematic | 91 | Loader Valve, Auxiliary Flow, Flushing Valve, Two Speed System, Load Sense |
| Master Parts Catalog (Serial RSD01032 and Up) | 92-124 | Operator Enclosure, Chassis, Radiator/Oil Cooler, Hydraulic Reservoir, Engine Assembly, Undercarriage |
| Master Parts Catalog (Serial RSD00700–RSD01031) | 125-156 | Operator Enclosure, Chassis, Radiator/Oil Cooler, Hydraulic Reservoir, Engine Assembly, Undercarriage |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Track deflection (with 90 lb. weight) | between .75 and 1 inch | p. 20 |
| Charge pressure (at test port) | between 625 and 700 psi. | p. 84 |
| Charge pressure (at pump) | between 400 and 450 psi. | p. 84 |
| Normal charge pressure (at test port) | between 625 and 700 psi. | p. 84 |
| Normal charge pressure (at pump) | between 400 and 450 psi. | p. 84 |
| Height to top of ROPS | 80 in. / 2023 mm | p. 4 |
| RC-100 | ||
| Drive Sprocket Drive Teeth Bolts torque | 105 ft-lb. | p. 37 |
| Drive Sprocket Lug Nut torque | 160 ft-lb. | p. 37 |
| Transmission Mounting Bolts torque | 85 ft-lb. | p. 37 |
| Bogie Wheel Retaining Nut torque | 125 ft-lb. | p. 37 |
| RC-100 Gross HP @ 2300 rpm | 99.5 hp / 74 kW | p. 4 |
| RC-85 | ||
| RC-85 Gross HP @ 2300 rpm | 86 hp / 64 kW | p. 4 |
ASV RC-85, RC-100 Common Problems This Manual Covers
ASV RC-85/RC-100 hydraulic controls dead or only partially responding, tracks move but lift arms won't
Check pilot pressure at the test port; the normal charge range is 625-700 psi, dropping to 400-450 psi at the pump (page 84). If it reads low, inspect the control lock solenoid and trace its circuit on the electrical schematic (page 90). Confirm the hydraulic tank is full at 20 gal (76 L).
Manual Section: Hydraulic System MalfunctionsDrive controls lag after joystick input, machine hesitates before responding to steering commands p. 84
Verify the control lock solenoid is releasing fully and that pilot pressure at the test port reads 625-700 psi (page 84). Follow the 'tracks will not move' troubleshooting steps, then inspect the solenoid wire connectors for corrosion and confirm the lap bar interlock seats completely before cycling the controls.
Manual Section: Hydraulic System MalfunctionsEngine cranks but won't fire, or turns over slowly and fails to start
Run the no-start sequence: check fuel level first (tank holds 26 gal / 98 L), then make sure the battery cables are clean and tight. Lower the lap bar fully to release the safety interlock. Check engine oil too; capacity with filter is 8.5 qt (8 L).
Manual Section: Machine No-Start/Crank IssuesRubber tracks sag, derail from bogie wheels, or feel loose during operation p. 20
Place a 90-lb. weight at the midpoint of the bottom track run and measure deflection; correct spec is 0.75-1 inch (page 20). Adjust the idler tensioner until deflection sits in that range. With the track slackened, inspect the bogie wheels and torsion suspension for wear, and replace worn rollers before retensioning.
Manual Section: General Visual InspectionHot oil warning light comes on during work cycles, hydraulic system temperature runs high
Top off the hydraulic tank first; it holds 20 gal (76 L). Check whether the fluid has passed its 500-hour change interval (page 78), since degraded oil traps heat. Clear the oil cooler and radiator fins of any debris blocking airflow. If the temperature stays high after the fluid is corrected, trace the flushing valve circuit on the hydraulic schematic (page 91).
Manual Section: Hydraulic System OverheatingUndercarriage clunking, unusual vibration, or rear torsion axle failure on certain units p. 37
Inspect the rear torsion axle mounts and carrier frame for cracks or loose hardware. Use the drivetrain parts diagram on page 105 to identify components. On RC-100 machines, torque the drive sprocket lug nuts to 160 ft-lb. (page 37).
Manual Section: Service Repair ManualFrequently Asked Questions
What do ASV RC-85/RC-100 error codes mean?
The manual lists warning lights for specific machine conditions: engine coolant temperature, glow plug operation, engine oil pressure, hydraulic oil temperature, and battery low-voltage. Should the coolant temperature, oil pressure, or hydraulic oil temperature light come on during normal operation, shut the machine down immediately, then diagnose and repair before continuing.
How to reset the track tension on an ASV RC-100?
Start by loosening the two bolts that fasten the drive table to the undercarriage frame rail. Extend or retract the tension turnbuckle until the track reaches proper tension. Then retighten or replace the two drive-table bolts, keeping the outside and inside bolts equally spaced in their slots so the drive sprocket stays aligned. With 90 lb. on the midpoint of the track, deflection should land between .75 and 1 inch.
What are the replacement specifications for Hydraulic control solenoids?
In the Pilot Control Manifold Assembly, the hydraulic control solenoid is part number 0200-364 (SOLENOID, W/DEUTSCH CONNECTOR). The spool solenoids are 0118-164 (SPOOL, SOLENOID, 3POSITION, 4WAY), 0118-165 (SPOOL, SOLENOID, 2POSITION, 3WAY), and 0118-168 (SPOOL, SOLENOID, 2POSITION, 4WAY).
What are the replacement specifications for Pilot pressure components?
At the pump, charge pressure should read between 400 and 450 psi; at the test port, between 625 and 700 psi. Auxiliary pressure should be 3300 psi. Take these readings with the engine warmed up and at wide open throttle, since correct operation depends on hitting these values.
What do I get after purchasing this ASV RC-85, RC-100 manual?
A 156-page Service Manual in searchable PDF, ready to download the moment checkout completes. Open it on a computer, tablet, or phone. No shipping wait.
Can I print this manual?
The PDF is DRM-free, so print whatever sections you want to take to the shop. Standard letter or A4 paper works fine.
Are there wiring harness diagrams in this ASV RC-85, RC-100 manual?
Yes. The manual includes full wiring diagrams covering the electrical circuits, harness routing, and connector pinouts for the ASV RC-85, RC-100.
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