1996–2002 Toro Reelmaster 6500-D / 6700-D Service Manual – Peugeot Engine (P/N 95871SL)

This Toro factory service manual, P/N 95871SL Rev. D (2002 edition), covers the 1996–2002 Reelmaster 6500-D and 6700-D equipped with the Peugeot XUD9AI engine. It documents 2WD and 4WD systems, with separate coverage for different cutting unit models and serial ranges.

Supplied as a 366-page English PDF with searchable text across the main service chapters and embedded bookmarks. Some reference sheets and diagram labels are not searchable.

• Engine repair: Engine removal, cylinder-head and bottom-end overhaul, valve adjustment, timing-belt replacement, injection-pump timing, and injector testing.

• Hydraulics and steering: Traction, reel-drive, steering, and lift circuit diagnosis, pressure and efficiency tests, plus pump, motor, valve, and cylinder repair.

• Electrical diagnosis: Diagnostic ACE checks, fault-memory retrieval, starter and charging tests, safety-interlock troubleshooting, wiring schematics, and connector identification.

• Axles and brakes: Planetary wheel-drive disassembly, wet multi-disc brake inspection, rear wheel-bearing adjustment, and 4WD rear-axle setup.

• Cutting units: Bedknife and reel adjustment, height-of-cut and attitude setup, backlapping, grinding, and reel and roller bearing replacement.

Written for service technicians performing troubleshooting, component overhauls, routine maintenance, and repair. The procedures use workshop measuring equipment and specified special tools.

Peugeot Engine and Fuel System

Engine repair covers removal, disassembly, inspection, and reassembly of the cylinder head, valve gear, crankshaft, and piston assemblies. Reference data includes connecting-rod torque specifications, valve clearances, bearing tolerances, and head-gasket selection based on piston protrusion.

Timing-belt replacement and tensioning accompany injection-pump timing, compression testing, injector checks, and thermostat inspection. The maintenance schedule includes timing-belt inspection intervals, while the tool section identifies engine overhaul set TOR4033 and tune-up set TOR4035.

Over-tightening the timing locking bolts can damage the injection-pump housing and disturb timing. Roto Diesel DPC pump testing and timing are covered, but fuel-delivery calibration is referred to a professional diesel service shop.

Hydraulic Repair and Circuit Testing

Circuit descriptions cover the hydrostatic traction drive, steering, reel drive, and cutting-unit lift. Hydraulic schematics distinguish Reelmaster 6500-D 2WD and 4WD layouts and the 6700-D lift circuit for cutting units 6 and 7.

Component procedures cover piston and gear pumps, wheel and reel motors, valve blocks, steering valves, and cylinders. Pressure, pump-efficiency, and case-drain tests support diagnosis; reference tables provide test specifications and fluid capacities.

Follow the factory safety guidelines for pressurized hydraulic circuits and rotating cutting units.

Electrical Controls and Fault Finding

Diagnostic ACE input/output checks, fault-memory retrieval, and DataLog procedures help distinguish electrical faults from apparent hydraulic failures before component removal. TurfDefender leak-detector testing is also covered.

Electrical drawings separate the 6500-D's S/N 50001–59999 circuitry from later Controller 1 layouts, including the S/N 90001 change. Controller 2 coverage addresses the 6700-D's outer cutting units.

The Main Wire Harness Connector Diagram, leak-detector electrical schematic, and wire lists support circuit tracing. Component tests cover starter, charging, glow-plug, and safety-interlock circuits; the ECU section warns that direct volt-ohmmeter testing of the controller can damage it.

Axles, Planetaries, and Brakes

Axle and brake repair extends to planetary wheel-drive disassembly, wet multi-disc brake inspection, and rear wheel-bearing adjustment. The 4WD rear-axle procedures include differential inspection, pinion-bearing preload, and backlash adjustment with selective shims.

Cutting Unit Repair and Setup

Coverage separates Models 03853, 03854, and 03856 from Models 03857, 03858, and 03859. Chapters 8 and 8.1 divide the latter group at serial numbers 80302, 81419, and 81993, respectively.

Repair procedures include bedbar removal, reel and roller bearing replacement, backlapping, and grinding. Exploded roller assembly views accompany torque data, grinding specifications, and wear limits.

Later-unit setup distinguishes new cutting units from used reels and bedknives, with attitude charts that account for wear. Gauge bar 98-1852 and angle indicator 99-3503 are specified, and blade-count configuration for ClipAce is documented.

File Contents and Readability

The 366-page total comprises four opening pages, 356 pages in Chapters 1–8.1, and the six-page wire-harness chapter. Within those chapters are four maintenance/service-record sheets, two inserted hydraulic pages, eight inserted electrical pages, and the 34-page Chapter 8.1; all are already included in the total.

Embedded bookmarks navigate chapters and individual procedures. Main text and wire lists are searchable; some charts, forms, and Controller 2 diagram labels are not. Dense schematic labels require zoom to read small wire codes, pin numbers, and component identifiers comfortably.

The separate operator's manuals and parts catalogs referenced by the service manual are not included.