Toro Reelmaster 6500-D / 6700-D Service Manual, 1996–2002 – 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 diesel engine. It documents 2WD and 4WD systems and separates cutting-unit procedures by model and serial range.

Search, Bookmarks, and Wiring Diagram Detail

Text search and diagram labels: The main service chapters and wire lists are searchable, and embedded bookmarks lead to chapters and individual procedures. Some reference sheets, forms, and Controller 2 diagram labels fall outside text search. Zoom in to read small wire codes and pin numbers, especially on the lighter Controller 2 drawings.

The download is one 366-page printable English PDF. The total includes four opening pages, 356 pages in Chapters 1–8.1, and the six-page wire-harness chapter. The chapter counts already include four maintenance and service record sheets, two inserted hydraulic pages, eight inserted electrical pages, and the 34-page cutting-unit Chapter 8.1. Blank pages are included in the total.

Diesel Overhaul, Hydraulic Tests, and Reel Service

These are selected shop procedures from the manual. It also covers optional lighting wiring and cutting-unit shield and fin adjustment.

• Engine repair: Engine removal, cylinder-head and bottom-end overhaul, valve adjustment, timing-belt replacement, injection-pump timing, and compression and injector testing.
• Hydraulics and steering: Traction, reel-drive, steering, and lift circuit diagnosis, with pressure and efficiency tests and repair procedures for pumps, motors, valves, and cylinders.
• 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, 2WD rear wheel-bearing adjustment, and 4WD rear-axle setup.
• Cutting units: Bedknife-to-reel adjustment, height-of-cut and attitude setup, backlapping, grinding, and reel and roller bearing replacement.

Toro wrote this manual for service technicians who troubleshoot and repair major systems. The procedures use workshop measuring equipment and specified special tools. Toro directs readers to the separate traction-unit and cutting-unit operator’s manuals for operating, maintenance, and adjustment instructions. Those manuals and the referenced parts catalogs are not included.

Peugeot Engine and Fuel System

Engine repair covers disassembly, inspection, and reassembly of the cylinder head, valve gear, crankshaft, and piston assemblies. The manual explains how piston protrusion determines head-gasket thickness and how bearing dimensions guide shell selection. It also covers thermostat testing, includes timing-belt inspection in the maintenance schedule, and identifies overhaul tool set TOR4033 and tune-up set TOR4035.

Overtightening the timing-gear locking bolts can damage the injection-pump housing and cause timing problems. The manual covers on-engine pump timing and fuel-delivery testing. It directs pump calibration to a diesel service shop.

Hydraulic Circuit Testing and Repair

The schematics distinguish the 6500-D 2WD and 4WD traction layouts and show the 6700-D lift circuit for the two outer cutting units. Component procedures cover the servo-controlled piston pump, gear pumps, wheel and reel motors, valve blocks, steering valves, and cylinders. The reel-motor efficiency test uses case-drain flow to help isolate a worn motor when a reel runs slow.

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

Electrical Controls and Fault Finding

Diagnostic ACE input and output checks, fault-memory retrieval, and the Data Log system help distinguish an electrical fault from a hydraulic problem before a component is removed. The manual also covers the TurfDefender leak detector. It warns that direct testing with a volt-ohm meter can damage the ECU.

The older 6500-D wiring, later Controller 1 layouts, and the 6700-D Controller 2 circuits have separate drawings. The main harness connector diagram and wire lists help trace a fault from a controller pin to the switch, sensor, or solenoid on that circuit.

Planetary Drives, Brakes, and 4WD Rear Axle

The planetary wheel-drive and brake sections cover disassembly and inspection of the rotating and stationary brake discs. The 4WD rear-axle procedures cover differential inspection, pinion-bearing preload, and shim selection for backlash.

Reel and Bedknife Setup

Separate cutting-unit chapters guide readers to the procedures for their model and serial range. The manual covers bedbar removal, reel and roller bearing replacement, and grinding specifications. The later-unit attitude charts distinguish new units from used reels and bedknives. The manual specifies gauge bar 98-1852 and angle indicator 99-3503 and shows how to configure blade count for ClipAce.

Sample Engine and Rear-Axle Specifications

For the Peugeot XUD9AI, the engine overhaul section lists a connecting-rod cap nut torque of 50 N·m (37 ft-lb). The valve adjustment table gives running clearances of 0.15 mm intake and 0.30 mm exhaust, with a tolerance of ±0.04 mm.

The 4WD rear-axle service section specifies 0.25–0.35 mm (0.010–0.014 in.) of backlash for the shimmed gear adjustment.