Case IH / International Harvester 856 XL Tractor Repair Manual Set, 1987 (P/N 1 091 624 R2)

The engine publications work together for mechanical, fuel-system, and charging/starting service. The tractor sections add the drivetrain, MFWD, hydraulic, and cab procedures for their listed models and configurations.

Coverage limits: Agriomatic power-shift transmission service requires separate manual P/N 1 090 942 R2, which is not included. The XL Control Centre section does include Powershift linkage adjustment.

The Sens-O-Draulic operating text refers to foldout flow diagrams that are not reproduced in this PDF. Electrical coverage centers on Bosch engine charging/starting equipment and shared-family MFWD controls rather than a complete tractor wiring book.

PDF Search, Section Bookmarks and Page Count

Text search and diagram detail: PDF search does not cover the workshop text. Embedded bookmarks open all 15 sections; use zoom for small terminal labels in alternator and starter circuits. PDF p. 650, in the MFWD filter/solenoid section, is upside down.

One printable, 808-page PDF contains the publications above, including 16 added cover pages and four blank divider pages.

Engine Overhaul, Drivetrain Repair and Hydraulic Diagnosis

These selected workshop topics highlight part of the coverage. Additional material includes engine run-in schedules and cab floor-mat and seal drawings.

• Engine overhaul: Cylinder-head and valve-seat repair, camshaft-bushing line boring, crankshaft inspection, piston/sleeve service, balancer timing, and lubrication and cooling-system overhaul.

• Fuel and turbochargers: Bosch VA...CR and VE...F pump overhaul, flow-bench calibration, nozzle service, and AiResearch or KKK (Schwitzer) turbocharger testing and repair.

• Transmission and PTO: Step-by-step removal, central and side-shift mechanisms, speed/range gearboxes, speed reducers, differential and lock, PTO, and pressure-fed lubrication.

• MFWD assemblies: Steering-cylinder resealing, axle removal, drive-shaft alignment, transfer-clutch rebuilds, differential/pinion setup, final drives, and accumulator, filter, and solenoid service.

• Sens-O-Draulic: Pilot-pressure and control-valve diagnosis, hydraulic fault charts, lift-cylinder and rockshaft repair, and draft/position linkage adjustment.

• XL Control Centre: Cab tilting and removal, glass replacement, tractor splitting, shift/control-linkage adjustment, and B/C-family hydraulic circuit drawings.

• Electrical diagnosis: DC generators and regulators, G1/K1 alternators, JD/JF starters, MFWD relay and switch tests, and brake-light switch adjustment.

Suited to mechanics experienced in diesel and drivetrain repair, with access to precision measuring tools, fuel-pump test equipment, and suitable lifting and support equipment.

Engine Inspection and Build Differences

The engine books cover the wider Neuss diesel family. Match the engine and application before selecting internal parts or pump data; the 856XL fuel sheets identify the DT-239 with Bosch VE4/11F 1150 R140.

Internal repair coverage includes crankcase counterbore resurfacing, crankshaft regrinding limits, sleeve protrusion, piston-to-sleeve fit, and connecting-rod service. The maintenance-free head gasket has different tightening and retorque requirements.

DT-402 notes distinguish the controlled-length No. 1 connecting rod to prevent interference with the oil pump. Lubrication views trace connecting-rod oil passages for piston-pin lubrication and piston cooling.

Handling and diagnosis: The sleeve-handling notes warn that knocks or drops can distort sleeves. Compression, boost, oil-pressure, air-restriction, and crankcase blow-by tests support engine assessment; the blow-by guidance calls for interpreting pressure alongside oil-consumption trends.

Pump Calibration and Workshop Tools

Application-specific flow-bench sheets identify pump and governor builds and give charging-pressure, timing-advance, fuel-delivery, idle, shutoff, and aneroid checks. These distinctions help select the correct test sheet instead of applying one pump setting across the engine family.

Flange- and crab-mounted nozzle holders receive separate treatment. Bosch KDEP tool lists and dimensioned drawings for locally made fixtures accompany the procedures, alongside tools such as FES 108, timing extension 1329 159C1, and pinion-shaft oil-seal installer CAS 1882.

Transmission and MFWD Setup

The transmission section notes 856XL differences in case and clutch-housing strength, bearings, and selected gearing. PTO coverage distinguishes independent and ground-speed arrangements; the range and reducer sections distinguish synchronized and non-synchronized layouts.

APL axle procedures extend to pinion depth, bearing preload, backlash, tooth contact, and final-drive setup. The steering-cylinder stripdown identifies the inner piston O-ring as a seal destroyed during rod removal.

The accumulator section applies specifically to hydraulic-brake tractors in 40 km/h versions. Its stored spring force, together with heavy axle and cab work, requires the specified holding/compression tools, pressure isolation, and proper lifting and support equipment.

Hydraulic Controls, Cab Linkages and Reference Drawings

Sens-O-Draulic covers the pilot-pressure unit, input, main, remote, and draft-sensing valves, plus the lift cylinder, rockshaft, and lower-link sensing device. Its pressure-checking layout and fault charts connect symptoms with the relevant tests.

XL Control Centre organizes access by cab position. Adjustment drawings cover range/speed, PTO, differential lock, Powershift, draft/position, lowering control, limit stop, valve plate, and auxiliary valves.

Reference illustrations include the DT-engine longitudinal section and timing-gear alignment, transistorized alternator circuit, speed/range transmission cutaways, and APL bevel-pinion setting diagram. Numbered photos, exploded views, torque tables, wear limits, and test sheets support inspection and reassembly. Parts selection and operating/lubrication guidance refer to the relevant parts catalog and operator's manual.

A Preview of MFWD Transfer-Clutch Clearances

The transfer-gearbox section gives clutch-disc clearance of 0.80–1.80 mm for its clutch-pack inspection and spacer-plate selection procedure.

Clutch-assembly end play is specified at 0.3–0.5 mm, with thrust-washer selection covered separately. These are assembly setup limits for the MFWD transfer gearbox, alongside its bearing-preload and operational checks.