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

• An 808-page PDF combining 15 scanned J I Case/Tenneco workshop sections for the Case IH/International 856 XL. Original section title pages were printed in November 1987; 2009 is the scan/compilation date, not a later OEM edition.
• Neuss-built diesel engine repair covers D-155, D-179, D-206, D-239, D-246, D-268, D-310, D-358, DT-239, DT-358, and DT402 engines, with diagnosis, internal inspection, machining data, timing, valve adjustment, and operating tests.
• Bosch fuel-system and turbocharger service addresses VA...CR and VE...F rotary pumps, aneroid and automatic timing devices, flange- and crab-mounted nozzle holders, pump overhaul, flow-bench calibration, and AiResearch or KKK (Schwitzer) turbochargers.
• 856 XL transmission and PTO repair includes transmission removal, central shifter service, synchronized speed/range gearboxes, synchronized and non-synchronized speed reducers, differential and lock, PTO, pressure-fed lubrication, setup, and operational checks.
• APL 335/345 MFWD axle work covers steering-cylinder resealing, axle removal, drive-shaft center-bearing alignment, transfer-gearbox clutch service, the 40 km/h hydraulic-brake accumulator, filter/shift solenoid, differential and pinion setup, and final drives.
• Sens-O-Draulic and XL Control Centre procedures include pilot-pressure and control-valve diagnosis, draft/position/lift linkage adjustment, cab tilting and removal, tractor-splitting procedures, hydraulic circuits, and fault charts.
• Electrical and factory-reference coverage includes DC generators and regulators, alternators, JD/JF starters, MFWD relay and switch testing, brake-light switch adjustment, torque tables, inspection limits, test values, and special-tool drawings.

Engine, Fuel, and Test Coverage

The engine books are factory family sections, not a D-358-only supplement. Their shared scope explains why smaller and larger Neuss engines appear in an 856 XL set. Match the engine identification before selecting pump specifications or internal parts. The basic-engine section goes well beyond routine maintenance: cylinder-head and valve-seat work, camshaft-bushing line boring, crankcase counterbore resurfacing, crankshaft inspection and regrinding limits, sleeve protrusion, piston-to-sleeve fit, connecting-rod service, balancer timing, lubrication and cooling-system overhaul, plus compression, boost, oil-pressure, air-restriction, and crankcase blow-by tests. It also identifies the maintenance-free head gasket and its different tightening and retorque requirements.

The fuel book uses application-specific flow-bench sheets rather than one generic pump setting. They identify pump and governor builds and cover charging pressure, timing advance, fuel delivery, idle, shutoff, and aneroid testing. Bosch KDEP tool lists and locally made fixtures are shown; other sections identify factory tools such as FES 108, timing extension 1329 159C1, and seal installer CAS 1862. The engine publications are cross-identified as Basic Engine No. 1 091 624 R2, Fuel System and Turbocharger No. 1 091 627 R2, and Electrical Equipment No. 1 091 630 R2.

Drivetrain, Hydraulic, and Cab Scope

The transmission section covers 743XL, 745XL, 844XL, and 856XL layouts and notes 856XL differences in the case, clutch housing, and selected gearing. MFWD coverage is organized around APL 335 and APL 345 front axles and shared B/C-family procedures. It provides working removal, rebuild, and setup procedures—center-bearing alignment, transfer clutch-pack clearance, pinion depth, bearing preload, backlash, and tooth-contact checks—not just exploded parts views.

Sens-O-Draulic runs from system description and flow charts through testing, fault finding, valve repair, and linkage adjustment. Covered units include the pilot-pressure unit, input, main, remote, and draft-sensing valves, lift cylinder, rockshaft, and lower-link sensing device. XL Control Centre material covers service with the cab in position, cab tilt and removal, glass replacement, tractor splitting, and adjustment of range, speed, PTO, differential-lock, Powershift, draft/position, lowering-control, limit-stop, and auxiliary-valve linkages.

Illustrations, Scope, and Workshop Cautions

Representative visuals include the DT-engine longitudinal section, timing-gear alignment diagram, transistorized alternator circuit, speed/range transmission cutaway, APL bevel-pinion setting diagram, and Sens-O-Draulic layout with fault charts. Hundreds of numbered illustrations, step photos, exploded views, sectional drawings, and test sheets support diagnosis, disassembly, inspection, repair, and reassembly.

The manual flags assembly traps that matter. On DT402 engines, the No. 1 connecting rod and its oil passage must remain correctly oriented; a blocked passage can deprive the piston of cooling oil and damage the piston or sleeve. During APL steering-cylinder assembly, driving the piston off-square can destroy the inner O-ring.

Coverage is organized by section, engine code, axle type, tractor family, and configuration rather than one blanket tractor serial-number range; the engine pages retain individual serial breaks and old/new component distinctions where applicable. This set does not replace a parts catalog or operator's manual, and its electrical content centers on engine charging/starting and MFWD controls rather than a complete tractor wiring book. The 40 km/h accumulator section warns of strong stored spring pressure, so axle, cab, transmission, hydraulic, and accumulator work requires proper lifting and support equipment, pressure isolation, and the holding or compression tools specified in the manual.