4231-12, S.

operation & maintenance instruction

“J-1.6-16” RELAY VALVE, Pc.No. 560996

“J-1.6-16” RELAY VALVE PORTION, Pc.No. 561001
FILLING PIECE PORTION, Pc. No. 561000
MAY, 1988
Supersedes issue dated September, 1986

NOTE: The following description and

operation is based on this device and
its components being new or this
device and its components having
"J-1.6-16" Relay Valve Portion Mounting Bracket (2 req’d)
been repaired, tested, installed and
maintained in accordance with
instructions issued by this and any Mounting 1/2-14 NPT
other applicable Wabtec Corporation Gasket Relay Valve Exhaust
publications.

WARNING: At the time any part is

replaced in this device, the operation of 6
the complete device must pass a series
of tests prescribed in the latest issue of EX
the applicable Wabtec Test Specification.
At the time this device is applied to the 30
brake equipment arrangement, a 16

stationary vehicle test must be made to Filling Piece Portion

insure that this device functions properly
Pipe Bracket Portion
in the total brake equipment arrangement.
(Consult your local Wabtec Pipe Bracket Mounting Face
Representative for identity of the test
specification, with latest revision date, that (Pc. No. 560996-0001 shown)
covers this device.)

IMPORTANT: Only Wabtec supplied

parts are to be used in the repair of this Legend
device in order to obtain satisfactory
operation. Commercially available non- Port No. Designation Flange or Tap Size
O.E.M. parts are unacceptable.
6 Main Reservoir 1" Flange with 1-111/2 NPT
NOTE: The part numbers and their 16 Control 1
/2" Flange with 1/2-14 NPT
associated descriptions are the property
30 Brake Cylinder 1" Flange with 1-111/2 NPT
of Wabtec Corporation and may not be
replicated in any manner or form without EX. Ex. or Control 100% 1-111/2 NPT
the prior sole written consent of an Officer
of Wabtec Corporation.

© 2000 WABCO Locomotive Products. A Wabtec Company. All rights reserved

May, 1988 Page 1 of 10

4231-12, S.2

operation & maintenance instruction

in these equipment arrangements, the Portions are mounted

to a manifold or pipe bracket which is also a component of
Check Valve
the Operating Unit or Equipment Rack. Consult your Wabtec
Corporation Representative for information on specific ap-
6 plications.
Piston
Stem
30
1.1 PIPE BRACKET PORTION
EX.

16
The Pipe Bracket Portion is semi-permanently mounted on
the vehicle. This Portion provides the means for the mount-
B B
"X" ing of the Filling Piece Portion and the Relay Valve Portion.
All pipe connections are made to the Pipe Bracket Portion,
100% Diaphragm
and Piston Assembly
A A which allows the Relay Valve Portion and Filling Piece Por-
tion to be removed from the equipment arrangement without
disturbing the vehicle piping.
60% Diaphragm
and Piston Assembly 1.2 FILLING PIECE PORTION, PC.NO. 561000
C
Legend When the Filling Piece Portion is mounted on a Pipe Bracket
Port No. Description or manifold it functions as a mounting device for the “J-1.6-
6 Supply
16” Relay Valve Portion Pc.No. 561001. All air connections
16 Control 60%
between the Pipe Bracket or Manifold and the Relay Valve
30 Brake Cylinder Delivery
Portion are made through this Filling Piece Portion. There
EX. Control (100%)
are no moving parts in this Portion. Two mounting gaskets
16 & EX. Ex. or Control (160%)
are required when using the Filling Piece Portion with the
Relay Valve Portion, one mounting gasket is required be-
This diagrammatic representation is for functional analysis
only. It is not to be used as an actual physical representa- tween the Filling Piece Portion and the Pipe Bracket or
tion of portion or pipe bracket configurations. Manifold on which it is mounted, and the other is required
between the Relay Valve Portion and Filling Piece Portion.
Figure 2 - Diagrammatic View
NOTE: The mounting gaskets will be a part of the device of
1.0 DESCRIPTION which the Filling Piece Portion and Relay Valve Portion are
components. These gaskets MUST BE ordered as indi-
Designed for use in equipment arrangements where the air vidual items.
pressure does not exceed 150 psig the “J-1.6-16” Relay
Valve, Pc.No. 560996 consists of a “J-1.6-16” Relay Valve 1.3 “J-1.6-16” RELAY VALVE PORTION, PC.NO. 561001
Portion, Pc.No. 561001, a Filling Piece Portion, Pc.No.
561000, a Pipe Bracket Portion, Pc.No. 560998, a right This double diaphragm operated, self-lapping valve, when
hand Mounting Bracket, Pc.No. 558840, a left hand Mount- used in conjunction with the Filling Piece Portion, Pc.No.
ing Bracket, Pc.No. 558839, and the hardware items and 561000, functions to direct air into or exhaust air from the
gaskets necessary to assemble the parts together as a unit. brake cylinder delivery pipe during the operation of the air
brakes at 60% of the piloting control pressure directed into
This “J-1.6-16” Relay Valve is available with floor or sus- port 16 plus (in addition to) 100% of the piloting control
pension mounting. The type of mounting is indicated by a pressure directed into port EX of this Portion.
four digit suffix code included in the piece number. Pc.No.
560996-0001 designates a “J-1.6-16” Relay Valve for sus- 2.0 OPERATION (Figure 2)
pension mounting. Pc.No. 560996-0002 designates a “J-
1.6-16” Relay Valve for floor mounting. 2.1 When control air pressure builds up in passage EX,
the flow of air is directed to chamber “A” under the 100%
NOTE: In certain applications the “J-1.6-16” Relay Valve piston and diaphragm assembly of the Relay Valve Portion.
Portion, Pc.No. 561001, and the Filling Piece Portion, When the air pressure in chamber “A” overcomes the air
Pc.No. 561000, are used in conjunction with one another pressure in chamber “B” and the force of the piston return
as a component of a pneumatic Operating Unit or as a spring the diaphragm and piston assembly will move caus-
component of a Locomotive Equipment Rack. When used

Page 2 of 10 May, 1988


operation & maintenance instruction
ing the stem of the piston to close against the check valve
which blanks off passage 30 (brake cylinder pipe) from
passage/exhaust port X. The check valve is then lifted off
its supply seat by the piston stem permitting air under pres-
sure from passage 6 (air supply) to flow into passage 30.
Passage 30 is also connected internally in the valve portion
to chamber “B” above the 100% piston and diaphragm as-
sembly. The build-up of brake cylinder air pressure in cham-
ber “B” along with the force of the piston return spring will
oppose the movement of the 100% diaphragm and piston
assembly initiated by the control air pressure admitted into
passage EX. An equalization of forces in chamber “B”
above and chamber “A” below the diaphragm and piston
assembly positions the assembly to allow the check valve to
again seek a seal with its seat and remain in lap position.
The maintaining feature of the Relay Valve Portion will func-
tion if pressure fluctuates in the brake cylinder delivery pipe.
If the pressure in passage 30 as well as the pressure in
chamber “B” drops the piston stem will move to open the
check valve. Supply air will then again flow into passage 30
as well as chamber “B” until an equalization of forces across
the diaphragm is again reached. The diaphragm assembly
is then positioned to permit the valve to reassume a lap
position.
A decrease of air pressure in passage EX (brake cylinder
control) results in a corresponding decrease in pressure in
the relay valve diaphragm chamber “A” which causes a
movement of the diaphragm assembly and piston stem. The
piston stem is forced to unseat from the check valve, per-
mitting air at brake cylinder delivery pipe (passage 30) to
flow to atmosphere at the exhaust port (port “X”). A gradu-
ated release of brake cylinder air out of passage 30 can be
obtained if control pressure in passage EX is intermittently
depleted. When an equalization of forces exists across the
diaphragm, the valve will again assume a lap position. The
amount of air pressure available for braking is a function of
the pressure in chamber “A”.
2.2 An air pressure build-up in control passage 16 will
cause a similar operation except that the control pressure
is built up on a diaphragm and piston assembly, (chamber
“C”), that is only 60% of the effective area of the diaphragm
and piston assembly being opposed by brake cylinder air
pressure. Brake cylinder delivery is therefore only 60% of
the pressure in control port 16.
2.3 When air under pressure is directed to both control
ports (EX and 16) the force to open the check valve is the
resultant sum of the force of the control pressure on the
60% and 100% diaphragms. If main supply pressure in
passage 6 is high enough, the brake cylinder pressure will
May, 1988 Page 3 of 10
4231-12, S.2
build-up to 160% of the control pressure.
3.0 MAINTENANCE SCHEDULE
IMPORTANT: The “J-1.6-16” Relay Valve Portion and Fill-
ing Piece Portion should be removed from the equipment
arrangement, taken to the shop, be thoroughly disassem-
bled, the parts cleaned, inspected, lubricated as specified,
assembled using NEW rubber parts, supplied by the Wabtec
Corporation, and the Relay Valve Portion tested for correct
operation according to the following vehicle application
schedule or more frequently if service conditions so indi-
cate.
RECOMMENDED FREQUENCY -
TYPE OF APPLICATION AT LEAST ONCE EVERY
Freight Cars 144 Months
Locomotive 12 Months
Passenger (Interstate) 36 Months
Transit 24 Months
4.0 PARTS CATALOG & REPLACEMENT PART INFOR-
MATION
4.1 PARTS CATALOG
4.1.1 When ordering replacement parts for the “J-1.6-16”
Relay Valve, Pc.No. 560996 or any of its component por-
tions refer to the current issue of the Wabtec Corporation
Parts Catalog 3231-12, S.2.
4.1.2 When ordering replacement parts for the “J-1.6-16”
Relay Valve Portion, Pc.No. 561001, and Filling Piece Por-
tion, Pc.No. 561000 refer to the current issue of the Wabtec
Corporation Parts Catalog of which these Portions are com-
ponents. Consult your Wabtec Corporation Representative
for the correct Part Catalog number.
4.1.3 NOTE: The reference numbers used in this publi-
cation and the reference numbers used in the Parts
Catalog(s) may differ. Check the descriptive parts name to
be sure that the desired part is ordered.
4.2 REPLACEMENT PARTS
4.2.1 IMPORTANT: To obtain satisfactory operation
and reliability of the “J-1.6-16” Relay Valve and the “J-
1.6-16” Relay Valve Portion, ONLY replacement parts
supplied by the Wabtec Corporation are to be used in
the maintenance of these devices.
4231-12, S.2
operation & maintenance instruction
5.0 SAFETY PROCEDURES & WARNINGS
Regular owner-operating property and shop safety proce-
dures are to be followed.
The work area is to be clean.
WARNING
The following statements of warning apply all or in part wher-
ever the symbol appears in the maintenance procedures.
Failure to observe these precautions may result in serious
injury to those performing the work and/or bystanders.
Ÿ The use of an air jet, which must be less than 30
p.s.i.g., to blow parts clean or to blow them dry af-
ter being cleaned with a solvent will cause particles
of dirt and/or droplets of the cleaning solvent to be
airborne. Wire brushing may also cause particles
of dirt, rust, and scale to become airborne. These
conditions may cause skin and/or eye irritation.
Ÿ When using an air jet, do not direct it toward an-
other person. Improper use of air jet could result in
bodily injury.
Ÿ Personal eye protection must be worn when per-
forming any work on this device or its components
parts to avoid any possible injury to the eyes.
Ÿ The use of solvents as cleaning agents and the use
of lubricants can involve health and/or safety haz-
ards. The manufacturers of the solvents and lubri-
cants should be contacted for safety data (such as
OSHA Form OSHA-20 or its equivalent). The rec-
ommended precautions and procedures of the manu-
facturers should be followed.
Ÿ When performing any test or work on devices or
equipment while they are on the vehicle (on car test,
etc.) special precautions must be taken to insure
that vehicle movement will not occur which could
result in injury to personnel and/or damage to equip-
ment.
Ÿ Assembly may be under a spring load. Exercise cau-
tion during disassembly so that no parts “Fly Out”
and cause bodily injury.
Ÿ All air supply and/or electric current to this device
and/or to any components part must be cut-off be-
fore this device and/or any component part is re-
moved from the equipment arrangement.
Page 4 of 10
Ÿ “Bottled” up air under pressure (even though air
supply is cut-off) may cause gaskets and/or parti-
cles of dirt to become airborne and an increase in
sound level when this device and/or any component
part is removed from the equipment arrangement.
Ÿ Personal eye and ear protection must be worn and
care taken to avoid possible injury when performing
any work on this device and/or component part.
Ÿ An adequate support or lifting device must be avail-
able to support the Device and/or Valve Portion(s)
during removal, installation and maintenance pro-
cedures.
6.0 CLEANING SOLVENTS & LUBRICANTS
6.1 CLEANING SOLVENT
6.1.1 The solvent used to clean the metal parts MUST be
an aliphatic organic solution, such as mineral spirits or naph-
tha, that will dissolve oil or grease and that will permit all
parts to be thoroughly cleaned without abrasion.
6.2 LUBRICANTS
The following lubricants are required:
6.2.1 #2 Silicone Grease, Wabtec Corporation Specifica-
tion M-7680-2; such as E. F. Houghton Co. Cosmolube 615,
or Dow Corning Corp. Molykote 55M, used to lubricate o-
rings, o-ring grooves, and the bearing surfaces of the bush-
ings into which o-ring assemblies are installed.
6.2.2 A compound consisting of one part Graphite, Wabtec
Corporation Specification M-7695-2, such as Superior Flake
Graphite Co. Super Flake 597, Joseph Dixon Crucible Co.
Microfyne Graphite, or National Carbon Co. Number 38 or
39 Graphite, and two parts of SAE 20 Oil, by weight; used
to lubricate the threads of the choke plug of the body after
the plug has been cleaned and before it is installed in place.
7.0 MAINTENANCE PROCEDURES
IMPORTANT: During the procedures which follow, DO NOT
use hard or sharp metal tools to remove o-rings, seals, dia-
phragms, or gaskets. Care MUST BE taken so that metal
parts are not damaged.
May, 1988

operation & maintenance instruction
7.1 PORTION REMOVAL & REPLACEMENT
“ON-CAR”
7.1.1 SAFETY PROCEDURES
7.1.1.1 ALL owner-operating property safety procedures
and the safety procedures and warnings listed in Section
5.0 MUST BE adhered to.
7.1.1.2 Vehicle wheels MUST BE chocked to prevent vehi-
cle movement.
7.1.1.3 Suitable warning placards should be placed on
and about the vehicle indicating that work is being per-
formed.
7.1.2 REQUIRED MATERIALS
7.1.2.1 A NEW or repaired “J-1.6-16” Relay Valve Por-
tion, Pc.No. 561001 which has been tested following the
procedures of the current issue of one of the following
Wabtec Corporation Test Specifications T-2491-O for use
with the “4D” Test Rack; T-2516-O for use with the “AB” Test
Rack; and T-3136-O for use with the “4C” Test Rack.
7.1.2.2 A NEW mounting gasket, Pc.No. 554601, used
between the Relay Valve Portion and the Filling Piece Por-
tion. This gasket MUST BE ordered as an individual item.
7.1.2.3 A NEW or cleaned and inspected Filling Piece
Portion Pc.No. 561000.
7.1.2.4 A NEW mounting gasket to be used between the
Filling Piece Portion and the Pipe Bracket or Manifold on
which the Portion is mounted. Check the Parts Catalog of
which the “J-1.6-16” Relay Valve Portion and Filling Piece
Portion are components for the correct part number for the
mounting gasket.
This gasket MUST BE ordered as an individual item.
7.1.3 PORTION REMOVAL & INSTALLATION
“ON-CAR”
7.1.3.1 Remove the mounting hardware, (such as four 5/8"
hex nuts) which secures the “J-1.6-16” Relay Valve Por-
tion, Filling Piece Portion, and the Mounting Gaskets to the
Pipe Bracket or Manifold.
NOTE: If self-locking type nuts are used they are to be
SCRAPPED and NEW nuts used during the installation pro-
cedure.
May, 1988 Page 5 of 10
4231-12, S.2
7.1.3.2 Remove the Relay Valve Portion, Mounting Gas-
ket, Filling Piece Portion, and the Mounting Gasket between
the Filling Piece and Pipe Bracket.
SCRAP the two mounting gaskets.
7.1.3.3 Visually inspect the Pipe Bracket or Manifold to be
sure that the ports are clear and unrestricted. If necessary
the ports may be “blown out” with a low pressure jet of clean
dry air. Exercise care so that dirt is not blown into the
ports.
Inspect the mounting surface of the Pipe Bracket or Mani-
fold to be sure that it is clean and free of damage. If neces-
sary clean the surface by wiping with a clean lint free cloth
or blow it clean with a low pressure jet of clean, dry air.
If the Pipe Bracket or Manifold is damaged it is to be re-
placed. NO repairs are permitted to laminated manifolds.
Contact your Wabtec Corporation Representative for infor-
mation on laminated manifolds.
7.1.3.4 Remove all protective materials from the replace-
ment Filling Piece Portion and the “J-1.6-16” Relay Valve
Portion. Be sure that ALL tape is removed from exhaust
ports and the mounting surfaces.
7.1.3.5 Install a NEW filling piece mounting gasket in place
on the Pipe Bracket or Manifold so that the part number on
the gasket faces away from the Pipe Bracket or Manifold.
(Part number on the gasket should be next to the Filling
Piece Portion when it is installed.)
7.1.3.6 Install the Filling Piece Portion in place.
7.1.3.7 Install a NEW mounting gasket, Pc.No. 554061 on
the Filling Piece Portion so that the part number on the
gasket faces away from the Filling Piece Portion. (Part
number on the gasket should be next to the Relay Valve
Portion when it is installed.)
7.1.3.8 Install the Relay Valve Portion in place over the
mounting gasket and on the Filling Piece Portion and se-
cure the parts in place by installing the appropriate mount-
ing hardware.
IMPORTANT: If self-locking nuts were removed during dis-
assembly, NEW self-locking nuts MUST BE used during
installation.
7.1.3.9 Provide adequate protection for the removed Por-
tions to prevent dirt and/or moisture from entering them and
transport them to the shop area for maintenance.
4231-12, S.2
operation & maintenance instruction
1/2 - 14 NPT
Figure 3 - Filling Piece Portion
7.1.3.10 IMPORTANT: Whenever any component of the
“J-1.6-16” Relay Valve, a “J-1.6-16” Relay Valve Portion,
or Filling Piece Portion is removed from an equipment ar-
rangement for any reason and the component and/or Por-
tions are replaced with a NEW or overhauled and tested
component or Portion, a stationary vehicle test MUST BE
made to be sure that the component, Portion and the Relay
Valve function properly in the equipment arrangement.
7.1.3.11 Remove ALL warning placards and wheel chocks
before attempting to move the vehicle.
7.2 FILLING PIECE PORTION - MAINTENANCE PRO-
CEDURES - “IN-SHOP”
(Figure 3)
7.2.1 CLEANING & INSPECTING
7.2.1.1 Wash the Filling Piece Portion in a bath of the
cleaning solvent as described in Section 6.1.
7.2.1.2 After the Portion is cleaned it MUST BE completely
dried. Use a low pressure jet of clean dry air to blow it dry.
7.2.1.3 Inspect the passageways of the Portion to be sure
that they are clean and unrestricted. If necessary blow the
passageways out with a low pressure jet of clean, dry air.
Exercise care so tht dirt is not blown into the passageways.
7.2.1.4 Inspect the Portion. If it is damaged in any way it
is to be replaced with a NEW Wabtec Corporation Part.
7.3 “J-1.6-16” RELAY VALVE PORTION -
MAINTENANCE PROCEDURES - “IN-SHOP”
IMPORTANT: In the procedures which follow DO NOT use
hard or sharp tools to remove o-rings, seals, gaskets, or
diaphragms. Exercise care so that NO damage is done to
metal parts.
Page 6 of 10
7.3.1 DISASSEMBLY (Figure 4)
7.3.1.1 If not already removed, remove and SCRAP the
mounting gasket (29). This gasket IS NOT a part of the
Relay Valve Portion but is a part of the device of which the
Relay Valve Portion is a component.
7.3.1.2 Remove the three 3/8" x 1" cap screws (1) which
secure the top cover (2) to the body (28) and then remove
the top cover (2).
7.3.1.3 Remove the carrier spring (3) from the check
valve and carrier assembly with o-ring (4A to 5).
7.3.1.4 Remove the check valve and carrier assembly
with o-ring (4A to 5) from the body (28) as a unit.
7.3.1.5 Remove and SCRAP the 11/8" O.D. o-ring (5) from
the carrier (4C).
7.3.1.6 CAREFULLY remove and SCRAP the 1/8" x 15/16"
cylindrical spring pin (4A) which secures the check valve
(4B) to the check valve carrier (4C).
7.3.1.7 Remove and SCRAP the check valve (4B) from
the carrier (4C).
7.3.1.8 Remove and SCRAP the top cover gasket (6).
7.3.1.9 Remove the five 1/2" x 41/2" cap screws (7) which
secure the small diaphragm cover (9) and bottom filling piece
(17) to the body (28) and then remove the filling piece (17)
and cover (9) as a unit.
7.3.1.10 Remove the large diaphragm piston assembly
(18 to 25) from the body (28).
7.3.1.11 Remove and SCRAP the two 11/8" O.D. o-rings
(24) from the stem of the piston (25).
7.3.1.12 Use an open end wrench to hold the piston stem
(25), then remove the 5/8-11 self-locking hex nut (18) from
the piston stem (25). Remove the diaphragm follower (19),
diaphragm (20), and piston head (21) from the piston stem
(25).
SCRAP the self-locking nut (18) and the diaphragm (20).
7.3.1.13 Remove and SCRAP the 7/8" O.D. o-ring (23)
from the piston stem (25).
7.3.1.14 Remove the piston return spring (22) from the
body (28).
May, 1988
 4231-12, S.2

operation & maintenance instruction

2
20
3
5

4C
4A
19 4
4B

6 29
18
28

17

27
16 14

15

13
24

26
12 25

11

10 23 24
9

22

8 21

Figure 4 - Exploded View

May, 1988 Page 7 of 10

4231-12, S.2
operation & maintenance instruction
7.3.1.15 Remove the three 3/4" ring gaskets (26) from the
bottom mounting face of the body (28).
7.3.1.16 Remove the two 1/4" x 7/8" fillister head screws (8)
which secure the small diaphragm cover (9) to the bottom
filling piece (17).
7.3.1.17 Remove and SCRAP the two 3/4" O.D. ring gas-
kets (14) from the bottom of the bottom filling piece (17).
7.3.1.18 Remove the small diaphragm piston assembly
(10 to 13) as a unit from the bottom of the bottom filling
piece (17).
7.3.1.19 Using a suitable spanner wrench to hold the small
diaphragm piston (13) carefully remove the 5/8" self-locking
nut (10) from the small diaphragm piston (13).
SCRAP the self-locking nut.
7.3.1.20 Remove the small diaphragm follower (11) and
small diaphragm (12) from the piston (13). SCRAP the
diaphragm.
7.3.1.21 Remove the piston spacer spool (15) and 1/2"
O.D. o-ring (16) from the bottom filling piece (17). SCRAP
the o-ring.
7.3.2 CLEANING & INSPECTING
7.3.2.1 NON-REUSABLE PARTS
ALL gaskets, o-rings, diaphragms, the check valve and the
self-locking nuts are to be SCRAPPED and replaced with
NEW Wabtec Corporation parts.
7.3.2.2 BODY
7.3.2.2.1 Remove the 1/4" choke plug (27) from the body
(28). Place the choke plug in a bath of the cleaning solvent
described in Section 6.1 to soak while the body (28) is
being cleaned.
7.3.2.2.2 Wash the body (28) in the prescribed cleaning
solvent, Section 6.1. A clean, lint-free cloth which has been
saturated with the cleaning solvent may be used to assist in
the cleaning of the exterior and interior surfaces of the body.
7.3.2.2.3 After the body has been cleaned, blow it com-
pletely dry using a low pressure jet of clean, dry air.
7.3.2.2.4 Inspect the body.
Page 8 of 10
If it is cracked, cut, broken, damaged in any way, or if the
bushing shows signs of excessive wear, or if the body is in
such a condition that may result in the unsatisfactory op-
eration of the Relay Valve Portion, it is to be replaced.
Be sure that ALL ports are clean and unrestricted. Use a
low pressure jet of clean, dry air to blow the ports out if
necessary. Exercise care so that no dirt is blown into the
ports.
7.3.2.2.5 The size and cleanliness of the choke plug (27)
is important and the following procedure MUST BE followed
when servicing the choke plug.
Remove the choke plug (27) from the solvent bath in which
it was soaking. DO NOT use metal tools to clean the plug.
Blow the choke plug completely dry using a low pressure jet
of clean, dry air.
Inspect the choke plug to be sure that it is clean and that
the choke is unrestricted and that the shape and size, 7/64"
drill, of the orifice is not changed. If the choke plug is
damaged in any way, it MUST BE replaced with a NEW
choke plug.
Coat the threads of the cleaned choke plug with a com-
pound consisting of one part graphite, Wabtec Corporation
Specification M-7695-2, and two parts of SAE-20 oil by
weight, then install the choke plug (27) into the port of the
body (28) from which it was removed.
7.3.2.3 REMAINING PARTS
7.3.2.3.1 Wash all of the remaining parts in the cleaning
solvent described in Section 6.1.
7.3.2.3.2 Springs may be wire brushed to assist in the
removal of any dirt, rust and scale.
7.3.2.3.3 After the parts have been cleaned, they MUST
BE completely dried. Use a low pressure jet of clean, dry
air to blow the parts dry.
7.3.2.3.4 Inspect the springs.
Replace any spring that is rusted, pitted, distorted, dam-
aged in any way, or if it has taken a permanent set.
Refer to the Parts Catalog listed in Section 4.0 for spring
information and identification.
7.3.2.3.5 Inspect the bottom filling piece (17).
May, 1988

operation & maintenance instruction
Replace the bottom filling piece if it is damaged or shows
signs of excessive wear. Pay particular attention to bush-
ings. Check the wasp excluder to be sure that it is clean
and not damaged. A damaged wasp excluder may be re-
moved from the body of the bottom filling piece by inserting
the blade of a small screw driver between the tangs of the
excluder and twisting it out of the body. A NEW wasp ex-
cluder, Pc.No. 555250, may then be pressed into place.
7.3.2.3.6 Inspect the remaining parts.
Replace any part that is cracked, cut, broken, excessively
worn, damaged in any way, or that is in such a condition
that may result in the unsatisfactory operation of the Relay
Valve Portion.
7.3.3 ASSEMBLY
7.3.3.1 Install the piston return spring (22) into the body
(28).
7.3.3.2 Install three NEW /4" ring gaskets (26) into their
3 ring (16) with #2 Silicone Grease, Wabtec Corporation
grooves in the filling piece mounting face of the body (28).
7.3.3.3 Coat the surfaces of a NEW 7/8" O.D. o-ring (23)
and two NEW 11/8" O.D. o-rings (24) with #2 Silicone Grease,
Wabtec Corporation Specification M-7680-2. Also fill the
o-ring grooves of the piston stem (25) and lightly lubricate
the bearing surfaces of the piston stem bushing of the body
(28) with the lubricant.
7.3.3.4 Install a NEW lubricated 7/8" O.D. o-ring (23) in its
groove on the piston stem (25). Remove any excess lubri-
cant by wiping with a clean, lint-free cloth.
7.3.3.5 Install the piston head (21) on the piston stem (25)
with the diaphragm bead groove of the head facing the
threaded end of the stem.
7.3.3.6 Install a NEW large diaphragm (20) on the piston
head (21) so that the small bead of the diaphragm fits into
the bead groove of the piston head (21).
7.3.3.7 Install the diaphragm follower (19) on the piston
stem (25).
7.3.3.8 Install a NEW 3/4" self-locking hex nut (18) on the
piston stem (23) to secure the diaphragm follower in posi-
tion. Torque the nut (16) to 60 to 65 foot pounds.
7.3.3.9 Install the two NEW lubricated 1 /8" O.D. o-rings
1 the groove on the check valve carrier (4C).
(24) into their grooves on the piston stem (25).
May, 1988 Page 9 of 10
4231-12, S.2
Remove any excess lubricant by wiping with a clean, lint-
free cloth.
7.3.3.10 Install the large diaphragm piston assembly into
the body (28) with the large bead of the diaphragm facing
the filling piece mounting face of the body.
7.3.3.11 Observe the position of the small diaphragm in
the exploded view.
Using a suitable spanner wrench to hold the small diaphragm
piston (13), install a NEW diaphragm (12) and the diaphragm
follower onto the piston (13) in the same position as illus-
trated. Use a NEW 5/8" self-locking hex nut (10) to secure
the assembly together.
7.3.3.12 Insert two NEW 3/4" ring gaskets (14) in their
respective grooves in the bottom face plate of the bottom
filling piece (17).
7.3.3.13 Lightly coat the surfaces of a NEW 1/2" O.D. o-
Specification M-7680-2. Install the NEW lubricated 1/2" O.D.
o-ring (16) and piston spacer spool (15) in the bottom filling
piece (17).
7.3.3.14 Place the small lower diaphragm piston assem-
bly (10 to 13) in the bottom filling piece (17) with the dia-
phragm bead correctly positioned in the bead groove.
7.3.3.15 Place the cover (9) on the bottom filling piece
and secure the cover (9) with the two 1/4" fillister head screws
(8).
7.3.3.16 Place this assembly onto the face mounting plate
of the body (28) making certain the large upper diaphragm
stays in place, then secure the assembly in place with the
five 1/2" x 41/2" cap screws (7).
7.3.3.17 Place a NEW check valve (4B) on the check
valve carrier (4C) and secure it in place using a NEW 1/8" x
15
/16" cylindrical spring pin (4A).
7.3.3.18 Coat the surfaces of a NEW 1-1/8" O.D. o-ring
(5) and fill the o-ring groove of the check valve carrier (4C)
with #2 Silicone Grease, Wabtec Corporation Specification
M-7680-2. Also lightly lubricate the carrier bushing in the
top cover (2) with the lubricant.
7.3.3.19 Install a NEW lubricated 11/8" O.D. o-ring (5) into
7.3.3.20 Install the check valve and carrier assembly (4A
4231-12, S.2

operation & maintenance instruction

to 5) into the body (28) check valve end first.
7.3.3.21 Place a NEW top cover gasket (6) in position on
the top cover mounting face of the body (28).
7.3.3.22 Install the carrier spring (3) into the check valve -
carrier assembly (4A to 5) previously installed in the body
(28).
7.4.2 IMPORTANT: Whenever the “J-1.6-16” Relay Valve
Portion is removed from an equipment arrangement for any
reason and it is re-installed or replaced with a NEW or
repaired Portion that has been tested according to the pro-
cedures of one of the test specifications listed in Section
7.4.1, a stationary vehicle test MUST BE performed to be
sure that the Portion functions properly in the equipment
arrangement.

7.3.3.23 Install the top cover (2) on the body (28) and
secure it in place using three 3/8" x 1" cap screws (1). Equally
tighten the screws.
7.4 TESTING & ADDITIONAL INFORMATION
7.4.1 IMPORTANT: After the “J-1.6-16” Relay Valve Por-
tion, Pc.No. 561001, has been assembled, BUT BEFORE it
is returned to service, it MUST pass a series of tests follow-
ing the procedure of the current issue of one of the follow-
ing Wabtec Corporation Test Specifications:
T-2491-O, used with the “4D” Test Rack
T-2516-O, used with the “AB” Test Rack
T-3136-O, used with the “4C” Test Rack
7.4.3 IMPORTANT: Whenever the “J-1.6-16” Relay Valve,
or ANY of its component Portions are removed from an
equipment arrangement for any reason and the Relay Valve
or component Portions are re-installed or replaced with NEW
or repaired and tested Portions (see Section 7.4.1) NEW
mounting gaskets MUST BE used.
IMPORTANT: Mounting gaskets are required between
the Relay Valve Portion and Filling Piece Portion, and
between the Filling Piece Portion and the Pipe Bracket
or Manifold. Check the appropriate Wabtec Corpora-
tion Parts Catalog as listed in Section 4.0 for gasket
part number and location.
7.4.4 Consult your Wabtec Corporation Representative if
additional information is required.

WABCO Locomotive Products

1001 Air Brake Avenue • Wilmerding, PA 15148
(412) 825-1000 • Fax (412) 825-1019
www.wabtec.com

Page 10 of 10 May, 1988