BUFFALO CREEK #43
ALCO HH660
Updates 2015
by Scott H.
January - June 2015
| You all know how brutal a winter we had so the work in Hamburg, New York, got off to a very slow start. Last year we were able to finish the work on the interior of the cab of Buffalo Creek #43 using a propane heater. By fall we moved onto working on the prime mover which is outside. |
 "(c)2015 smph50 - Electrical Cabinet door with Pyrene Fire Extinguisher mounted. (10K) - CLICK to Enlarge (125K)") |
One decent day in January we were able to mount a vintage "Pyrene" Heavy Vehicle fire extinguisher on the electrical cabinet wall. Although it is empty, it adds to the authentic equipment found in the cab of many early diesels. |  "(c)2015 smph50 - Heavy Vehicle Pyrene Fire Extinguisher. (10K) - CLICK to Enlarge (125K)") |
 "(c)2015 smph50 - GE Model GT551D1 DC Generator. (10K) - CLICK to Enlarge (125K)") |
By April the weather had broke and were able to get back to cleaning and resetting the 36 main generator carbon brushes. There are four sets of four and one set of three on each side of the generator. Each brush had to be removed, the holder filed clean and the brush replaced with the correct tension. |  "(c)2015 smph50 - One of 10 Carbon brush holders. (10K) - CLICK to Enlarge (125K)") |
 "(c)2015 Robert Martin - Crawling under the generator to get to the bottom brush set. (10K) - CLICK to Enlarge (125K)") |
The two four sets at the bottom were a real pain to work on upside down. After the main generator was finished the smaller Exciter/Aux Generator was a piece of cake! In early May we filled the cooling system for the first time since we repaired one of the 24 radiator segments last year. It took almost an hour to put 285 gallons of water into the system and we were all relieved to find we had no leaks! |  "(c)2015 smph50 - Water guage in the cab showing a full system. (10K) - CLICK to Enlarge (125K)") |
| On our next outing we borrowed an electric oil pump from the Buffalo Southern Railroad to "pre-lube" the engine. The crankshaft had not been turned since 2009 so it needed to be done again. |
 "(c)2015 smph50 - Bob M. places the oil pump suction tube into the bottom of the crankcase. (10K) - CLICK to Enlarge (125K)") |
Bob Martin put the sucker tube into the bottom of the crankcase and then the oil was forced by the electric pump into the engine through the timing chain cover. Rick Burns and I removed each of the compression plugs at the top of the cylinders. When nice clean oil began to drip freely from the bottom of the crankshaft we were ready to "Bar it over." |  "(c)2015 Robert Martin - Rick B. and myself remove the six compression plugs at the top of each cylinder. (10K) - CLICK to Enlarge (125K)") |
| The flywheel cover was removed to access to the holes in the flywheel into which a large round bar is inserted and you lean into it. It took two of us to get the first 1/10 of a turn going but after that everything moved freely! |
 "(c)2015 smph50 - Close up of the twin primary coarse fuel filters. (10K) - CLICK to Enlarge (125K)") |
With the prime mover lubricated, we turned our attention to the fuel system. The M&S 538 prime mover is equiped with a coarse primary and a fine secondary filtering system. Jim L. pulled the two pre-filter screens and cleaned the interior of the housings and Rick B. cleaned the secondary filter container. |  "(c)2015 smph50 - Rick B. cleans the secondary filter container and installed the new filter. (10K) - CLICK to Enlarge (125K)") |
| Jim was able to buy a new filter right off the shelf at NAPA. The fuel tank was a concern due to the condition of the top of the tank which is also the sub-floor of the locomotive. Last year we scaled, primed and greased the top of the tank to prevent any further decay. We drained almost a quart of water from the fuel sump before clean diesel fuel came out. |
 "(c)2015 smph50 - 72 volt electric fuel pump motor and pressure relief valve. (10K) - CLICK to Enlarge (125K)") |
Bob M. took the 72volt DC fuel pump motor to Dell Electric to have it tested. In the meantime, we used a cordless drill to turn the fuel pump and prime the line up to the secondary filter |  "(c)2015 smph50 - Using a cordless drill we were able to pump clean fuel up to the secondary filter and fuel injector rail. (10K) - CLICK to Enlarge (125K)") |
July 2015
 "(c)2015 smph50 - Three 12 volt batteries supply 36 volts to electric fuel pump motor. The guys at Dell Electric cut the commutator and installed new brushes and bearings. It runs like new! Thank You! (10K) - CLICK to Enlarge (125K)") |
On July 1st, we reinstalled the rebuilt fuel pump motor. A big Thank You! goes out to the great guys at Dell Electric, 202 Lake St Hamburg, NY 14075, who donated their services. Using three 12 volt batteries in series, we anticipated a higher fuel pressure but still only read 11 psi at the guage. We quickly found that the pressure relief valve above the pump was stuck open which only allowed 1/4 of the fuel to be delivered to the engine and the rest back into the tank. |  "(c)2015 smph50 - 11 pounds on Fuel Oil Pressure gauge . (10K) - CLICK to Enlarge (125K)") |
 "(c)2015 smph50 - Fuel pump pressure relief valve. (10K) - CLICK to Enlarge (125K)") |
Rebuilding the pressure relief valve was pretty easy. Once the valve was disassembled, all of the parts were cleaned, the cylinder honed smooth, the piston polished and the seat cleaned up with valve grinding compound. After assembly using air pressure, we set the spring tension on the valve to hold the piston closed until 35 psi. |
 "(c)2015 smph50 - Fuel pump pressure guage now shows 57psi. (10K) - CLICK to Enlarge (125K)") |
July 9th, we reinstalled the pressure relief valve and put 36 volts into the fuel pump motor. The fuel oil pressure guage held at a steady 57psi. This reading will drop when the prime mover is started. Jim L. installed a missing fuel injector pump cover plate which we fabricated. |  "(c)2015 smph50 - Injector fuel pump cover plate installed. (10K) - CLICK to Enlarge (125K)") |
 "(c)2015 smph50 - Bob M. primes another interior engine compartment door. (10K) - CLICK to Enlarge (125K)") |
While Rick, Jim and myself worked on the fuel system, Bob M. continued to clean, prime and paint the interior of the 14 engine compartment doors. For the 4th of July, Joe K. pulled out an old photo of Buffalo Creek ALCO S2 #46 (built 2/1947) at the Ganson Street engine house in Bi-Centennial paint. The locomotive is now on the Livonia, Avon and Lakeville Railroad as LA&L#14! |  "(c)1976 JKocsis - Buffalo Creek ALCO S2 #46 in Bi-Centennial paint. (10K) - CLICK to Enlarge (125K)") |
 "(c)2015 smph50 - Bob M. applies the finish coat of grey on the engineer's back rest. (10K) - CLICK to Enlarge (125K)") |
We had another great day for outdoor work so Bob M. and Jim L. moved forward with more paint work. Jim and Bob sanded, primed and painted two more engine compartment doors with industrial grey enamel and finished the paint on the engineer's seat back rest. |  "(c)2015 smph50 - Jim L. applies industrial grey enamel to another engine compartment door. (10K) - CLICK to Enlarge (125K)") |
 "(c)2015 RJBurns - Using a flameless heat gun, heat shrink tube seals a battery cable. (10K) - CLICK to Enlarge (125K)") |
Rick B. and I moved onto the electrical system with the nice weather. Over the years, the battery cables were kept insulated by layers and layers of friction tape, crude but effective. We removed several of the old layers and then slid a new piece of high dielectric heat shrink tubing over the entire cable length into the metal conduit. A flameless heat gun sealed the tubing tight. |  "(c)2015 smph50 - Ragged friction tape is now replaced with clean heat shrink. (10K) - CLICK to Enlarge (125K)") |
| We had another beautiful day on July 23rd to work on the electrical system. Anxious to check out our battery cables, we moved our 36 volt battery pack out to the fireman's side walkway. The battery compartment cover was removed and the batteries connected with jumper cables. Using a VOM, we were pleased to see we had 36.8 volts at the battery knife switch. After cleaning the contacts of the fuses and switch, we delicately closed the switch and then opened it when the sparks flew! After removing all three main fuses (compressor, radiator fan and auxiliary generator) we found the problem in the aux generator circuit. With that fuse removed and the battery switch closed, we had 36 volts to the control stand which gave us power to the fuel pump, lights and radiator fan! |
| We found out that the Forward/Reverse control handle on the control stand was in the full forward position. This was causing the big EF & GF relays to try and close when the battery switch was closed and the field coils on the starter/aux generator were being energized. This was way too much current for our 36 volt battery pack to supply and is what caused the electrical arc. |
 "(c)2015 smph50 - The three main appliance fuses, 100amp Control, 150amp Fan and 400amp Compressor . (10K) - CLICK to Enlarge (125K)") |
 "(c)2015 TScazafavo - Removing the six foot long battery compartment cover. (10K) - CLICK to Enlarge (125K)") |
 "(c)2015 smph50 - We used heavy duty jumper cables to connect the batteries to the electrical system. (10K) - CLICK to Enlarge (125K)") |
 "(c)2015 TScazafavo - VOM shows 36.8 volts to the knife switch. (10K) - CLICK to Enlarge (125K)") |
 "(c)2015 TScazafavo - Ready to close the knife switch for the first time. (10K) - CLICK to Enlarge (125K)") |
 "(c)2015 smph50 - Generator lead to traction motor #1 gets fresh heat shrink insulation. (10K) - CLICK to Enlarge (125K)") |
We had another productive day for our last work session in July. While Rick B. worked on testing relay coils and control stand fuses, I moved onto the electrical leads from the generator to the traction motors under the locomotive. Just like the original battery cables, oil and heat had taken its toll on the old friction tape. After all the decay was removed, new heat shrink tubing made for a nice safe cable. |  "(c)2015 smph50 - All four generator to traction motor leads now have new insulation. (10K) - CLICK to Enlarge (125K)") |
August 2015
 "(c)2015 smph50 - Extra electrical insulation provided by flexible vinyl tube. (10K) - CLICK to Enlarge (125K)") |
Rick B. finished cleaning and lubrication the fuel injector reset bar and it now snaps into place. We also added an extra layer of electrical protection to the generator to traction motor leads with flexible vinyl tubing. The lead lugs were cleaned and matched and are now bolted together with stainless steel socket head cap screws. A length of rubber tube was used to cover the connections before the leads were clamped to the bottom of the locomotive. |  "(c)2015 smph50 - Rubber tube covers the connector lugs. (10K) - CLICK to Enlarge (125K)") |
 "(c)2014 smph50 - The crowds await the arrival of the Fair Train in 2014. (10K) - CLICK to Enlarge (125K)") |
The biggest event for Hamburg, New York in August is the arrival of the James E. Strates "Fair Train." Hundreds of people turned out to see Buffalo Southern ALCO #5010 RS11, pull the 37 ride loaded flat cars past the old Erie Railroad freight house for unloading down the tracks. We were not able to get much done due to all the visitors but it was fun explaining what we were doing to the young and old. The following week, heavy thunderstorms rained us out. |
| On the 27th we finished many of the details necessary to ensure everything would be ready for our "prestart" inspection by the Buffalo Southern. Bob M. worked on wiring details while Rick B. and I pulled the six valve covers to inspect and prelube the rocker arms. All six valve chests looked clean and had no issues. We also sealed the crankcase covers and barring cover with silicone that were removed when we turned the engine over. |
 "(c)2015 RJBurns - A veiw from the top of the locomotive down as BobM. and I inspect wiring. (10K) - CLICK to Enlarge (125K)") |
 "(c)2015 RJBurns - All six valve covers were removed to inspect the valve chests. The pipe in the middle of the photo is the overflow outlet from the 275 gallon cooling system expansion tank. (10K) - CLICK to Enlarge (125K)") |
 "(c)2015 RJBurns - The view of a nice clean valve chest showing two exhaust and two intake valves as well as fuel injector pipe and overflow tube. (10K) - CLICK to Enlarge (125K)") |
 "(c)2015 RJBurns - Prelubing the rocker arms, not required but worth the effort. (10K) - CLICK to Enlarge (125K)") |
September 2015
By Scott MP Hawbaker
 "(c)2015 smph50 - Bob M. prepares the interior of one of the four generator safety covers for priming. (10K) - CLICK to Enlarge (125K)") |
As electrical bugs were being worked out on the locomotive, the rest of our team attended to other details that needed attention. On such task was the flaking paint on the interior and exterior of the five sheet metal generator safety covers. Bob M. took on the job of wire brushing, sanding and priming the inside and exterior of all five covers. When dry, they will be top coated with the industrial gray enamel which we have been using. |
 "(c)2015 smph50 - Snap on aluminum electrical cabinet vent cover. (10K) - CLICK to Enlarge (125K)") |
To keep rain, snow and leaves from getting into the two roof vents for the radiator fan and electrical cabinet, we were covering them with 6 mil plastic. However, the plastic covers would have to be replaced every year due to sun decay. I obtained a large sheet of 20 guage aluminum which worked out great! Both covers can be removed in less than a minute when needed. |  "(c)2015 smph50 - 36 inch aluminum radiator fan cover. (10K) - CLICK to Enlarge (125K)") |
| Over a year ago when the cab was being painted, we removed almost 20 feet of bent up 1/4" copper tubing that supplies the rear wiper motor with air pressure. The original tubing was poorly attached, not straight and covered with chipping paint. Rick B. bought a new 20 foot roll of tubing whuch was carefully bent to the correct profile and attached with new copper straps and screws. The shiny tubing will take on a nice patina after a month or two to match the brass wiper motor. |  "(c)2015 smph50 - New copper tubing air supply line. (10K) - CLICK to Enlarge (125K)") |
October 2015
By Scott MP Hawbaker
 "(c)2015 smph50 - Primer on the plow of the Jordan Spreader where we left off. (10K) - CLICK to Enlarge (125K)") |
While painting of the generator covers got finished, Rick B. worked in the cab and I turned my attention to a project started two years ago. The Buffalo Southern Railroad has been such an asset and friend to our endeavors' that we needed a way to help pay them back for all their help. 60 feet behind #43 is one of their Jordan Spreaders which needed paint. We agreed that when time allowed we would paint as much of the plow as we could. We tried a 3800psi power washer and 26 grit 7" grinders and niether would remove the many layers of peeling, checked and cracked paint. |
 "(c)2015 smph50 - Needle scaling the plow blade. (10K) - CLICK to Enlarge (125K)") |
Needle scaling was the only way we found that would leave a surface that could be cleaned up with a grinder and made the steel ready for primer. Although the process works well, it is very slow. After two work sessions, we had almost all of the plow scaled and ready for primer. Bob M. applied primer on all the bare metal on the first warm day we had this month. |  "(c)2015 smph50 - Bare steel covered with primer thanks to Bob M. (10K) - CLICK to Enlarge (125K)") |
 "(c)2015 smph50 - Bob M. finishes applying primer. (10K) - CLICK to Enlarge (129K)") |
October 8th was a perfect day for painting with 64' sunny skies and low humidity. We finished the needle scaling on one small section, hit it with the 36 grit grinder and then primed the bare surface. On the other side of the blade we wiped it down with mineral spirits, and then sprayed on two medium coats of "Sunburst Yellow" enamel. It sure brightened up the siding! |  "(c)2015 smph50 - One half of the spreader plow blade in Sunburst Yellow. (10K) - CLICK to Enlarge (125K)") |
 "(c)2015 smph50 - Jordan Spreader plow blade complete in Sunburst Yellow. (10K) - CLICK to Enlarge (129K)") |
The 15th was another great day to paint with clear skies and low humidity. We finished painting the right side of the Jordan Spreader plow blade and it came out great! We also finished up the five generator cover plates that Bob M. restored. He also picked up and donated, three nice "Danger 600 Volts" signs he found at the ArtCraft Train Show last weekend. |  "(c)2015 smph50 - Generator covers installed with 600 Volt warning signs. (10K) - CLICK to Enlarge (125K)") |
November 2015
 "(c)2015 smph50 - Bob M. finishes painting the front coupler on the Jordan Spreader. (10K) - CLICK to Enlarge (125K)") |
November weather in Western New York has been 7' above normal so far. On November 5th we did some touch up on the plow blade and painted the coupler. Two weeks later we installed two tempered hardboard covers over the radiators. Weather permitting they will be painted black soon. |  "(c)2015 RMartin - Tempered hardboard covers installed over radiators. Soon to be painted black. (10K) - CLICK to Enlarge (125K)") |
 "(c)2015 RMartin - Contractor bags secured to the journal covers (10K) - CLICK to Enlarge (125K)") |
With the record snowfall we had last year, small amouts of water kept getting into the journal boxes. As a temporary fix, Bob M. and new team member Jeffery Luke, secured eight contractor bags over the journal box covers. |  "(c)2015 RMartin - This should keep the snow out! (10K) - CLICK to Enlarge (125K)") |
December 2015
 "(c)2015 RJBurns - Bob M. finishes painting the front coupler on the Jordan Spreader. (10K) - CLICK to Enlarge (125K)") |
With Western New York enjoying a record breaking no snowfall season, we were able to finish the black topcoat on the radiator covers. Combined with the radiator fan and electrical cabinet covers, #43 will stay dry inside with what ever the weather brings! |  "(c)2015 RJBurns - Tempered hardboard covers installed over radiators. Soon to be painted black. (10K) - CLICK to Enlarge (125K)") |
 "(c)2015 smph50 - Bob M. applies polyurethane foam weather stripping to the journal box. (10K) - CLICK to Enlarge (125K)") |
 "(c)2015 smph50 - Journal box cover needs to be preped and primed after straightening. (10K) - CLICK to Enlarge (125K)") |
It was 54' on the 10th of December so we continued work on the journal box covers. Bob M. and Jeff L. applied Polyurethane Foam around the box under the cover. They also straightened one cover which had a nasty bow in it. I was able to finish the 1/4" copper air line to the rear wiper motor. |  "(c)2015 smph50 - New 1/4 inch copper tube is finished to the rear window wiper motor. (10K) - CLICK to Enlarge (125K)") |
| The WNYRHS greatly appreiciates all the generous donations to this project to date. However, we could still use your help! All Donations to the WNYRHS, Inc. are Tax-Deductable! If you would like to mail in a donation, send it to WNYRHS Inc., PO Box 416, Buffalo, New York 14231-0416 or |
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