Hello to all - new to the forum, and I have a very difficult problem on my hands!
After installing new load tray belts in a Denon DCD-2560 single CD player from the early 1990's and after testing it with a few open/close cycles. the drawer failed to open. Inspection showed that the gear that moves the entire rack back and forth had broken - not just a crack, but a section of the gear broke away. Luckily all teeth are still intact, and it fits back together correctly.
The tricky part with this gear is that is uncommon - it has 7 teeth and is rather small, and is made out of nylon/delrin plastic. I tried to super glue the gear back together and let it cure overnight. This worked for about 100 open/close cycles, but eventually the gear didn't hold together. It's very difficult to glue this type of plastic, as much searching/reading has shown.
I'm looking to see if anybody has thoughts/ideas on how to get a replacement gear for this unit - many hours of searching have turned up 0 results. As well I'll consider having a gear 3D printed, but most of the online tools available to create a custom gear have a minimum requirement of 8 teeth on the gear. I know it may be possible to send the gear in, but I do want to keep costs under control in this situation.
As well if anyone has thoughts or experience on actually repairing nylon gears of this sort it would be greatly appreciated for any ideas! Thanks in advance!
Outside diameter of the gear is 9.75mm - hard to measure as no even number of teeth, but that's after many tries with the caliper.
After installing new load tray belts in a Denon DCD-2560 single CD player from the early 1990's and after testing it with a few open/close cycles. the drawer failed to open. Inspection showed that the gear that moves the entire rack back and forth had broken - not just a crack, but a section of the gear broke away. Luckily all teeth are still intact, and it fits back together correctly.
The tricky part with this gear is that is uncommon - it has 7 teeth and is rather small, and is made out of nylon/delrin plastic. I tried to super glue the gear back together and let it cure overnight. This worked for about 100 open/close cycles, but eventually the gear didn't hold together. It's very difficult to glue this type of plastic, as much searching/reading has shown.
I'm looking to see if anybody has thoughts/ideas on how to get a replacement gear for this unit - many hours of searching have turned up 0 results. As well I'll consider having a gear 3D printed, but most of the online tools available to create a custom gear have a minimum requirement of 8 teeth on the gear. I know it may be possible to send the gear in, but I do want to keep costs under control in this situation.
As well if anyone has thoughts or experience on actually repairing nylon gears of this sort it would be greatly appreciated for any ideas! Thanks in advance!
Outside diameter of the gear is 9.75mm - hard to measure as no even number of teeth, but that's after many tries with the caliper.
Welcome to the forum.
I moved your thread to here, it might draw more attention.
Good luck finding a solution.
Hugo
I moved your thread to here, it might draw more attention.
Good luck finding a solution.
Hugo
Here is a service manual for a 2560 (file was too large to upload). From the parts listing, I think the gear you are looking for is part ref. 21-1, but no part number is listed for this. Looking at the listing of CD player DACs and transport mechs, it appears that this uses a Sony KSS-151A (for a plain 2560), or a KSS-150A / KSS-210A for a G or GL. Possibly your most realistic fix would be to buy a complete transport. Here is complete KSS-150A, for example.
