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One or both of the Green Aligner Belts have broken. If this break occurs, it would usually occur at the 
Weld Splice. 

Replace the Green Belt of the Belt Aligner Assembly using the following procedure. 

 

Replacement of the Green Belt from the Aligner, Paper Entrance Side. 

Replacement of the Green Belt from the Aligner, Paper Exit Side. 

 

The following step-by-step directions inform you how to remove and then assembly the components 
necessary to access the Paper Entrance Side Aligner Green Belt. 

It will help you to reference your SmartPunch Service Manual part drawings as you follow this process. 

Special Tools Required: 
•  Twelve inch metal ruler or similar straight edge. 

•  Phillips Head Screw Driver 7” or less in total length. 

•  Alan wrenches (5/64” & 9/64”). 

•  Nut Driver (1/4” & 5/16”). 

•  Rare Earth Magnet Snake Neck (optional – good for retrieving any hardware that happens to fall in 

hard to reach spots). 

•  Snap Ring pliers. 

• E-Ring tool 

During assembly, be sure not to over tighten any of the mounting screws. 

Step 1:  

Disconnect the SmartPunch from Power. Retain the power cord in your possession for your 
safety. 

Step 2:  

Disconnect the Communication Cable to the Finisher. 

Step 3:  

Unlatch the GBC SmartPunch from both the Finisher and the Multi-function/printer. 

You must first remove the screw that secures the latch in place (if so equipped). 

Step 4: 

Open the Front Door (A) of the SmartPunch.  

Step 5: 

Remove the Paper Chip Tray (B), empty it and replace it. This is to prevent difficulty in 
finding any small parts that you may drop into the chad. 

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BINDER SIDE

FINISHER SIDE

B

A

 

Step 6: 

To remove the Rear Cabinet/Cover (C) of the SmartPunch,  

1.  Remove the “5” screws on Exit side and “3” screws on Entrance side. 

2.  Slide the Rear Sheet Metal Cabinet/Cover off of the SmartPunch. 

You do not need to lift upward and you do not need to remove the Top Cover. 

Step 7:   

Disconnect the Entrance Sensor Wire from the Side Frame. 

Step 8:   

Remove the “4” screws that secure the Front Paper Chute (D), set aside. 

Step 9:   

To remove the J2 Flipper, Door Latch (E). 

A.  Unhook the spring of the J2 Flipper on the right end. 
B.  Remove only one (the one closest to the frame) of the “E” Rings of the J2 Flipper on 

the left end (front Door side). 

C.  Push the J2 Flipper in toward the front Door until it clears the rear frame. 
D.  Pull the entire J2 Flipper, Door Latch out and set it aside. 

Step 10: 

Remove the “4” screws that secure the Docking Bracket (F). Remove, and set aside. 

 

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Step 11: 

To remove Entrance Aligner Panel, Idler Paper Guide Assembly        (item 19) 

a.  Remove “2” E-Rings from the Pivot Shaft (G). 
b.  Slide the Shaft (G) all the way out through the front of the SmartPunch. 
c.  Remove the Fan (H) that prevents access to the Flexible Cable. To remove, simply pull 

it off of the Shaft. 

d.  Remove the Flexible Cable using an Alan Wrench. 
e.  Remove the rear top Pulley (I). 
f. 

Loosen the Belt Idler (J). 

g.  Remove the Belt and Pulley. 
h.  Loosen screw from the Solenoid Link. 
i. 

Remove the Solenoid Assembly (K) and link from the Diverter Shaft, leave it hang. 

j. 

Remove the two E-Rings of the Entrance Diverter Assembly, slide the Diverter out and 
set it aside. 

K

G

I

J

H

FRONT DOOR SIDE

L

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Step 12: 

To remove the Drive Side, Paper Entrance Guide Aligner Assembly (L), which is the large 
sheet metal Assembly that actually, containers the Green Belt and Aligner. 

A.  Remove the “6” Screws that secure the face of this Assembly. 
B.  Remove the “2” screws that secure this Assembly from the Side Frame. 
C.  Pull and walk the entire sheet metal assembly of the Paper Guide Aligner Assembly up 

and outward. You can grab the Assembly at the Roller cut out with your fingers. 

IMPORTANT:  

As you do this, disconnect the Sensor harness behind the Assembly as soon as you 
are able to reach it. 

 

Step 13: 

Before you remove the Green Belt Aligner Roller Assembly from the sheet metal paper 
guide, observe the perfectly flush surfaces of the Green Belt Aligner Roller Assembly to 
the sheet metal surface of the Rear, Drive Side, and Paper Guide Aligner Assembly. Hold 
a straight edge like a 12”metal ruler across the surface of the sheet metal face and the 
metal (w/o a belt) Green Belt Aligner Roller itself. Note that the two metal surfaces are 
flush. 

 

 

Step 14: 

Remove the Green Belt Aligner Roller Assembly by removing the “4” screws (S). 

IMPORTANT: Leave the Flex Shaft (FS) attached. 

Step 15: 

Stretch the new Belt (B) onto the Aligner Roller Assembly, green side out. Rotate the 
Shaft (S) to confirm that the belt tracks properly.

 

STRETCH

B

FS

FS

S