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D.  Remove and set aside the Rear Aligner, Idler Paper Guide Assembly. 

Step 9: 

To remove the curved sheet metal Exit Paper Guide Assembly 

A.  Remove the “4” Screws (2 rear and 2 front) of the curved sheet metal Exit Paper Guide 

Assembly 

B.  Unplug the Sensor 

C. 

Pull the entire sheet metal Exit Paper Guide Assembly out, set aside.

 

 

 

Step 10: 

To remove the Rear, Drive Side, and Paper Guide Aligner Assembly. This is the large 
Sheet Metal Assembly within the SmartPunch that actually contains the Green Belt Aligner 
itself. 

IMPORTANT: Walk the Belt off of the Aligner Pulley at the rear. 

A.  Remove the “2” screws that hold the Block to the Frame.  Now – the Coupler is loose 

and the Rear Panel will come out. 

B.  Remove the “6” Screws that secure the face of this Assembly. 

C.  Remove the “2” Screws that secure this Assembly from the top. 

D. 

Pull and walk the entire sheet metal assembly of the Paper Guide Aligner up and outward. You 
can grab the Assembly at the Roller cut out with your fingers. 

 

The Helical coupling is very delicate, be gentle. 

In order to access these screws, you must first remove the Die Set Storage Shelf and the 
Cable Shield attached to the Die Storage Shelf at the paper entrance side. Moving the 
Die Storage Shelf aside will enable better access to the “2” screws with a short (7” or 
less) Phillips Screw Driver. 

 

 

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ALIGNER DRIVE
BELT ASSY

 

            

E.  Bend in the Tab of the frame near the middle, front area to allow enough clearance to 

work the sheet metal Paper Guide Aligner Assembly out. 

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

Step 11: 

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 12: 

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

 

 

 

Important: Leave the Coupler attached. 

Step 13: 

Stretch the new green belt onto the Aligner Roller Assembly, green side out. 
• Take care when handling the Aligner Roller Assembly so as not to damage the Flex 

Coupling. 

•  Rotate the shaft to confirm that the belt tracks properly. 

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Step 14: 

Slide the Aligner into place, loosely attach the “4” Pan Head Screws with the “4” Lock 
Washers.

 

BELT

STRETCH

ROTATE

 

 

Check that the metal surface of the Aligner Roller Assembly is flush with the Sheet Metal surface of the 
Paper Guide. A 12” metal ruler works well to check this adjustment. Slip the ruler under the green belt 
and press it flat against the two surfaces. Adjust the Aligner and snug the screws when perfectly flush.  

The green belt should look like the drawing shown after step 11.  

As a double check, hold the entire Paper Guide assembly up so that you can visually inspect the 
alignment between the sheet metal surface and 

the metal surface of the Aligner. The Green Belt should appear 

to be even and just floating above the surface of the sheet metal. 

ALIGN
& FIX SCREWS

 

Step 15: 

To install the Paper Guide Assembly into the SmartPunch.

 

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PAPER EXIT
SIDE

FRONT DOOR

D

SIDE

SIDE

PAPER ENTERANCE

ASSEMBLE BACK

 

 

A. 

As you slide the Paper Guide Assembly into place,  

a.  Hook up the Sensor Harness to the Sensor on the back. 

b.  Lift it up slightly to clear the lower Transition Paper Guide. 

c.  Be sure to clear the Sensor Bracket at the top left. 

d.  Be sure that the Flex Coupling Shaft is sticking out of the rear of the SmartPunch 

properly. 

B. 

Visually check all around the mounting area of the Paper Guide Assembly and that the 

Sensor Harness is properly connected. 

C.  Loosely secure it in place with “3” screws on the left and “3” on the right. 

D.  Loosely install the “2” top screws. A useful tip might be to secure the Screw to the tip of your 

Screwdriver with a small piece of masking tape to assist you in finding the hole.  

E. 

Once all “8” mounting screws have been properly started you have good alignment. You 

may now go back and tighten the screws until they are snug. Do not over tighten the 
“2” screws on top! 

Step 16: 

Install the “2” Screws to secure the Bearing Block for the Pulley arrangement at the rear of 
the SmartPunch. Press the block to the top of the punch before tightening 

Step 17: 

Install the Pulley and Belt onto the Pulley Block. Once properly aligned, check Belt and 
Pulley movement. Tighten the Set Screw.

 

Step 18: 

Install the Die Set Storage Rack with “3” screws front and “3” screws back. Remember to 
attach the Ground Strap at the middle screw on the rear (belt side). Start each screw to 
achieve proper alignment, then go back over each screw and tighten it. 

Step 19: 

Install the Cable Guard on top of the Die Set Storage Rack (“2” Screws). 

Step 20: 

Install the curved sheet metal Exit Paper Guide with Idler Roller “4” Screws. 

 

 

 

Start all “4” screws, (2 on front and 2 on back) then tighten.