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Step 21: 

Connect the Sensor Wire Harness at the top rear of the Exit Paper Guide. 

Step 22: 

To install the Idler Aligner Paper Guide. 

A.  Hold it loosely in place. 

B.  Press the Nylon Flange Bearings into place, through both pieces of sheet metal, with 

the Flange to the inside 

C.  Slide the Shaft through the front of the machine, while holding the Nylon Flange 

Bearing in place. 

D.  Secure with “2” E-Rings on the inside of the bearing. 

E.  Inspect by pressing in on the bottom area of the sheet metal for:  

#1 should see a slight deflection of each Idler Roller as you press,  
#2 as you press, you can turn the Pulley’s at the rear of the SmartPunch and see the 
Idler Rollers rotate smoothly. 

Step 23: 

Bend the small metal tab back into place. 

Step 24: 

Install the J2 Shaft back into place by inserting it first into the front, then the back. 

Step 25: 

Close the J2 Flipper Latch. 

Repeat the test of rotating the pulleys to ensure smooth rotation of the Idler Rollers. 

Step 26: 

Attach the J2 Shaft Spring 

Install the front E-Ring to secure J2. 

 

Step 27: 

Attach the Docking Plate using “4” Screws and install spring from Plate to Door. 

Step 28: 

Attach the Back Rear Cover using the 7 screws (2 for the Entrance and 5 for the Exit side). 

 

Test the SmartPunch by running 10 copies in bypass mode, 

 

Then 1 sheet in punch mode, 

 

Then 10 sheets in punch mode, 

 

Then 100 sheets in punch model 

This entire process takes approximately 60 minutes. First time maybe a little longer.

 

AFTER ASSEMBLY

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The SmartPunch Chad Control Mechanism directs Paper Chad into the Chad Disposal Container, 
significantly reducing the amount of Chad that could flow through the paper path. There will be some 
Chad that falls outside the Chad Container. In one circumstance, when the customer changes their Die 
Set, some Chad always comes with the Die and falls to the bottom of the machine or to the floor. As a 
general practice, it is a good Preventative Maintenance practice to vacuum the inside of the SmartPunch 
periodically. 

 

Step 1:  

Disconnect power and communication cable. 

Step 2:  

Open door and remove Die Set, chad bin, and rear cover (opposite the door).  

Once you remove the screws that secure the rear cover, it will slide out from under the 
top cover. You do not need to remove the top cover. 

 

Step 3:  

Remove the two screws holding the Die rail at the front of the SmartPunch. 

Step 4:  

Remove the four screws holding the Die rail at the rear of the SmartPunch. 

Step 5:  

Remove the wire that attaches the solenoid to the PC board.  After all the screws and the 
wire are removed you can now remove the back gauge and rail as an assembly.   

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BACK GAUGE ASSY

 

Step 6:  

Facing the back gauge pull the rail from the right side first and slide out the assembly.  

Step 7:  

Install the new back gauge. Also, when replacing the two screws that hold the die rail make 
sure you install the brush that is provided in the kit. 

Step 8:  

Reattach the wire harnesses using wire ties. Add a small loop to the new wires coming from 
the new Solenoid to the PCB and using a wire tie, secure the harness so that it is not in the 
path of the Chip Tray.  

Step 9:  

Install the chad bin.  

Step 10:  

Install the new (see footnote below) die set. Test the SmartPunch system running first one 
page at a time, then two pages then 5 pages, then 10 pages and lastly run 50 test pages. 

Step 11:  

Replace the cover and run a few more test jobs. 

Step 12: 

Skew Adjustment: Check for proper hole alignment to paper edge.  

The back gauge is designed to give you some adjustment when the three screws are loosened. 

It will give you up and down play, which allows you to remove skew. 

If not, paper can slip past the paper stops and give you a deep punch. This may occur if the back gauge 
is tightened into place in it’s bottom most position. This situation is most likely to occur when using the 
VeloBind or PB die sets, which are at one end of the Back Gauge tolerance spectrum. 

Three-Hole Die Set: At the other end of the Back Gauge tolerance is the Three-Hole Die Set. If the 
customer owns a Three-Hole Die, check this die to see if it is easy to insert and remove. If the die is too 
tight you will need to lower the back gauge slightly to achieve the tightness you desire, while still retaining 
the PB and VeloBind functionality mentioned above. 

 

 

 

 

 

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1. Open 

punch 

door. 

2.  Turn punch knob J3 to home position. 

3.  Open top cover J1. 

4.  Open front paper door lever J2. 

5.  Open exit paper door lever J8. 

6.  Open bottom U-channel J7 by pressing in lever J6 and lower. 

7.  Clear paper from all these areas by turning knobs as shown. 

8.  When all the paper is cleared the jam light will no longer be illuminated if it is a sensor is till be 

activated.