Canon Time Clock DU7 1175 000 User Manual

Professional

Puncher-A1

SERVICE

MANUAL

DU7-1175-000

NOVEMBER 2005

REV. 0

CANON Professional Puncher-A1 REV. 0 PRINTED IN U.S.A.

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1. INTRODUCTION

1.1 INTRODUCTION

The Professional Puncher-A1 is an innovative solution for punching paper and

offers the following design features:

• Quick-change die sets that are self-latching without tools or levers.

• All Professional Puncher-A1 die sets include an Identifying Label providing user

with the hole pattern and name.

• Convenient storage area for three extra Die Sets located above the sheet bypass.

1.2 PROFESSIONAL PUNCHER-A1 FAQ’S

The CANON Professional Puncher-A1 will perform best when used for applications

that it was designed to perform. To ensure complete satisfaction, operate the

Professional Puncher-A1 within the following design parameters.

Professional 208V, 60Hz

(North America)

Professional 230/240V,

50Hz (Europe)

Sheet Sizes Supported:

Punching

Letter-21.59cm x 27.94cm

(29.74cm edge only)

A4-21.59cm x 29.74cm

(29.74cm edge only)

Bypass Mode (not punching)

5.5" x 8.5" upto 11" x 17"

supports all stocks and

weights that the printer

supports in bypass mode.

5.5" x 8.5" upto 11" x 17"

supports all stocks and

weights that the printer

supports in bypass mode.

Paper Weights Supported:

Punching

75gsm (20lb Bond) to 216

gsm (80lb Cover)

75gsm (20lb Bond) to 216

gsm (80lb Cover)

Bypass Mode (not punching)

Physical Dimensions

Physical Weight

52 gsm (16lb Bond) to 216

gsm (80lb Cover)

52 gsm (16lb Bond) to 216

gsm (80lb Cover)

12" width x 38.5" height x

28.5" depth

12" width x 38.5" height x

28.5" depth

70kgs (154lbs)

Shipping Weight

115.5kgs (254lbs)

Power Consumption:

Power Supply

Electrical

208V, 60Hz (Single Phase) 230/240V, 50Hz

(Single Phase)

1.8A/1.7A, 240W, 1160

BTU/Hr

1.8A/1.7A, 240W, 1160

BTU/Hr

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8.5” x 11” (LEF) Only:

Professional Puncher-A1 is designed to punch this size only (LEF) no exceptions.

Attempting to punch a sheet size other than 8.5” x 11” (LEF) will cause a jam.

• Professional Puncher-A1 cannot punch tabs. Tabs will have to be run, punched

and inserted offline.

• Use a colored sheet insert (instead of the tab) in the job workflow for easier tab

insertion after the job has been run.

Die Sets:

The CANON Professional Puncher-A1 is capable of punching a variety of hole-punch

patterns by simply changing the Die Set. Die sets can be changed in seconds

without tools. The Die Sets currently available are listed below:

North America (Letter)

3-hole

Europe (A4)

4-hole / 2hole

Velo Bind 11-hole

Velo Bind 12-hole

CombBind 19-hole

CombBind 20 or 21

Wire Bind (2 types) Round

Wire Bind (2 types) Square

21-hole Wire Bind

32-hole Wire Bind

23-hole Wire Bind

34-hole Wire Bind

Color coil 44-hole (2 types)

Color Coil 47 hole (2 types)

44-hole RND

44-hole Oval

47-hole – RND

47-hole – Oval

Punch Pattern Samples (North America – Letter Shown)

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2. INSTALLATION

2.1 UNPACKING

UNPACKING

• Inspect the outside of the package for shipping damage. If there is evidence of

shipping damage, contact the shipping carrier immediately.

• Remove the punch from its shipping carton.

• Inspect for any concealed damage to unit. If there is evidence of concealed

shipping damage, contact the shipping carrier immediately.

• Remove all shipping tape from doors and levers.

2.2 UNIT SET-UP

Step One: Connect the communication cable.

Step Two: Connect the power cord.

2.3 UNIT OPERATION

• Check to ensure that the paper chip tray is securely in place.

• Check to ensure that a Die Set is installed properly and that any extra Die Sets are

securely stored in the Die Storage Area.

• Run a small test job in “Bypass” mode. Check to ensure that the job is not

punched and bypasses properly.

• Run a small job with Punch Enabled. Check the punched holes of the job.

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CANON PROFESSIONAL PUNCHER-A1 DIE SET - INFORMATION SHEET

IMPORTANT NOTICE REGARDING THE DIE SETS PLEASE READ

Your CANON Professional Puncher-A1 die set (C4, W2 and W3 versions), is

supplied with a felt pad containing oil, a pad retaining magnet and shield*. Do not

throw these items away!

The felt pad will provide lubrication to the punch pins under normal usage and will

help to keep the punch pins clean. The magnet is intended to keep the felt pad in

place during typical handling. If the pad and magnet came off of this die set during

shipping or unpacking, please replace them as indicated in the accompanying

diagram.

Keep this sheet as a reference in the event that the pad and magnet are removed or

replaced.

FELT PAD

MAGNET

SHEILD

SHOULDER BOLT

WITH SPRING

Felt Pad and Retaining Magnet are not required or included with the 3-Hole, PB,

C4, ProClick^®or VB die sets.

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3. MAINTENANCE

3.1 INSPECTION, CLEANING AND LUBRICATION

The following maintenance should be performed once annually, under normal use.

Operational Inspection

1. If operating properly, the Professional Puncher-A1 will punch the same types of

copy paper and cover materials handled by the copier/printer. It will run at the

speed of the printer.

2. Hole quality will vary between different grades of paper.

External Cleaning

1. Make sure you disconnect the Professional Puncher-A1 from its power source

before cleaning. The cover may be cleaned with a soft cloth moistened with mild

detergent and warm water.

2. Do not use chemical cleaners or solvents as these may have a harmful effect.

Use detergent sparingly to avoid contact with electrical components.

Internal Cleaning

Before internal cleaning, be sure to disconnect power to the Professional Puncher-

A1 and ensure that you retain control of the power cord.

Occasionally, it will be necessary to remove the rear cover and remove paper dust

built up around the motor and other electrical components. Use a vacuum cleaner if

possible. A small paintbrush can also be used but extreme care should be used

around electrical components.

Internal Inspection

Whenever the cover has been removed for corrective maintenance, visually inspect

for defects such as loose screws or nuts, abraded wire insulation, loose terminals,

etc. Correct any defects before returning the machine to service.

Lubrication Points and Recommended Lubricant

• Lubricate the punch pins and/or the felt pad once every 50,000-punch cycles with

oil (High Quality Machine Oil is recommended).

• Method:

1. Sparingly depress the Pin Guide so that the Punch Pins protrude from

the bottom plate, oil the ends of the pins and wipe clean.

2. Apply oil directly to the felt pad (If so equipped).

3. Apply two drops of oil to each of the two shoulder bolts and springs.

• If Punch Drive Module Assembly is ever removed for service, check for sufficient

grease on the cranks.

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GREASING CRANKS

Die Sets

Professional Puncher-A1 Die Sets have an average expected life of approximately

500,000 sheets of paper. This life may vary depending on variables such as

following the lubrication schedule described above, the type of paper being punched,

the cover stocks being punched and the typical length of the average job.

3.2 DIE SET MAINTENANCE

Die sets have a minimum life expectancy of 500,000 cycles depending on

application, environmental factors and maintenance. Periodic lubrication of the

punch pins can extend the life significantly. CANON recommends use of a high

quality machine oil (do not use spray oils) every 50,000-punch cycles.

SHOULDER BOLT

WITH SPRING

SPRING

The die set cannot be repaired or adjusted.

Other than lubrication, if a Die set is damaged or worn, the Die set should be

replaced.

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3.3 PREVENTATIVE MAINTENANCE SCHEDULE

The following preventative maintenance should be performed during the regular

printer inspection intervals.

• Disconnect the main cord set and retain it in your control for your safety.

• Remove the rear cover.

• Perform a visual inspection; clean, adjust and replace components as required.

• Vacuum Paper Chad out of Back Gage Mechanism and Die Guide as well as

base.

• Optical Sensors; Remove dust and particles from the lens using a soft cloth.

• Inspect Timing Belts for wearing or fraying.

• Inspect any Latching Mechanisms, clear any jams paper debris.

• Inspect Left / Right Punch alignment by running paper with each die set, check for

even hole alignment by folding the paper in half. If adjustment is required, ensure

that the Die Latch is properly adjusted.

• Inspect the Door closing latch for proper alignment, if bent, instructs the operator

to avoid closing the door with paper path latches out of place.

• Lubrication of the Die Set Pins (see note above)

• Cams (when punch is pulled), lubricate with high quality grease

• Inspect the Idler Rollers, clean if necessary.

• Inspect the Drive Rollers, clean if necessary.

• Inspect the Paper Path Panels, clean if necessary.

• Inspect each Die Set for wear. Run at least 100 sheets of paper. Look for signs of

excess paper jamming. Inspect the hole quality. Hanging chad or ragged holes can

lead to paper jams. If the hole is cut sharp enough that there is no hanging chad

and the paper passes through the system without catching and jamming, the die

set still has life.

As with any electro-mechanical device, isolated component failures may occur.

3.4 SETTING THE RIGHT EXPECTATIONS

Product Positioning:

Professional Puncher-A1 provides a flexible, cost effective punching solution for light

to medium level production oriented customers.

• Designed for customers that have the need to punch their documents at a

maximum of 60-70% of their overall workflow.

• Recommended punching limit to 200k sheets per month. (600k sheets in

bypass mode)

• Die Sets will decrease in performance over time based on the types of stocks and

weights that are being punched.

• CANON guarantees a minimum of 500k punches per die set. However, if

paper stock punched is typically 20lb bond, then up to 2 million punches can

be achieved.

• Should be regarded as a long-term supply item.

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4. ADJUSTMENT AND SPECIAL PROCEDURES

4.1 TOOL RECOMMENDATIONS

What you need to service the CANON Professional Puncher-A1:

1. Standard Measure Tools (English as opposed to metric)

a. Open End Ignition Wrench – ¼” (required only for Chad Kit installation)

b. Open the End Wrench 9/16”(for adjustable casters)

c. Nut Driver, 5/16”

d. Nut Driver, ¼” (see note below)

e. Allen Wrench, 3/32” (comes with Chad Control Kit)

f. Allen Wrench, 5/64”

g. Allen Wrench, 9/64”

2. Other recommended tools

a. Needle Nose Pliers (Side Cutters)

b. Wire Cutters

c. Screw Driver, Phillips Head

d. Screw Driver, Flat Head, Small

3. Supply of Wire Tie Wraps

NOTE: A nut driver head of ¼” is the most common size for the barrel of a

Magnetic or interchangeable tip screwdriver.

4.2 DIE SET POSITION CRADLE ADJUSTMENT, CENTERING

PUNCHED HOLES

The die set position cradle is set in the factory; however, because of the punched-

hole spacing on the PB die sets, there is a minimal amount of paper on each edge of

the punched paper. The die set position cradle may have to be fine adjusted to

center the punched-hole pattern in the paper.

Listed below are the step-by-step instructions to adjust the die set to the proper

position:

• The punched-hole alignment must be checked on a piece of punched paper. Fold

the punched sheet of paper in half and the punched-holes should be aligned. If the

punched-holes are not aligned, then the die set cradle must be adjusted to align

the punched holes.

NOTE: The paper path is always constant, if the holes are not centered; you

must adjust the die set cradle.

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PUNCHED HOLE ALIGNMENT CHECKING

• The back cover on the Professional Puncher-A1 must be removed to access the

die set position cradle.

CRADLE

• Before adjusting the die set position cradle, you must first note what direction the

die set cradle must move.

• Before you adjust the die set position cradle, you must loosen the lock-down

screw.

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PRESS HERE

TO TILT

ADJUSTMENT

SCREW

LOCK-DOWN

SCREW

LOOSEN

SCREW

• Observe the punched paper; if the punched-holes are too close to the rear of the

machine, then you must turn the adjustment screw counter-clockwise.

TURN COUNTER-

CLOCKWISE

• If the punched-holes are too close to the front of the machine, then you must turn

the adjustment screw clockwise.

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TURN

CLOCKWISE

• Using a flat-head screwdriver, turn the adjustment screw clockwise or counter-

clockwise to move the die set position cradle.

NOTE: Seven full turns of the adjustment screw result in a ¼” change in the

punched hole position.

• Before tightening the lock-down screw, tilt or bias the assembly towards the

bottom of the machine and tighten the lock-down screw. This will ensure positive

engagement between the locking lever and the die set.

TIGHTEN

SCREW

TILT TO BOTTOM

OF M/C

• Run a test sample of punched paper and recheck paper alignment. Re-adjust if

necessary.

4.3 REMOVAL OF PUNCH MODULE

1. Examine the Drive Belts. Note the consistency in tightness of the belts. They

should all have approximately ¼” of deflection; remove the four drive belts items

1, 2, 3, 4.

Disconnect the Sensor Wire Connection

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2. Remove 4 screws in front and 2 in back

3. Cut any wire ties that may prevent freedom of movement to slide the Punch

Module (A) outward

4. Remove the Back Gauge Assembly (B).

5. Remove the black Knob (C) at the front (customer side) of the Punch Module

Drive Shaft.

FRONT SIDE

6. Slide the Punch Module unit part way out to reach and unplug the Punch Sensor

Harness (Red, Black, White wires)

7. Slide the entire Punch Assembly (C) out and lay it beside the Professional

Puncher-A1. Take care not to damage wires or Rollers as you do so.

8. Lubricate the Drive Cams sparingly of the punch module using a multi-purpose,

extreme pressure lubricant, preferably formulated with Teflon.

Note: This lubrication is not required during the normal life but is reasonable to do

this of the module every needs service.

9. To replace any component of the punch Module, disassemble components as

required

4.4 GREEN BELT REPLACEMENT, ALIGNER PANEL REMOVAL,

EXPLANATION

The following procedure explains how to remove the Entrance Side Aligner Panel

and the Exit Side Aligner Panel.

The basic intent of this procedure is to access and replace the Green Aligner Belts,

but once you know how to follow this procedure you are now able to access other

components as well.

SYMPTOM

Paper will stop moving through the Punch paper path.

CAUSE

One or both of the Green Aligner Belts have broken. If this break occurs, it would

usually occur at the Weld Splice.

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PROCEDURE TO REPLACE ALIGNER BELTS

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

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

4.5 GREEN BELT REPLACEMENT, PAPER ENTRANCE 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,

P/N FC3-3633-0000

It will help you to reference your Professional Puncher-A1 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

NOTE: During assembly, be sure not to over tighten any of the mounting

screws.

Step 1:

Disconnect the Professional Puncher-A1 from Power. Retain the power

cord in your possession for your safety.

Step 2:

Step 3:

Disconnect the Communication Cable to the Finisher.

Unlatch the CANON Professional Puncher-A1 from both the Finisher and

the Printer.

NOTE: You must first remove the screw that secures the latch in place

(if so equipped).

Step 4:

Step 5:

Open the Front Door (A) of the Professional Puncher-A1.

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

Step 6:

To remove the Rear Cabinet/Cover (C) of the Professional Puncher-A1,

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 Professional Puncher-A1.

NOTE: You do not need to lift upward and you do not need to remove the Top

Cover.

Step 7:

Step 8:

Step 9:

Disconnect the Entrance Sensor Wire from the Side Frame.

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

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.

FRONT DOOR

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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

Professional Puncher-A1.

C. Remove the Fan (H) that prevents access to the Flexible Cable. To

remove it 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.

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.

E. Remove the “2” screws that secure this Assembly from the Side

Frame.

F. 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

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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

Step 16: Slide the Aligner into place, loosely attach the “4” Pan Head Screws with

the “4” Lock Washers.

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.

NOTE: 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 or parallel, and just floating above

the surface of the sheet metal.

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Step 17:

To install the Paper Guide Assembly into the Professional Puncher-A1.

1. 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

Professional Puncher-A1 properly.

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

that the Sensor Harness is properly connected.

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

4. Loosely install the “2” top screws.

5. 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.

SENSOR

FLEXIBLE

SHAFT

ALIGN & FIX

SCREWS

Step 18:

Step 19:

Install the Flexible Shaft (item 5).

Install the curved sheet metal Exit Paper Guide (item 7) with Idler Roller

“4” Screws.

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

Step 20: Connect the Sensor Wire Harness at the top rear of the Exit Paper

Guide.

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Step 21: Install the J2 Shaft back into place by inserting it first into the front, then

the back.

INSTAL J2 SHAFT

Step 22:

Close the J2 Flipper Latch.

Repeat the test of rotating the pulleys to ensure smooth rotation of the

Idler Rollers.

Step 23:

Step 24:

Attach the J2 Shaft Spring. Install the front E-Ring to secure J2.

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

Professional Puncher-A1 and see the Idler Rollers rotate smoothly.

Step 25:

Step 26:

Attach the Docking Plate using “4” Screws.

Attach the Back Rear Cover using the 7 screws (2 for the Entrance and

5 for the Exit side).

Test the Professional Puncher-A1 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.

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AFTER ASSEMBLY

4.6 GREEN BELT REPLACEMENT, PAPER EXIT SIDE

The following step-by-step directions inform you how to remove and then assembly

the components necessary to access the Paper Exit Side Aligner Green Belt,

P/N FC3-3633-0000

It will help you to reference your Professional Puncher-A1 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.

• Nut Driver

• 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

NOTE: During assembly, be sure not to over tighten any of the mounting

screws.

Step 1:

Disconnect the Professional Puncher-A1 from Power. Retain the power

cord in your possession for your safety.

Step 2:

Step 3:

Disconnect the Communication Cable to the Finisher.

Unlatch the CANON Professional Puncher-A1 from both the Finisher and

the Printer.

NOTE: You must first remove the screw that secures the latch in place

(if so equipped).

Step 4:

Open the front door (A) of the Professional Puncher-A1.

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BINDER SIDE

Step 5:

To remove the Rear Cabinet/Cover (B) of the Professional Puncher-A1,

1. Remove the 5 screws on Exit side and 2 screws on Entrance side.

2. Slide the Rear Sheet Metal Cabinet/Cover off of the Professional Puncher-A1.

NOTE: You do not need to lift upward and you do not need to remove

the Top Cover.

Step 6:

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

A. Remove only one (the one closest to the frame) of the “E” Rings of

the J2 Flipper on the right end (front Door side).

B. Push the J2 Flipper in toward the front Door until it clears the rear

frame.

C. Pull the entire J2 Flipper, Door Latch out and set it aside.

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Step 7:

Unhook spring from the Docking Plate (D) and Door. Remove the “4”

screws that secure the Docking Bracket. Remove, and set aside.

PAPER ENTERANCE

FRONT DOOR

SIDE

PAPER EXIT

SIDE

Step 8:

To remove the Rear Aligner, Idler Paper Guide Assembly

A. Remove “2” E-Rings from the Pivot Shaft.

B. Slide the Shaft all the way out through the front of the Professional

Puncher-A1.

C. Remove the “2” Nylon Bearings.

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.

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Step 10: To remove the Rear, Drive Side, and Paper Guide Aligner Assembly.

This is the large Sheet Metal Assembly within the Professional Puncher-

A1 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.

NOTE: The Helical coupling is very delicate, be gentle.

NOTE: 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.

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, Paper Guide Aligner Assembly. Hold a straight edge

like a 12”metal ruler across the surface of the sheet metal face and the

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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.

Assembly Process

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.

Step 14: Slide the Aligner into place, loosely attach the “4” Pan Head Screws with

the “4” Lock Washers.

ROTATE

STRETCH

BELT