Cisco 12010 series User manual

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Maintaining the Router
Your router is equipped as ordered and is ready for installation and startup when
it is shipped. As your networking requirements change, you may need to upgrade
the system by adding or changing components. This chapter describes how to
maintain router components.
Procedures for maintaining the router are described in the following sections:
•Powering Off the Router, page 7-2
•Removing and Installing the Front Covers and Bezel Extenders on Original
Cisco 12010 Series Routers, page 7-3
•Removing and Installing the Front Door on Cisco 12010 Enhanced Series
Router, page 7-11
•Cleaning or Replacing the Chassis Air Filter, page 7-16
•Cleaning or Replacing the Chassis Air Filter, page 7-16
•Removing and Replacing the Blower Module, page 7-23
•Removing and Replacing AC and DC Power Subsystem Components,
page 7-27
•Removing and Replacing Cards from the Chassis, page 7-61
•Upgrading the Switch Fabric in the Cisco 12410 Router, page 7-67
•Removing and Installing a Chassis, page 7-69

Chapter 7 Maintaining the Router
Powering Off the Router
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Prerequisites and Preparation
Before you perform any of the procedures in this chapter, be sure that you:
•Review the “Safety Guidelines” section on page 2-2.
•Read the safety and ESD-prevention guidelines described in the “Compliance
and Safety Information” section on page 2-3.
•Ensure that you have all of the necessary tools and equipment before
beginning the procedure.
•Have access to the following documents during the installation:
– Regulatory Compliance and Safety Information for Cisco 12000 Series
Routers publication that shipped with the router (PN 78-4347-xx)
Powering Off the Router
Most Cisco 12010, Cisco 12410, and Cisco 12810 series routers field-replaceable
units (FRUs) can be removed and replaced with the power on and the system
operating. This is known as online insertion and removal (OIR). Power supplies,
line cards, the RP, CSCs, SFCs, and alarm cards all support OIR. Unless otherwise
noted, the maintenance tasks described in this chapter can be performed while the
router remains powered on.
In some cases it may be necessary to power off the router, for example, to upgrade
both power supplies and PDUs. Use the following procedure to power off the
router.
Step 1 Set the power switch on each power supply to the off (0) position.
Step 2 Power off all circuit breakers for the source power lines connected to the power
supplies.
Step 3 Verify that the Pwr OK indicator on each power supply is off.
Step 4 Verify that the OK indicator on the blower module is off.

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Chapter 7 Maintaining the Router
Removing and Installing the Front Covers and Bezel Extenders on Original Cisco 12010 Series Routers
Removing and Installing the Front Covers and Bezel
Extenders on Original Cisco 12010 Series Routers
The front covers are fastened to the chassis by ball studs that insert into clips on
the front of the chassis. The front covers are referred to as snap-on front covers.
The partial front cover on the air filter door is fastened to the air filter door by four
screws inserted from the back side of the air filter door. This partial front cover is
referred to as the air filter door front cover.
Note Recently released routers have bezel extenders installed on the front cover (bezel)
for the line card and route processor (RP) card cage to bring the cover out an
additional 2 inches (50.8 mm) to allow more room for cables. If your chassis does
not have these extenders and you want to purchase them, contact Cisco sales. (See
the “Attaching Bezel Extenders to the Front Cover” section on page 7-6 if you are
installing the bezel extenders.)
Removing the Front Covers
The front covers are held in place by ball studs that snap into clips on the chassis.
Refer to Figure 7-1 and use the following procedure to remove the snap-on front
covers.
Step 1 Grasp the outside edges of the blower module front cover and pull it straight out
to detach the front cover from the chassis.
Step 2 Repeat Step 1 for the RP and line card cage front cover.

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Installing the Front Covers
Refer to Figure 7-1 and use the following procedure to install the front covers.
Step 1 Hold the front cover by its outside edges and align the ball studs with the ball stud
clips on the front of the chassis.
Step 2 Push the front cover into the ball stud clips and the front cover is flush with the
front of the chassis.
Step 3 Repeat Step 1 and Step 2 for the remaining front cover.

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Chapter 7 Maintaining the Router
Removing and Installing the Front Covers and Bezel Extenders on Original Cisco 12010 Series Routers
Figure 7-1 Removing and Installing the Front Covers

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Attaching Bezel Extenders to the Front Cover
Use the following procedure to attach the bezel extenders to the card cage front
cover.
Step 1 Remove the line card and RP card cage front cover from the chassis as described
in the “Removing the Front Covers” section on page 7-3.
Step 2 Remove the four ball studs from the front cover (Figure 7-2, item 3).
Step 3 Screw the four ball studs into the threaded holes on the bezel extenders (two ball
studs for each bezel extender) using a wrench to secure them.
Caution Do not overtighten the ball studs. Overtightening the ball studs could damage the
threaded hole on the bezel extender.
Step 4 Attach the bezel extenders to the front cover:
a. Facing the inside of the front cover, align the screw holes in the left side bezel
extender with the mounting screw holes in the front cover (Figure 7-2,
item 4).
Note If you cannot align both screw holes on the front cover inserts, you have
the incorrect bezel extender. Try the other bezel extender on this side.
b. Fasten the bezel extender to the front cover with the mounting screws
(Figure 7-2, item 2).
Caution Do not overtighten the screws. Overtightening the screws could damage the
threaded holes in the front cover.
c. Repeat Steps aand bto fasten the right side bezel extender to the other side
of the front cover (Figure 7-2, item 5).

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Chapter 7 Maintaining the Router
Removing and Installing the Front Covers and Bezel Extenders on Original Cisco 12010 Series Routers
Figure 7-2 Attaching the Bezel Extenders to the Front Cover
1Line card and RP card cage front cover (bezel) 4Left side bezel extender
2Mounting screws 5Right side bezel extender
3Ball studs ––

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Step 5 Hold the front cover by its outside edges and align the ball studs with the ball stud
clips on the front of the chassis (Figure 7-3).
Figure 7-3 Attaching the Front Cover Using Bezel Extenders
Step 6 Push the front cover into the ball stud clips so that the front cover is flush with the
front of the chassis.

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Chapter 7 Maintaining the Router
Removing and Installing the Front Covers and Bezel Extenders on Original Cisco 12010 Series Routers
Removing and Replacing the Air Filter Door Front Cover
Use the following procedure to remove and replace the air filter door front cover.
Step 1 Loosen the captive screws on each side of the air filter door and swing the door
away from the switch fabric and alarm card cage.
Figure 7-4 Opening the Air Filter Door
Caution Be especially careful not to damage the honeycomb screen on the back of the air
filter door and on the inside of the switch fabric and alarm card cage. Damaging
the honeycomb screen can restrict the air flow and cause overheating and diminish
EMI protection.

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Step 2 Remove the (4) screws from each corner that fasten the partial front cover to the
air filter door (Figure 7-5).
•Set aside the screws; you will need them to install the replacement front
cover.
Figure 7-5 Removing the Air Filter Door Front Cover
Step 3 Hold the replacement front cover by its outside edges and align the screw holes in
the front cover with the holes on the air filter door.
Step 4 Secure the front cover to the air filter door using the (4) screws that you removed
in Step 2.
Caution Do not overtighten the screws. Overtightening the screws can damage the
threaded holes in the air filter door.
Step 5 Close the air filter door and tighten the captive screws.
Caution Align and seat the door carefully to avoid damaging the EMI-preventive gaskets
on the door. The air filter door must be closed and secured at all times to maintain
correct EMI performance.

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Chapter 7 Maintaining the Router
Removing and Installing the Front Door on Cisco 12010 Enhanced Series Router
Removing and Installing the Front Door on
Cisco 12010 Enhanced Series Router
The Cisco 12010 enhanced series routers have a new 1–piece front door. The
router ships with the door hinge mounted on the left side of the chassis so that it
opens from right-to-left. This section describes how to change the front door to
open from left-to-right by installing the hinge on the opposite side.
Use the following procedure to change the location of the hinge.

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Removing and Installing the Front Door on Cisco 12010 Enhanced Series Router
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Step 1 Open the front door by pressing the right latch button (Figure 7-6).
Figure 7-6 Opening the Front Door
1Front Door Latch

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Chapter 7 Maintaining the Router
Removing and Installing the Front Door on Cisco 12010 Enhanced Series Router
Step 2 Remove the front door by lifting the (top and bottom) hinge pins to free the door
from the chassis (Figure 7-7).
Caution Make sure you are holding the front door securely so it does not drop when you
release it from the chassis.
Step 3 Reinstall the hinge pins into the chassis hinge brackets.

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Removing and Installing the Front Door on Cisco 12010 Enhanced Series Router
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Figure 7-7 Removing or Installing Hinge Pins

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Chapter 7 Maintaining the Router
Removing and Installing the Front Door on Cisco 12010 Enhanced Series Router
Step 4 Remove the bumpers and pivot blocks from the door as shown in Figure 7-8.
Figure 7-8 Removing the Bumpers and Pivot Blocks
1Bumpers 2Pivot blocks

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Cleaning or Replacing the Chassis Air Filter
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Step 5 Reinstall the hardware to the opposite sides of the front door:
a. Mount pivot blocks to the left side and tighten the screws until snug.
b. Mount the bumpers to the right side and tighten the screws until snug.
Step 6 Attach the front door to the chassis:
a. Remove the hinge pins from the hinges on the right side of the chassis.
b. Align the pivot blocks on the front door with the hinges on the right side of
the chassis and install the hinge pins to hold the door in place (see
Figure 7-7).
c. Close the front door by pressing the latch button allowing the door latch to
engage with the hinge pins on the chassis.
Cleaning or Replacing the Chassis Air Filter
The Cisco 12010, Cisco 12410, and Cisco 12810 series routers are equipped with
a user-serviceable air filter that prevents dust from being drawn into the router.
One time per month (or more often in dusty environments), examine the air filter
for damage and cleanliness.
Caution Damage to the air filter can restrict the airflow, cause overheating in the router,
and degrade EMI performance. Be careful when cleaning and replacing the filter.
The following procedures describe how to replace the air filter on original series
routers and enhanced series routers.
•Cleaning or Replacing an Original Series Chassis Air Filter, page 7-17
•Cleaning or Replacing an Enhanced Series Chassis Air Filter, page 7-20

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Chapter 7 Maintaining the Router
Cleaning or Replacing the Chassis Air Filter
Cleaning or Replacing an Original Series Chassis Air Filter
Use the following procedure to clean or replace an original series air filter.
Step 1 Loosen the captive screw on each side of the air filter door and pivot open the door
(Figure 7-9).
Figure 7-9 Opening the Chassis Air Filter Door

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Step 2 Remove the air filter by pushing it up and out of the door (Figure 7-10).
Caution Be careful not to damage the honeycomb screens on the back of the air filter door
and in the fabric card cage. Damage to the honeycomb screens can restrict airflow,
cause overheating, and affect EMI performance.
Note Your air filter may have small tabs located on the top of the filter that you
can use to pull the air filter out of the door.
Figure 7-10 Removing the Chassis Air Filter

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Chapter 7 Maintaining the Router
Cleaning or Replacing the Chassis Air Filter
Step 3 Visually check the condition of the air filter to determine whether to clean it or
install a new replacement filter:
•Dirty—You can either vacuum or replace the filter.
Caution Do not vacuum the air filter while it is installed in the chassis. Before you clean
it, you must remove the air filter completely to prevent contaminants from being
drawn into the router.
•Worn or torn—If the filter appears worn or torn, dispose of it in a responsible
manner and install a new replacement (ACS-GSR10-FLTR=).
Step 4 Slide the new or cleaned air filter into the air filter door.
•The metal braces on the back of the air filter should face toward the switch
fabric and alarm card cage.
Step 5 Close the air filter door and tighten the captive screws.
Caution Align and seat the door carefully to avoid damaging the EMI-preventive gaskets
on the door. The air filter door must be closed and secured at all times to maintain
correct EMI performance.

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Cleaning or Replacing an Enhanced Series Chassis Air Filter
Use the following procedure to clean or replace the enhanced series air filter.
Step 1 Loosen the captive screw on each side of the air filter door and pivot the door open
(Figure 7-11).
Figure 7-11 Opening the Chassis Air Filter Door