Cisco 2654T6 User manual

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Cisco XR 12416 and Cisco XR 12816 Router Chassis Installation Guide
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APPENDIX
A
Repackaging the Router
Revised: March 16, 2009, OL-17440-01
Introduction
This appendix describes two separate but related router repackaging tasks:
•How to remove the router from the equipment rack and repackage the router
for shipment if it becomes necessary to transport it to another location or
return it to Cisco Systems.
•How to repackage a defective chassis to return it to the factory.
Where appropriate, you are referred to specific procedures in Chapter 3,
“Installing the Router,”and Chapter 5, “Maintaining the Router.”
This appendix contains the following sections:
•Repackaging the Routers, page A-1
•Repackaging the Replaced Router Chassis, page A-24
Repackaging the Routers
This section describes how to remove the entire router system from the equipment
rack and repackage the router should it become necessary to transport it to another
location or return it to Cisco Systems.

Appendix A Repackaging the Router
Repackaging the Routers
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This section contains the following information and procedures:
•The Router Shipping Package, page A-2
•Tools and Equipment, page A-6
•Safety Recommendations, page A-6
•Removing the Router from the Rack, page A-7
•Installing the Router on the Shipping Pallet, page A-16
•Completing the Repackaging, page A-23
Note You must use the original shipping package supplied by Cisco when repackaging
the router. If you do not have the original system package, contact your
Cisco service representative for assistance.
The Router Shipping Package
Figure A-1 shows the router in an exploded view of the parts making up the
shipping package components.
Because of the weight and height of the router, the router shipping pallet
incorporates a scissor-jack platform. This scissor-jack platform enables a team of
two installers to remove a fully-loaded router from the pallet and insert it into an
equipment rack, or extract a fully loaded router from a rack, without removing any
of the components from the router chassis.
The router should be bagged to protect it against dust and electrostatic discharge
(ESD) and secured to the scissor-jack platform by four anchor clips. The anchor
clips are inserted into slots along the bottom edges of the router chassis side
panels and secured to the scissor-jack platform by four bolts. In turn, the
scissor-jack platform is secured to the shipping pallet by eight hold-down brackets
that are bolted to the top of the shipping pallet.
The shipping pallet consists of a U-shaped wood and foam pallet body and a wood
and foam pallet front bar. The pallet front bar fastens to the open end of the pallet
body to create the fourth bearing surface for the scissor-jack platform and to
complete the base needed to support the walls of the shipping container.

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Appendix A Repackaging the Router
Repackaging the Routers
When the router and scissor-jack platform are installed on the pallet, the router
and scissor-jack platform are suspended over the well formed by the pallet body
and pallet front bar. When the scissor-jack platform is expanded to lower the
platform base and support the weight of the router, the bolts securing the
hold-down brackets to the top of the pallet can be removed. After the brackets
have been detached from the pallet, the router and scissor-jack platform can be
separated from the pallet by removing the pallet front bar from the pallet body and
pulling the pallet body away from the scissor-jack platform.
The side walls of the shipping container are formed by two U-shaped, interlocking
corrugated panels. The panels overlap to form the narrow ends of the container
and are locked together by twelve plastic locking clips inserted into holes in the
corrugated panels. Two foam inserts fit around the top of the router to act as a
protective cushion and add rigidity to the packaging scheme by serving as a fixed
buffer between the router, the corrugated side walls of the shipping container, and
the corrugated top cap that holds the side walls in place. With the corrugated top
cap installed, the entire shipping package is double-strapped end-to-end and
side-to-side to secure the shipping container and its contents to the pallet.

Appendix A Repackaging the Router
Repackaging the Routers
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Figure A-1 Router Shipping Package Components
29660
Top cap
U-shaped panel
Foam cap
PalletAccessories package
OPEN

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Appendix A Repackaging the Router
Repackaging the Routers
The accessories for the router ship in five boxes that are assembled into a package.
(See Figure A-2.) The accessories package is packed against the back panel of the
router on the extended deck of the pallet body.
Figure A-2 Router Accessories Package
29661
Bottom cap
Top cap
Center-mount
rack-mounting
brackets
Rack-mounting
platform
Corrugated
spacer
Cable
trough
Cable
trough
Accessory box
Foam

Appendix A Repackaging the Router
Repackaging the Routers
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Tools and Equipment
You need the following items to remove the router from the equipment rack and
repackage it for shipping:
•ESD-preventive wrist strap
•Flat-blade screwdrivers
•Number 1 and number 2 Phillips screwdrivers
•3/8-inch (10-mm) nutdriver (for systems equipped with the DC-input power
shelf)
•9/16-inch (14-mm wrench) wrench
•3/4-inch (19-mm) socket and ratchet wrench
•Safety hand truck with retractable safety leg wheels and security strap, such
as the Stevens Appliance Truck Company “Escort,” Model STEV SRT-M-66
(distributed by McMaster-Carr as Model 2654T6), or an equivalent safety
hand truck.
•Antistatic sacks or other ESD-preventive storage environment
•The original router shipping package supplied by Cisco. If you do not have
the original router shipping package, contact your Cisco service
representative for assistance.
Safety Recommendations
Before you begin the procedures in this appendix, review the following safety
information:
•The safety recommendations listed in the“Safety Recommendations” section
on page 2-2 in Chapter 2, “Preparing for Installation.”
•The safety warnings listed in the publication Regulatory Compliance and
Safety Information for the Cisco 12000 Series Internet Router that
accompanied your router

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Appendix A Repackaging the Router
Repackaging the Routers
Removing the Router from the Rack
This section describes how to remove the router from the equipment rack.
A fully-equipped router can weigh as much as 415 lb (188 kg). Because of the
weight and height of the router, Cisco provides a rack-mounting system for the
router that enables a team of two installers to extract a fully-loaded router from a
rack without removing any of the components from the router chassis. For
information on the router rack-mounting system, refer to “A fully equipped router
with an optional two-level AC-input power shelf can weigh as much as
440 pounds (200 kg). The router ships on a scissor-jack platform that enables two
people to install a fully loaded router into a rack without removing any of the
components from the chassis.” section on page 3-2.
Note As an option, you can elect to remove some of the components from the chassis
to reduce the top-end weight of the chassis and lower the center of gravity, making
the chassis more stable as you move it. The procedures for removing components
are described in the “Unpacking and Positioning the Router” section on page 3-3.
Procedures in the following sections describe the steps for removing the chassis
from the equipment rack:
•Powering Down the Router, page A-7
•Removing the Front Covers, page A-8
•Disconnecting RP Cables, page A-8
•Disconnecting Alarm Card Cables, page A-8
•Disconnecting Power Cables from the Power Shelf, page A-8
•Removing Components from the Chassis to Reduce Weight, page A-9
•Detaching the Supplemental Bonding and Grounding Connection, page A-10
•Removing the Router from the Equipment Rack, page A-11
Powering Down the Router
Power down the router as instructed in the “Powering Down the Router” section
on page 5-2.

Appendix A Repackaging the Router
Repackaging the Routers
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Removing the Front Covers
Remove all of the front covers from the chassis as instructed in the “Removing the
Chassis Front Covers” section on page 3-7. You will install them on the chassis
after it has been secured on the shipping pallet?
Disconnecting RP Cables
You must disconnect any cables that are connected to the RP console port,
auxiliary port, or either of the Ethernet ports, RJ-45 or MII. Identify each of the
RP cable connections and write them down on a piece of paper before you
disconnect the cables. After disconnecting the cables, remove them from the
chassis and place them safely aside.
Refer to the following descriptions in Chapter 2, “Preparing for Installation.” for
information on RP cables:
•GRP Console and Auxiliary Port Connection Guidelines, page 2-24
•PRP Console and Auxiliary Port Connection Guidelines, page 2-27
•GRP Ethernet Connection Equipment, page 2-29
•PRP Ethernet Connection Equipment, page 2-36
Disconnecting Alarm Card Cables
You must disconnect any cable that is connected to the external alarm port on
either or both of the alarm cards. Identify the alarm cable connections and write
them down on a piece of paper before you disconnect the cables. After
disconnecting the cables, remove them from the chassis and place them safely
aside.
For information on alarm card cables, refer to the “Alarm Card Connection
Guidelines” section on page 2-33.
Disconnecting Power Cables from the Power Shelf
If your router is equipped with either the standard or optional AC-input power
shelf, disconnect the AC-input power cords from their receptacles on the back
panel of the power shelf as instructed in the “Removing and Installing the
Standard One-Level AC-Input Power Shelf” section on page 5-32.

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Appendix A Repackaging the Router
Repackaging the Routers
If your router is equipped with the DC-input power shelf, disconnect the eight
source DC positive and negative power cables and the single ground cable from
the terminal studs on the back panel of the power shelf as instructed in the
“Removing and Installing a DC-Input Power Shelf” section on page 5-54.
Removing Components from the Chassis to Reduce Weight
A fully-equipped router can weigh as much as 415 lb (188 kg). To reduce the
top-end weight of the chassis and lower the center of gravity, which might make
the chassis more stable as you move it, you may choose to remove some of the
components from the chassis.
Procedures in the following sections describe the steps for removing some of the
router components:
•Removing Power Modules, page A-9
•Removing the Blower Modules, page A-10
•Removing the Cards from the Chassis Card Cages, page A-10
Removing Power Modules
Each AC-input power supply weighs 12.7 lb (5.7 kg). By electing to remove the
three power supplies from the standard AC-input power shelf, you reduce the
top-end weight of the chassis by approximately 38.1 lb (17.1 kg). By electing to
remove the four power supplies from the optional AC-input power shelf, you
reduce the top-end weight of the chassis by approximately 50.8 lb (22.8kg)
Remove the AC-input power supplies as described in the “Installing AC-Input
Power Supplies” section on page 3-75.
Each DC-input power entry module weighs 6.4 lb (2.9 kg). By electing to remove
the four power entry modules from the power shelf, you reduce the top-end weight
of the chassis by approximately 25.6 lb (11.6 kg). Remove the DC-input power
entry modules as described in the“Removing DC-Input PEMs” section on
page 3-12.

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Repackaging the Routers
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Removing the Blower Modules
The blower module weighs 20.5 lb (9.3 kg). By removing the upper blower
module from the chassis, you reduce the top-end weight of the chassis by the
weight of the blower module. Unless you plan to strip all components to reduce
the overall weight of the chassis so you can shift the chassis by lifting it manually,
there is no advantage in removing the lower blower module. Remove the blower
modules as described in the “Removing the Blower Modules” section on
page 3-14.
Removing the Cards from the Chassis Card Cages
Unless you plan to strip all components to reduce the overall weight of the chassis
so you can shift the chassis by lifting it manually, there is no advantage in
removing the cards from the card cages. Reducing the overall weight of the
chassis is offset by the requirement to store the cards in an ESD-preventive and
dust proof (for fiber-optic cards) environment.
If you elect to remove the cards from the chassis card cages, remove the cards as
described in Chapter 3, “Installing the Router.”
•Removing the Cards from the Upper Card Cage, page 3-18,
•Removing the Cards from the Lower Card Cage, page 3-20,
•Removing the Cards from the Switch Fabric Card Cage, page 3-22
Detaching the Supplemental Bonding and Grounding Connection
If your router has one or more bonding and grounding cables attached to any of
the bonding and grounding receptacles on the chassis, you must detach these cable
lugs from the chassis before you remove the chassis from the equipment rack.
Detach the bonding and grounding cable lugs from the chassis as instructed in the
“Detaching the Supplemental Bonding and Grounding Connection” section on
page 5-104.