Cisco 4000-M series Parts list manual

1
Doc. No.
Cisco Systems, Inc.
All rights reserved.
170 West Tasman Drive
San Jose, CA 95134-1706
USA
Cisco Systems, Inc.
Corporate Headquarters
Copyright © 1996
Replacing the Cisco 4000 Series Power Supply
Cisco Product Number: PWR-4X00-AC=, PWR-4X00-DC=
This document contains instructions for replacing AC and DC power supplies in Cisco 4000 series
routers.
This document is for the power supply installer, who should be familiar with electronic circuitry and
wiring practices and have experience as an electronic or electromechanical technician.
If you have a Cisco 4000-M, Cisco 4500-M, or Cisco 4700-M router, use this document with
the Cisco 4000 Series Installation Guide and the Cisco 4000 Series Public Network Certification
document that shipped with your router. If you have a Cisco 4000 router, refer to the Cisco 4000
Hardware Installation and Maintenance publication. If you have a Cisco 4500 or Cisco 4700 router,
refer to the Cisco 4000 Series Hardware Installation and Maintenance publication.
This document contains the following sections, including step-by-step procedures for replacing a
Cisco 4000 series power supply:
•Overview of the Cisco 4000 Series Power Supplies
•Safety Recommendations
•Safety with Electricity
•Tools and Equipment Required
•Accessing the Power Supply
•Removing AC and DC Power Supplies
•Replacing AC and DC Power Supplies
•Replacing the Component Tray
•Replacing Connections to the Router
78-3504-01

2Replacing the Cisco 4000 Series Power Supply
•Troubleshooting the Power Supply Installation
•Cisco Connection Online
Warning Before working on a chassis or working near power supplies, unplug the power cord on
AC units; disconnect the power at the circuit breaker on DC units.
Note Translations for all safety warnings included in this document are in the appendix “Translated
Safety Warnings” in the Cisco 4000 Series Installation Guide.
Caution To avoid damaging ESD-sensitive components, discharge all static electricity from your
body before opening the chassis. Before performing procedures described in this document, review
the sections “Safety Recommendations,” “Safety with Electricity,” and “Tools and Equipment
Required.”
Note The following warnings are applicable if single-mode FDDI, single-mode OC3 ATM, or BRI
network processor modules are installed in a Cisco 4000 series router.
Warning Invisible laser radiation may be emitted from the aperture ports of the single-mode FDDI
card when no cable is connected. Avoid exposure and do not stare into open apertures. Following is
an example of the warning label that appears on the product:
Warning The ports labeled “Ethernet,” “10BaseT,” “Token Ring,” “Console,” and “AUX” are
safety extra-low voltage (SELV) circuits. SELV circuits should only be connected to other SELV
circuits. Because the BRI circuits are treated like telephone-network voltage, avoid connecting the
SELV circuit to the telephone network voltage (TNV) circuits.
Warning The ISDN connection is a source of voltage that should be inaccessible to user contact.
Do not attempt to tamper with or open any public telephone operator (PTO)-provided equipment or
connection hardware. Any hardwired connection (other than by nonremovable,
connect-one-time-only lug) must be made only by PTO staff or suitably trained engineers.
AVOID EXPOSURE–Invisible Laser rad-
iation is emitted from transmit ports.
1300 NM
CLASS 1 LASER PRODUCT
WARNING
H3159

Replacing the Cisco 4000 Series Power Supply 3
Overview of the Cisco 4000 Series Power Supplies
Warning Do not work on the system or connect or disconnect cables during periods of lightning
activity.
Warning Network hazardous voltages are present in the BRI cable. If you detach the BRI cable,
detach the end away from the router first to avoid possible electric shock. Network hazardous
voltages also are present on the system card in the area of the BRI port (RJ-45 connector), regardless
of when power is turned off.
Overview of the Cisco 4000 Series Power Supplies
Figure 1 illustrates the AC and DC power supplies.Figure 2 shows an AC power supply mounted in
a Cisco 4000 series router. Table 1 contains the AC power supply specifications and Table 2 contains
the DC power supply specifications.
Figure 1 Cisco 4000 Series AC and DC Power Supplies
Figure 2 Rear View of Cisco 4000 Series Router Showing Power Supply Location
H7252
AC power supply DC power supply
Serial 
module
H4596
10BASE-T
TX
RX
AUI
LNK
POL
TX
RX
AUI
LNK
POL
ETHERNET AUI
PORT-0
PORT-1
PORT-3 PORT-2 PORT-1 PORT-0
7 6 5 4 32 1 0
ISDN
BRI
PORT-7 PORT-6 PORT-5 PORT-4
Slot 3 10BaseT
ports AUI
ports Slot 2
Chassis
release screw
Ethernet module
Four port 
BRI 
module Auxiliary port Console port
BRI ports
Serial interface ports
Slot 1
Power
On/off switch
LEDs
P-3
P-1
P-2
P-0
P-3 P-2 P-1` P-0
LP
CN
TD
TC
RD
RC
LP
CN
TD
TC
RD
RC
LP
CN
TD
TC
RD
RC
LP
CN
TD
TC
RD
RC

4Replacing the Cisco 4000 Series Power Supply
Safety Recommendations
Table 1 Cisco 4000 Series AC Power Supply Specifications
Table 2 Cisco 4000 Series DC Power Supply Specifications
Safety Recommendations
Follow these guidelines to ensure general safety:
•Keep the chassis area clear and dust-free during and after installation.
•Place the removed chassis cover in a safe place.
•Keep tools away from walk areas where you or others could fall over them.
•Do not wear loose clothing that may get caught in the chassis. Fasten your tie or scarf and roll up
your sleeves.
•Wear safety glasses when working under conditions that may be hazardous to your eyes.
•Do not perform any action that creates a potential hazard to people or makes the equipment
unsafe.
Safety with Electricity
Warning Beforeworkingon equipment thatisconnected to powerlines, removejewelry(including
rings, necklaces, and watches). Metal objects will heat up when connected to power and ground.
This can cause serious burns or even result in welding to the terminals.
Follow these guidelines when working on equipment powered by electricity:
•Locate the room’s emergency power-off switch. Then, if an electrical accident occurs, you can
quickly shut the power OFF.
•Before working on the system, turn OFF the power and unplug the power cord.
•Disconnect all power before doing the following:
—Working on or near power supplies
1. The AC power supply autoselects either 110 or 220 VAC operation.
1. AWG = American Wire Gauge
Description Specification
Input voltage 100 to 240 VAC1
Frequency 50 to 60 Hz
Current Rating 3.0 A maximum at 100 VAC, 1.5 A maximum at 240 VAC
Description Specification
Input voltage 40 to 72 VDC
Current Rating 5.0 A maximum at 40 VDC, 2.8 A maximum at 72 VDC
Wire gauge for DC-input
power connections 14 AWG1

Replacing the Cisco 4000 Series Power Supply 5
Tools and Equipment Required
—Installing or removing a router chassis or network processor module
—Performing a hardware upgrade
•Do not work alone if potentially hazardous conditions exist.
•Look carefully for possible hazards in your work area, such as moist floors, ungrounded power
extension cables, and missing safety grounds.
•Never assume that power is disconnected from a circuit. Always check.
•If an electrical accident occurs, proceed as follows:
—Use caution, and do not become a victim yourself.
—Turn off power to the system.
—If possible, send another person to get medical aid. Otherwise, determine the condition of the
victim and then call for help.
—Determine if the person needs rescue breathing or external cardiac compressions; then take
appropriate action.
Preventing Electrostatic Discharge Damage
Electrostatic discharge (ESD) can damage equipment and impair electrical circuitry. It occurs when
electronic printed circuit cards are improperly handled and can result in complete or intermittent
failures.
Always follow ESD prevention procedures when removing and replacing the power supply. Ensure
that the router chassis is electrically connected to earth ground. Wear an ESD-preventive wrist strap,
ensuring that it makes good skin contact and operates effectively. Connect the clip to an unpainted
surface of the chassis frame to safely channel unwanted ESD voltages to ground.
Caution If no wrist strap is available, ground yourself by touching the metal part of the chassis. For
safety, periodically check the resistance value of the antistatic strap, which should be between
1 to 10 megohms (Mohms).
Tools and Equipment Required
Thefollowing tools andequipmentarerequiredto removeandinstall powersuppliesina Cisco 4000
series router:
•ESD cord and wrist strap
•Number 1 Phillips screwdriver
•Wire cutters to cut cable tie-wraps

6Replacing the Cisco 4000 Series Power Supply
Accessing the Power Supply
Accessing the Power Supply
To access the power supply of a Cisco 4000 series router, you must first remove the component tray.
Procedures for removing the component tray follow.
Some Cisco 4000 series routers have a safety latch tab on the chassis that affects removing the
component tray. (See Figure 3 and Figure 4.)
If your chassis has a safety latch tab, refer to the next section, “Removing the Component Tray from
a Chassis with a Safety Latch.”
If your chassis does not have a safety latch tab, go to the section “Removing the Component Tray
from a Chassis without a Safety Latch.”
Note The power cable and power switch are on the lower right of the rear panel of the router. The
system console port, auxiliary port, and module ports appear to the left of the power cable and
switch. (See Figure 2.)
Removing the Component Tray from a Chassis with a Safety Latch
Warning Do not touch the power supply when the power cord is connected. For systems with a
power switch, line voltages are present within the power supply even when the power switch is OFF
and the power cord is connected. For systems without a power switch, line voltages are present
within the power supply when the power cord is connected.
Take the following steps to remove the component tray from a chassis with a safety latch:
Step 1 Turn OFF the system power.
Step 2 Attach your ESD-preventive wrist strap.
Step 3 Removeallnetwork cables. ProceedwithStep 4 if youhavean ACpowersupply. Proceed
with Step 5 if you have a DC power supply.
Step 4 If you have an AC-powered router, remove the power cord.
Warning Before performing any of the following procedures, ensure that power is removed from
the DC circuit. To ensure that all power is OFF, locate the circuit breaker on the panel board that
services the DC circuit, switch the circuit breaker to the OFF position, and tape the switch handle of
the circuit breaker in the OFF position.
Step 5 If you have a DC-powered router, take the following steps to remove the power cables:
(a) Use a screwdriver to loosen the captive installation screws on the terminal block
cover.
(b) Lift and remove the terminal block cover.
(c) Use a screwdriver to remove the three power leads from the terminal block in the
following order: negative, positive, then ground.

Replacing the Cisco 4000 Series Power Supply 7
Accessing the Power Supply
Warning Before opening the chassis, disconnect the telephone-network cables to avoid contact
with telephone-network voltages.
Step 6 Loosen the nonremovable chassis release screw on the rear panel of the chassis. (See
Figure 3.)
Step 7 Pull on the handle located on the upper right corner of the chassis to slide the component
tray out of the chassis shell until the safety latch catches. (See Figure 3.)
Figure 3 Component Tray Removal for Chassis with a Safety Latch
Warning Before releasing the safety latch, support the component tray from underneath, either on
your work surface or with your hands, to prevent injury.
Step 8 Support the component tray with one hand, push down on the safety latch tab, and pull
the component tray out completely.
Step 9 Set the component tray on your work surface.
Proceed with the section “Removing AC and DC Power Supplies.”
Rear of chassis Handle
AUX CONSOLE
INPUT 100-240VAC 50/60HZ 3.0-1.5 AMPS
Safety latch tab
Hand supporting 
component tray
H1965
Chassis shell
Chassis release 
screw

8Replacing the Cisco 4000 Series Power Supply
Accessing the Power Supply
Removing the Component Tray from a Chassis without a Safety Latch
Warning Do not touch the power supply when the power cord is connected. For systems with a
power switch, line voltages are present within the power supply even when the power switch is off
and the power cord is connected. For systems without a power switch, line voltages are present
within the power supply when the power cord is connected.
Take the following steps to remove the component tray from a chassis without a safety latch:
Step 1 Turn OFF the system power.
Step 2 Attach your ESD-preventive wrist strap.
Step 3 Removeallnetwork cables. ProceedwithStep 4 if youhavean ACpowersupply. Proceed
with Step 5 if you have a DC power supply.
Step 4 If you have an AC-powered router, remove the power cord.
Warning Before performing any of the following procedures, ensure that power is removed from
the DC circuit. To ensure that all power is OFF, locate the circuit breaker on the panel board that
services the DC circuit, switch the circuit breaker to the OFF position, and tape the switch handle of
the circuit breaker in the OFF position.
Step 5 If you have a DC-powered router, take the following steps to remove the power cables:
(a) Use a screwdriver to loosen the captive installation screws on the terminal block
cover.
(b) Lift and remove the terminal block cover.
(c) Use a screwdriver to remove the three power leads from the terminal block in the
following order: negative, positive, then ground.
Warning Before opening the chassis, disconnect the telephone-network cables to avoid contact
with telephone-network voltages.
Step 6 Loosen the nonremovable chassis release screw on the rear panel of the chassis. (See
Figure 4.)
Caution Support the component tray from underneath, either on your work surface or with your
hands, to prevent it from falling.

Replacing the Cisco 4000 Series Power Supply 9
Removing AC and DC Power Supplies
Figure 4 Component Tray Removal for Chassis without a Safety Latch
Step 7 Pull on the handle located on the upper right corner of the chassis to slide the component
tray out of the chassis shell while you support the component tray with one hand.
Step 8 Set the component tray on your work surface.
Proceed with the section “Removing AC and DC Power Supplies.”
Removing AC and DC Power Supplies
After you remove the component tray from the chassis shell, remove the power supply from the
chassis.
Take the following steps to remove a power supply:
Caution When cutting the cable tie-wraps be careful not to cut into the power cables.
Step 1 Locate the power cable harness located on the rear of the power supply (toward the front
of the router), then carefully cut the cable tie-wraps on the harness. (See Figure 5.)
Note The number and placement of the cable tie-wraps in your router may differ from the
illustration.
Step 2 Locate the main power connector on the motherboard. Grasp the plug on the ends, press
in toward the middle, and lift the plug away from the connector. (See Figure 6.)
Step 3 Locate the two small two-pin connectors used to power the fans. Separate both of the
small connectors by grasping each end of the connector firmly and then pulling the
connector apart. (See Figure 5.)
AUX CONSOLE
INPUT 100-240VAC 50/60HZ 3.0-1.5 AMPS
H2899
Rear of chassis Handle
Support the component
tray with your hand
Chassis shell
Chassis release 
screw

10 Replacing the Cisco 4000 Series Power Supply
Removing AC and DC Power Supplies
Figure 5 Power Supply Wiring Harness
Figure 6 Power Supply Connection to the Motherboard
H7090
Cable tie-wraps
Power supply
Eight-pin connector
to the motherboard
Two, two-pin
connectors
to the fans
H7091