Cisco 7606-S User manual

CHAPTER
5-1
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5
Removal and Replacement Procedures
This chapter describes how to perform removal and replacement procedures for Cisco 7600 series router
field-replaceable units (FRUs). It contains the following sections:
•Preventing Electrostatic Discharge Damage, page 5-2
•Removing and Replacing the Power Supply, page 5-2
•Removing and Replacing the PEM, page 5-106
•Removing and Replacing the Fan Assembly, page 5-113
•Installing the Air Filter Assembly on a Cisco 7606 Router and the Cisco 7606-S Router (Optional),
page 5-119
•Installing the Air Filter Assembly on a Cisco 7606 Router and the Cisco 7606-S Router (Optional),
page 5-119
•Replacing the Air Filter on a Cisco 7609 Router and the Cisco 7609-S Router (Optional), page 5-124
•Installing the Thermistor Module on a Cisco 7606-S Router, page 5-125
•Installing the Thermistor Module on a Cisco 7609-S Router, page 5-126
•Upgrading the Cisco 7600 Series Routers to a WS-SUP720-3BXL, page 5-128
Warning Only trained and qualified personnel should be allowed to install, replace, or service this equipment.
Caution Use two hands to support the power supply during removal and replacement procedures.
Warning During this procedure, wear grounding wrist straps to avoid ESD damage to the card. Do not directly
touch the backplane with your hand or any metal tool, or you could shock yourself.
For instructions on installing and replacing modules, refer to the Cisco 7600 Series Internet Router
Module Installation Guide.

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Chapter 5 Removal and Replacement Procedures
Preventing Electrostatic Discharge Damage
Preventing Electrostatic Discharge Damage
Electrostatic discharge (ESD) damage, which can occur when electronic cards or components are
improperly handled, results in complete or intermittent failures. Port adapters and processor modules
consist of printed circuit boards that are fixed in metal carriers. Electromagnetic interference (EMI)
shielding and connectors are integral components of the carrier. Although the metal carrier helps to
protect the board from ESD, use a preventive antistatic strap during handling.
Following are guidelines for preventing ESD damage:
•Always use an ESD wrist or ankle strap and ensure that it makes good skin contact.
•Connect the equipment end of the strap to an unfinished chassis surface.
•When installing a component, use any available ejector levers or captive installation screws to
properly seat the bus connectors in the backplane or midplane. These devices prevent accidental
removal, provide proper grounding for the system, and help to ensure that bus connectors are
properly seated.
•When removing a component, use any available ejector levers or captive installation screws to
release the bus connectors from the backplane or midplane.
•Handle carriers by available handles or edges only; avoid touching the printed circuit boards or
connectors.
•Place a removed component board-side-up on an antistatic surface or in a static shielding container.
If you plan to return the component to the factory, immediately place it in a static shielding
container.
•Avoid contact between the printed circuit boards and clothing. The wrist strap only protects
components from ESD voltages on the body; ESD voltages on clothing can still cause damage.
•Never attempt to remove the printed circuit board from the metal carrier.
Caution For safety, periodically check the resistance value of the antistatic strap. The measurement should be
between 1 and 10 megohm (Mohm).
Removing and Replacing the Power Supply
This section describes how to remove and install power supplies for the Cisco 7600 series routers.
Note In systems with redundant power supplies, you can replace the faulty supply while the system is
operating.
Required Tools
A flat-blade or number 2 Phillips-head screwdriver is required to perform these procedures.
Additionally, a wire cutter or scissors is necessary for cutting cable tie-wraps.

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Chapter 5 Removal and Replacement Procedures
Removing and Replacing the Power Supply
Removing an AC-Input Power Supply
This section covers the AC-input power supply removal procedure for the following AC power supplies
and Cisco 7600 series routers:
•950 W AC and 1400 W AC power supplies for the Cisco 7603 router
•2700 W AC power supply for the Cisco 7604 route
•1900 W AC power supply for the Cisco 7606 router
•2700 W AC power supply for the Cisco 7606 router
•2700 W AC power supply for the Cisco 7606-S router
•3000 W AC and 4000 W AC power supplies for the Cisco 7609 and Cisco 7613 routers
•4000 W AC power supply for the Cisco 7609-S router
•6000 W AC power supply for the Cisco 7609, Cisco 7609-S, and Cisco 7613 routers
Warning Hazardous voltage or energy is present on the backplane when the system is operating. Use caution
when servicing.
Note In systems with redundant power supplies, you can replace the faulty supply while the system is
operating.
Note This procedure covers the removal of the power supply only. For information on removing the power
entry module (PEM), see the “Removing and Replacing the PEM” section on page 5-106.
Follow these steps to remove a power supply:
Step 1 Turn the power switch to the Off (0) position on the power supply or PEM for the power supply you are
removing.
Note Figure 5-1 shows the location of the AC-input PEMs on the Cisco 7603 router. The location of
the PEMs is the same for AC and DC PEMs on the Cisco 7603 router and Cisco 7606 router.
Note If you are planning on installing a PWR-2700-AC power supply in a Cisco 7606 router, you must remove
any PEMs and install a blank PEM filler plate. See Removing and Replacing the PEM, page 5-106.

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Chapter 5 Removal and Replacement Procedures
Removing and Replacing the Power Supply
Figure 5-1 PEM Location
Step 2 Disconnect the power cord from the power source. Do not touch the metal prongs on the power cord
when it is still connected to the power supply or PEM.
Step 3 Remove the power cord from the power connection on the PEM. Do not touch the metal prongs
embedded in the PEM.
Note The AC power cord for the 4000 W power supply is hard-wired and cannot be removed from the
supply.
Step 4 Loosen the captive installation screws on the power supply. (See Figure 5-2 for the Cisco 7603 router,
Figure 5-3 for the Cisco 7604 router, Cisco 7606 router, andCisco 7606-S router, Figure 5-4 for the
Cisco 7609 router, Cisco 7609-S router, and Cisco 7613 router.)
Figure 5-2 Cisco 7603 Router—Power Supply Captive Installation Screws
SUPERVISOR2
WS-X6K-SUP2-2GE
STATUS
SYSTEM
CONSOLE
PWRMGMT
RESET
CONSOLE
CONSOLE
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PCMCIA EJECT
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63191
PEM 1 PEM 2
63183
INPUT
OK
FAN
OK
OUTPUT
FAI L
Captive installation screws
Status LEDs

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Chapter 5 Removal and Replacement Procedures
Removing and Replacing the Power Supply
Figure 5-3 Cisco 7604 Router , Cisco 7606 Router, Cisco 7606-S—Power Supply Captive Installation
Screws
Figure 5-4 Cisco 7609 Router, Cisco 7609-S Router, and Cisco 7613 Router— Power Supply Captive
Installation Screws
Step 5 Cisco 7603 router, Cisco 7609 router, Cisco 7609-S, and Cisco 7613 router—Grasp the power supply
handle with one hand and slide the power supply part of the way out of the chassis. Place your other hand
underneath the power supply (see Figure 5-5 for Cisco 7603 router, and Figure 5-6 for Cisco 7609, Cisco
609-S, and Cisco 7613 routers), and slide the power supply completely out of the chassis.
Cisco 7604, Cisco 7606 router, Cisco 7606-S router—Grasp both power supply handles, as shown in
Figure 5-7, and slide the power supply completely out of the chassis.
INPUT OK
FAN OK
OUTPUT FAIL
63895
Captive installation screws
Status LEDs
Power
switch
INPUT
OK
FAN
OK
OUTPUT
FAIL
Captive installation
screw
Status LEDs
85756
I
0

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Chapter 5 Removal and Replacement Procedures
Removing and Replacing the Power Supply
Figure 5-5 Cisco 7603 Router—Handling an AC-Input Power Supply
63032
INPUT
OK
FAN
OK
OUTPUT
FAIL
INPUT
OK
FAN
OK
OUTPUT
FAIL

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Chapter 5 Removal and Replacement Procedures
Removing and Replacing the Power Supply
Figure 5-6 Cisco 7609 Router, Cisco 7609-S, and Cisco 7613 Router— Handling an AC-Input Power
Supply
INPUT
OK
FAN
OK
OUTPUT
FAIL
o
INPUT
OK
FAN
OK
OUTPUT
FAIL
o
SUPERVISOR2
WS-X6K-SUP2-2GE
STATUS
SYSTEM
CONSOLE
PWRMGMT
RESET
CONSOLE
CONSOLE
PORT
MODE
PCMCIA EJECT
PORT1 PORT2
SwitchLoad
100%
1%
LINK
LINK
SUPERVISOR2
WS-X6K-SUP2-2GE
STATUS
SYSTEM
CONSOLE
PWRMGMT
RESET
CONSOLE
CONSOLE
PORT
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PCMCIA EJECT
PORT1 PORT2
SwitchLoad
100%
1%
LINK
LINK
SWITCHFABRICMDL
STATUS
SELECT
NEXT
WS-C6500-SFM
ACTIVE
SWITCHFABRICMDL
STATUS
SELECT
NEXT
WS-C6500-SFM
ACTIVE
OC12POSMM
OSM-40C12-POS-MM
STATUS 1
2
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4
CARRIER
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8PORT OC3 POS MM
OSM-8OC3-POSMM
STATUS 1
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79897
INPUT
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FAN
OK
OUTPUT
FAIL
I
0

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Chapter 5 Removal and Replacement Procedures
Removing and Replacing the Power Supply
Figure 5-7 Cisco 7604, Cisco 7606, Cisco 7606-S Routers—Handling an AC-Input Power Supply
Step 6 If the power supply bay is to remain empty, install a blank power supply filler plate (Cisco
part number 800-16727-01 for the Cisco 7603 router, 800-19193-01 for the Cisco 7606 router,
800-28533-01 for the Cisco 7606-S router, and 700-03104-01 for the Cisco 7609 and Cisco 7613
routers) over the opening and secure it with the captive installation screws.
Installing an AC-Input Power Supply
This section covers the AC-input power supply installation procedure for the Cisco 7600 series routers.
Warning This product requires short-circuit (over current) protection, to be provided as part of the building
installation. Install only in accordance with national and local wiring regulations.
Follow these steps to install an AC-input power supply:
Step 1 Ensure that the system (earth) ground connection has been made. For ground connection instructions,
see the “System Ground Connection” section on page 3-19.
Step 2 If necessary, remove the blank power supply filler plate from the chassis power supply bay opening by
loosening the captive installation screws.
Step 3 If your power supply has a power switch (see Figure 5-4), verify that the power switch is in the Off (0)
position.
63901
INPUT OK
FAN OK
OUTPUT FAIL
INPUT OK
FAN OK
OUTPUT FAIL

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Chapter 5 Removal and Replacement Procedures
Removing and Replacing the Power Supply
Step 4 Cisco 7603 router, Cisco 7609 router, and Cisco 7613 router—Grasp the power supply handle with one
hand. Place your other hand underneath the power supply (see Figure 5-5 for Cisco 7603 router and
Figure 5-6 for Cisco 7609 and Cisco 7613 routers). Slide the power supply into the power supply bay.
Make sure that the power supply is fully seated in the bay.
Cisco 7604, Cisco 7606, Cisco 7606-S routers—Grasp both power supply handles, as shown in
Figure 5-7. Slide the power supply into the power supply bay. Make sure that the power supply is fully
seated in the bay.
Note If you are installing a PWR-2700-AC power supply in a Cisco 7606 router, you must remove any
preinstalled PEMs. You must also install a blank PEM filler plate for each power supply you are
installing. See Removing and Replacing the PEM, page 5-106.
Step 5 Securely tighten the power supply captive installation screws. (See Figure 5-2 for the Cisco 7603 router,
Figure 5-3 for the Cisco 7604 router, the Cisco 7606 router, and the Cisco 7606-S router, and Figure 5-4
for the Cisco 7609 and the Cisco 7613 routers.)
Warning Power supply captive installation screws must be tight to ensure protective grounding continuity.
Step 6 Plug the power cord into the power supply or PEM.
Step 7 Connect the other end of the power cord to an AC-input power source.
Caution In a system with dual power supplies, connect each power supply to a separate input source. In case of
a power source failure, the second source will most likely still be available.
Step 8 Turn the switch on the power supply or PEM to the On (|) position.
Step 9 Verify power supply operation by checking that the power supply LEDs are in the following states:
•INPUT OK LED is green
•FAN OK LED is green
•OUTPUT FAIL LED is not lit
If the LEDs indicate a power problem, see the “Identifying Startup Problems” section on page 4-2 for
troubleshooting information.
Removing a DC-Input Power Supply
This section describes the DC-input power supply removal procedure for the Cisco 7600 series routers:
•Removing PWR-950-DC Power Supply from a Cisco 7603 Router, page 5-10
•Removing PWR-1500-DC Power Supply from a Cisco 7603-S Router, page 5-11
•Removing PWR-2700-DC/4 Power Supply from a Cisco 7604 Router, page 5-13
•Removing PWR-1900-DC Power Supply from a Cisco 7606 Router, page 5-15
•Removing PWR-2700-DC Power Supply from a Cisco 7606 Router, page 5-17
•Removing PWR-2700-DC Power Supply from a Cisco 7606-S Router, page 5-19

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Chapter 5 Removal and Replacement Procedures
Removing and Replacing the Power Supply
•Removing a WS-CDC-2500W Power Supply from a Cisco 7609 Router, page 5-21
•Removing a WS-CDC-2500W Power Supply from a Cisco 7613 Router, page 5-24
•Removing a PWR-4000-DC Power Supply from a Cisco 7609 Router or a Cisco 7609-S Router, page
5-26
•Removing a PWR-6000-DC Power Supply from a Cisco 7609 or a Cisco 7609-S Router, page 5-29
•Removing a PWR-6000-DC Power Supply from a Cisco 7613 Router, page 5-37
Removing PWR-950-DC Power Supply from a Cisco 7603 Router
Warning Before performing any of the following procedures, ensure that power is removed from the DC circuit.
Warning Voltage is present on the backplane when the system is operating. To reduce risk of an electric shock,
keep hands and fingers out of the power supply bays and backplane areas.
Follow these steps to remove a DC-input power supply:
Step 1 Verify that power is off to the DC circuit connected to the DC PEM for the power supply you are
removing (Figure 5-8).
Figure 5-8 PEM Location
Step 2 Loosen the captive installation screws on the power supply (Figure 5-9).
SUPERVISOR2
WS-X6K-SUP2-2GE
STATUS
SYSTEM
CONSOLE
PWRMGMT
RESET
CONSOLE
CONSOLE
PORT
MODE
PCMCIA EJECT
PORT1 PORT 2
Switch Load
100%
1%
LINK
LINK
OSM-4OC12POS-SI
4PORTOC-12POSSMIR
STATUS1
1
2
2
3
3
4
4RESET
LINK
LINK
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CARRIER
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68154
DC PEM 1 Cable clips
DC PEM 1
terminal block
screws
DC PEM 2