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REVIEW DRAFT—CISCO CONFIDENTIAL
APPENDIXA
Repackaging the Router
Revised: February 12, 2008, OL-xxxxx-xx
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 procedure
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Appendix A Repackaging the Router Repackaging the Routers REVIEW DRAFT—CISCO CONFIDENTIAL 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 ro
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Appendix A Repackaging the Router Repackaging the Routers REVIEW DRAFT—CISCO CONFIDENTIAL 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 b
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OPEN Appendix A Repackaging the Router Repackaging the Routers REVIEW DRAFT—CISCO CONFIDENTIAL Figure A-1 Router Shipping Package Components Top cap Foam cap U-shaped panel Accessories package Pallet Cisco XR 12416 Router Chassis Installation Guide OL-xxxxx-xx A-4 29660
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Appendix A Repackaging the Router Repackaging the Routers REVIEW DRAFT—CISCO CONFIDENTIAL 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 Corrugated spacer Top cap Accessory box Cable Cable trough trough Center-mount Rack-mounting rack-mounting platform brackets Foam Bottom cap Cisco XR
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Appendix A Repackaging the Router Repackaging the Routers REVIEW DRAFT—CISCO CONFIDENTIAL 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 t
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Appendix A Repackaging the Router Repackaging the Routers REVIEW DRAFT—CISCO CONFIDENTIAL 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 r
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Appendix A Repackaging the Router Repackaging the Routers REVIEW DRAFT—CISCO CONFIDENTIAL 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. I
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Appendix A Repackaging the Router Repackaging the Routers REVIEW DRAFT—CISCO CONFIDENTIAL 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 a
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Appendix A Repackaging the Router Repackaging the Routers REVIEW DRAFT—CISCO CONFIDENTIAL 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.
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Appendix A Repackaging the Router Repackaging the Routers REVIEW DRAFT—CISCO CONFIDENTIAL Removing the Router from the Equipment Rack This section describes how to remove a fully-loaded router from the equipment rack using the scissor-jack platform. If you elected to empty the chassis before attempting to remove it from the equipment rack, remove the chassis as described in the “Removing and Installing a Chassis” section on page 5-53. To remove a fully-loaded router from the equipment ra
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Appendix A Repackaging the Router Repackaging the Routers REVIEW DRAFT—CISCO CONFIDENTIAL Figure A-3 Preparing the Scissor-Jack Platform Warning Do not attempt to lift the chassis with the handles on the back and sides of the chassis. These handles are not designed to support the weight of the chassis, and should be used only to steady and guide the chassis while it is being inserted into or removed from an equipment rack. To reduce the risk of damage to the chassis and serious bodily i
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Appendix A Repackaging the Router Repackaging the Routers REVIEW DRAFT—CISCO CONFIDENTIAL Figure A-4 Transferring the Router to the Scissor-Jack Platform Step 5 With one person positioned on the side of the router to prevent it from tipping, install the four chassis anchor clips through the slots in the bottom of the chassis, align the holes with the bolt holes in the platform, and insert and tighten the four bolts to prevent the chassis from shifting on the scissor-jack platform. (See
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Appendix A Repackaging the Router Repackaging the Routers REVIEW DRAFT—CISCO CONFIDENTIAL Figure A-5 Installing the Chassis Anchor Clips Front of chassis Step 6 With one person positioned on the side of the router to prevent it from tipping, use the 3/4-inch (19-mm) socket and ratchet wrench to turn the scissor-jack screw clockwise slowly and close the scissor-jack platform to lower the chassis. (See Figure A-6.) Cisco XR 12416 Router Chassis Installation Guide OL-xxxxx-xx A-14 DOWN CDHN
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Appendix A Repackaging the Router Repackaging the Routers REVIEW DRAFT—CISCO CONFIDENTIAL Figure A-6 Closing the Scissor-Jack Platform to Lower the Chassis Chassis anchor clip and bolt (2 on each side) Front of chassis Scissor-jack screw Scissor-jack platform Counter-clockwise Clockwise expands platform closes platform Step 7 Position the safety hand truck at one side of the router, slide the router and scissor-jack platform onto the safety hand truck, and secure the router to the hand tr
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Appendix A Repackaging the Router Repackaging the Routers REVIEW DRAFT—CISCO CONFIDENTIAL Installing the Router on the Shipping Pallet Figure A-7 shows how to install the router and scissor-jack platform on the shipping pallet. Figure A-7 Installing the Router and Scissor-Jack Platform on the Pallet Pallet body Pallet front bar Top view of pallet parts Cisco XR 12416 Router Chassis Installation Guide OL-xxxxx-xx A-16 DOWN CDHNT CD LOOP RA LA DOWN CDHNT CD LOOP RA LA 29186 A X O SO E I I CR
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Appendix A Repackaging the Router Repackaging the Routers REVIEW DRAFT—CISCO CONFIDENTIAL To reinstall the router and scissor-jack platform on the shipping pallet, use Figure A-7 as a reference and follow these steps: Step 1 Use the hand truck to move the chassis to a level, open space with a solid floor. Step 2 Tilt the chassis upright so that it stands on the scissor-jack platform, then remove the hand truck. Step 3 Use the bolts from the original shipping package to attach the eight ho
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Appendix A Repackaging the Router Repackaging the Routers REVIEW DRAFT—CISCO CONFIDENTIAL Step 8 Shift the pallet to ensure that it is positioned evenly all the way around the scissor-jack platform and the bolt holes in the hold-down brackets on the sides of the scissor-jack platform are aligned with the holes in the top of the shipping pallet. Step 9 Turn the scissor-jack screw slowly clockwise to close the scissor-jack platform and lower the top of the scissor-jack platform slowly unt
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Appendix A Repackaging the Router Repackaging the Routers REVIEW DRAFT—CISCO CONFIDENTIAL Reinstalling Components in the Router If you elected to remove components from the chassis before removing it from the rack, you must now reinstall all the components in the chassis. Reinstalling the Cards in the Upper and Lower Card Cages Reinstall all of the cards from the upper and lower card cages in their original slots. � Reinstall all of the cards in the upper card cage as instructed in the “
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Appendix A Repackaging the Router Repackaging the Routers REVIEW DRAFT—CISCO CONFIDENTIAL If you removed DC-input power entry modules, reinstall each power entry module as instructed in the “Installing DC-Input Power Entry Modules” section on page 3-78. Reinstalling the Front Covers When the router is repackaged for shipping, two foam inserts must be paced around the top of the router. To avoid interference with the foam inserts, the front cover for the power shelf and upper blower modu
