REVIEW DRAFT—CISCO CONFIDENTIAL APPENDIX A 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.
Appendix A Repackaging the Router Repackaging the Routers REVIEW DRAFT—CISCO CONFIDENTIAL This section contains the following information and procedures: Note • 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 You must use the original shipping package supplied by Cisco when repackaging the rou
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.
Appendix A Repackaging the Router Repackaging the Routers REVIEW DRAFT—CISCO CONFIDENTIAL Figure A-1 Router Shipping Package Components OPEN Top cap Foam cap 29660 U-shaped panel Accessories package Pallet Cisco XR 12416 Router Chassis Installation Guide A-4 OL-xxxxx-xx
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.
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 truc
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 router chassis.
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.
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.
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.
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.
Appendix A Repackaging the Router Repackaging the Routers REVIEW DRAFT—CISCO CONFIDENTIAL Preparing the Scissor-Jack Platform T O/L AC 2 L R R CA JO NO ITI MA MI CR E IER TIV RR PK AC CA RX T TX TX RX RX 3 3 1 TX TX RX E IER TIV RR PK AC CA RX 0 TX CD LA LA 29189 CDHNT RA CDHNT RA LOOP LOOP DOWN DOWN CD TX 0 0 RX RX TX TX 1 1 RX RX TX TX 2 2 T RX 0 E IER T TIV RR PK CA RX T EC EJ -1 OT SL -0 OT SL AC X AU T SE RE TX 4 4 RX RX E IER LL TIV RR CE AC
Appendix A Repackaging the Router Repackaging the Routers REVIEW DRAFT—CISCO CONFIDENTIAL Transferring the Router to the Scissor-Jack Platform 29659 Figure A-4 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.
Appendix A Repackaging the Router Repackaging the Routers REVIEW DRAFT—CISCO CONFIDENTIAL Installing the Chassis Anchor Clips LT O/ AC 2 L R R CA JO NO ITI MA MI CR RX RX 4 4 TX TX R E IE T TIV RR PK AC CA RX 0 TX CD LA LA 29188 CDHNT RA CDHNT RA LOOP LOOP DOWN DOWN CD TX 0 0 RX RX TX TX 1 1 RX RX TX TX 2 2 RX RX TX 1 TX 3 3 RX RX R E IE T TIV RR PK AC CA RX R LL CE IE E TIV RR AC CA RX 0 E IER T TIV RR PK AC CA RX X AU T SE RE -1 OT SL -0 OT SL T EC EJ
Appendix A Repackaging the Router Repackaging the Routers REVIEW DRAFT—CISCO CONFIDENTIAL Figure A-6 Closing the Scissor-Jack Platform to Lower the Chassis LT O/ AC L R R CA JO NO ITI MA MI CR R E IE T TIV RR PK AC CA RX TX TX 3 RX RX E IER T TIV RR PK CA RX R E IE T TIV RR PK AC CA RX 0 TX CD LA 29187 CDHNT RA LOOP LOOP DOWN CDHNT RA DOWN LA CD TX 0 0 RX RX TX TX 1 1 RX RX TX TX 2 2 RX RX TX 1 TX 3 AC T EC EJ -1 OT SL -0 OT SL 0 X AU T SE RE TX 4 4 RX R
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.
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.
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.
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.
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.
Appendix A Repackaging the Router Repackaging the Routers REVIEW DRAFT—CISCO CONFIDENTIAL Repackaging the Vertical Cable-Management Troughs To repackage the vertical cable-management troughs, follow these steps: Step 1 Place the six screws in a plastic bag. Step 2 Insert the trough into the long plastic bag. Step 3 Put the foam cap on each end of the trough. Step 4 Place the trough and the bag of screws into the corrugated carton. Step 5 Close and seal the carton.
Appendix A Repackaging the Router Repackaging the Routers REVIEW DRAFT—CISCO CONFIDENTIAL Repackaging the Miscellaneous Accessories To repackage the all of the miscellaneous accessory pieces, follow these steps: Step 1 Put the box containing the front cover for the power shelf and upper blower module into the large miscellaneous accessories box. Step 2 Put all of the other miscellaneous accessory pieces in the box. Step 3 Close and seal the carton.
Appendix A Repackaging the Router Repackaging the Routers REVIEW DRAFT—CISCO CONFIDENTIAL Completing the Repackaging To repackage the router, use Figure A-1 on page A-4 as a reference and follow these steps: Step 1 Verify that the anchor clips fastening the chassis to the scissor-jack platform are installed correctly and that the bolts are tight. Step 2 Verify that the bolts fastening the hold-down brackets to the sides of the scissor-jack platform and the top of the pallet are tight.
Appendix A Repackaging the Router Repackaging the Replaced Router Chassis REVIEW DRAFT—CISCO CONFIDENTIAL Step 7 To fasten the two U-shaped side panels together, use Figure A-1 on page A-4 as a reference and follow these steps. a. Starting at one of the top holes on one narrow side panel, align the holes in the inner and outer corrugated panels. b. Open a plastic locking clip by pulling the wedge block out of the clip. c.
Appendix A Repackaging the Router Repackaging the Replaced Router Chassis REVIEW DRAFT—CISCO CONFIDENTIAL This section contains the following information and procedures: • The Router Replacement Chassis Shipping Container, page A-25 • Tools and Equipment, page A-25 • Safety Recommendations, page A-25 • Reinstalling the Replaced Chassis on the Shipping Pallet, page A-25 • Repackaging the Replaced Chassis for Shipment, page A-26 The Router Replacement Chassis Shipping Container Except for the diff
Appendix A Repackaging the Router Repackaging the Replaced Router Chassis REVIEW DRAFT—CISCO CONFIDENTIAL Repackaging the Replaced Chassis for Shipment Repackage the replaced chassis for shipment as described in the “Completing the Repackaging” section on page A-23, earlier in this appendix.
