Cisco 12012 Installation and Configuration Guide
Repackaging the Router
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Repackaging the Cisco 12012

Table Of Contents

Repackaging the Cisco 12012

Tools Required

Safety Recommendations

Removing the Cisco 12012 from a Rack

Powering Down the Cisco 12012

Removing the Blower Modules

Removing the Card Cage Assembly

Removing the Frame from the Rack

Replacing Components in the Cisco 12012

Replacing the Blower Modules

Replacing the Card Cage Assembly

Completing the Repackaging

Repackaging the Redundant AC-Input Power Supplies

Repackaging the Accessories Box

Installing the Side Panels, End Panels, and Top of the Shipping Container


Repackaging the Cisco 12012


This chapter provides procedures for repackaging the Cisco 12012 should it become necessary to transport the system to another location or return it to Cisco Systems.
(Where appropriate, you are referred to specific procedures in the chapter ".")

Required packaging for the Cisco 12012 consists of the following items:

Shipping pallet

Foam cap

Wooden shipping container

Large cardboard box

Power supply foam inserts

Accessories box

Miscellaneous packing hardware


Note   Use Cisco-specified packaging when repackaging the Cisco 12012. You can order system packaging using Product Number PKG-GSR12=.


Tools Required

You need the following tools and supplies to perform the repackaging procedure:

1/4-inch flat-blade screwdriver

3/16-inch flat-blade screwdriver

Pliers

10-mm nutdriver

9/16-inch wrench

Wire cutters

ESD wrist strap

Antistatic mat

Shipping tape

Safety Recommendations

Before you begin the procedures in this appendix, review the following safety information:

The safety recommendations listed in the section "Safety Recommendations" in the chapter "."

The safety warnings listed in the document Regulatory Compliance and Safety Information for the Cisco 12012 Gigabit Switch Router (Document Number 78-4347-xx) that accompanied your Cisco 12012.

Removing the Cisco 12012 from a Rack

This section contains the procedures for removing the Cisco 12012 from a rack.

Powering Down the Cisco 12012

Perform the following steps to power down the Cisco 12012:


Step 1 Turn the power supply power switch counterclockwise to OFF (STANDBY on an AC-input power supply) on all power supplies installed in the Cisco 12012.

Step 2 Verify that the system has powered down by checking that the input OK (or AC OK) LEDs on the power supplies are off and the green OK LEDs on both blower modules are off.

Step 3 Turn off any circuit breakers to which the power supplies are connected, and disconnect all power cords or cables from the Cisco 12012 power supplies.

Removing the Blower Modules

The Cisco 12012 has two blower modules that provide cooling air to the card cage assembly. The blower modules slide on rails into and out of the top and bottom of the frame and attach to the frame with two captive screws each.

Remove the blower modules according to the procedures in the section "Removing the Blower Modules" in the chapter "."

Removing the Card Cage Assembly

The card cage assembly comprises one assembly that includes the upper card cage, the lower card cage, and the power supply bays. The assembly slides into and out of the front of the frame and attaches to the frame with six captive screws.


Note   A fully populated card cage assembly weighs approximately 230 lb (104.3 kg). To make the card cage assembly easier to remove, first remove all components from the card cage assembly (see the appropriate sections in the chapter "").



Caution   
An empty card cage assembly weighs 65 lb (29.5 kg). You need two people to safely lift the assembly. To prevent injury, keep your back straight and lift with your legs, not your back.

Remove the card cage assembly according to the procedures in the section "Removing the Card Cage Assembly," in the chapter "."

Removing the Frame from the Rack

This section provides the procedures for removing the Cisco 12012 frame from the rack and for placing it on the shipping pallet. You need a 3/16-inch flat-blade screwdriver and a 9/16-inch wrench to perform this procedure.

Perform the following steps to remove the frame from the rack:


Step 1 Position the shipping pallet as close as possible to the rack where the Cisco 12012 is installed.


Caution   
An empty frame weighs 75 lb (34 kg). You need two people to safely lift the frame. To prevent injury, keep your back straight and lift with your legs, not your back.

Step 2 With one person positioned on each side of the frame, grasp the front and side of the frame. (See .)

Step 3 Have a third person remove the eight screws that secure the frame to the rack. Place the eight screws in the accessories box.

Step 4 Slide the frame out the front of the rack and place it on the shipping pallet. Orient the frame so that the front of the frame points toward the front of the pallet.

Step 5 Install the four frame anchors through the slots in the bottom of the frame to secure the frame to the pallet. Tighten the four lag screws to prevent frame movement.

Step 6 If a brace bar is installed in the rack, remove the two screws that secure it, then remove the brace bar from the rack. Place the brace bar and two screws in the accessories box.

Figure A-1 Removing the Frame from the Rack

Replacing Components in the Cisco 12012

This section contains the procedures to replace the components in the Cisco 12012 once it is on the shipping pallet.

Replacing the Blower Modules

The blower modules slide on rails into and out of the top and bottom of the frame and attach to the frame with two captive screws each.

Replace the blower modules according to the procedures in the section "Reinstalling the Blower Modules," in the chapter "."

Replacing the Card Cage Assembly

This section contains the procedures to replace the card cage assembly in the frame, the cards in the upper card cage, the cards in the lower card cage, and the DC-input power supplies in the power supply bay.

If your system is configured with three or four AC-input power supplies, two AC-input power supplies are shipped installed in the power supply bay and the third and fourth AC-input power supplies are shipped removed from the system and packaged separately on the pallet.

Replace the card cage assembly according to the procedures in the section "Reinstalling the Card Cage Assembly," in the chapter "."


Note   Do not connect any power cords or cables to the power supplies or connect any interface cables to the line cards, RP, or alarm card.



Caution   
An empty card cage assembly weighs 65 lb (29.5 kg). You need two people to safely lift the assembly. To prevent injury, keep your back straight and lift with your legs, not your back.

Completing the Repackaging

This section provides procedures for completing the Cisco 12012 repackaging. Included are procedures for positioning the large cardboard box on the pallet, repackaging the third and fourth AC-input power supplies in the large cardboard box, and repackaging the accessories box in the large cardboard box.

If your system is configured with AC-input power supplies, proceed to the section "Repackaging the Redundant AC-Input Power Supplies," for the procedure on repackaging the power supplies for shipment.

If your system is configured with DC-input power supplies, perform the following steps:


Step 1 Position the empty large cardboard box on the front of the pallet so that the two foam brackets mounted to the outside of the box are positioned under the system air filter tray. These foam brackets prevent the cardboard box from coming loose during transit.

Step 2 Stack the bottom and top halves of the power supply foam inserts in the large cardboard box.

Step 3 Proceed to the section "Repackaging the Accessories Box," in this appendix, to complete the repackaging procedure.

Repackaging the Redundant AC-Input Power Supplies

Two AC-input power supplies are shipped installed in the Cisco 12012 power supply bay. If your system is configured with three or four AC-input power supplies, the third and fourth power supplies are shipped packaged in foam inserts inside a large cardboard box mounted to the front of the pallet.

Perform the following steps to repackage the third and fourth AC-input power supplies in their shipping container:


Step 1 Position the empty large cardboard box on the front of the pallet so that the two foam brackets mounted to the outside of the box are positioned under the system air filter tray. These foam brackets prevent the cardboard box from coming loose during transit.

Step 2 Place the bottom half of the power supply foam insert in the bottom of the large cardboard box.

Step 3 Wrap the AC-input power supply in a plastic bag and place the packaged power supply faceplate-up in one of the cutouts in the bottom foam insert. Repeat this step for the fourth power supply.

Step 4 Place the top half of the foam insert over the top of the power supplies.

Repackaging the Accessories Box

Perform the following steps to repackage the accessories box and place it in the large cardboard box (see ):


Step 1 Place all of the accessories (including brace bar, AC power cords, documentation, and mounting hardware) in the accessories box and tape the box shut.

Step 2 Place the accessories box on top of the power supply foam insert.

Step 3 Fold the flaps down and tape the top of the cardboard box.

Step 4 Place the foam top cap on the top of the Cisco 12012.

Installing the Side Panels, End Panels, and Top of the Shipping Container

Perform the following steps to install the wooden side and end panels and the wooden top cap on the shipping container (See ):


Step 1 Install the two wooden side panels on the pallet by performing the following steps:

(a) Position one of the shipping packaging wooden side panels on the pallet so that the four tabs on the bottom of the side panel are facing out and fit into the four slots on the edge of the pallet.

(b) While holding the side panel, bend the four tabs outward 180 degrees with pliers or a flat-blade screwdriver.

(c) Repeat steps (a) and (b) for the second side panel.

Figure A-2 Cisco 12012 Shipping Packaging

Step 2 Install the two wooden end panels on the pallet by performing the following steps:

(a) Position the shipping packaging wooden end panel on the pallet so that the two tabs on the bottom of the panel are facing out and fit into the two slots on the pallet.

(b) While holding the end panel, bend the two tabs outward 180 degrees with pliers or a flat-blade screwdriver.

(c) Repeat steps (a) and (b) for the front panel.

Step 3 Secure the four sides of the shipping container together by performing the following steps:

(a) Grasp an end panel with one hand and a side panel with the other hand and fit the two panels together so that the six tabs on the end panel fit into the six slots on the side panel.

(b) While holding the two panels, bend the six tabs outward 180 degrees to secure the two panels together.

(c) Repeat steps (a) and (b) for the remaining three sides.

Step 4 Position the wooden top cap over the top of the shipping container so that the twelve tabs on the sides of the shipping container fit into the twelve slots on the top cap.

Step 5 Bend the 12 tabs outward 180 degrees with pliers or a flat-blade screwdriver.

The Cisco 12012 is now repackaged and ready to be transported. Use a forklift or pallet jack to move the repackaged Cisco 12012.