Cisco 12404 Internet Router Installation and Configuration Guide
Chapter 5 - Maintaining the Cisco 12404 Internet Router
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Maintaining the Cisco 12404 Internet Router

Table Of Contents

Maintaining the Cisco 12404 Internet Router

Overview

Tools and Equipment

Powering Off an AC Powered Router

Powering Off a DC Powered Router

Removing and Installing the Front Door on Cisco 12404 Enhanced Series Router

Removing and Replacing an AC Power Entry Module

Troubleshooting an AC PEM Installation

Removing and Replacing a DC Power Entry Module

Troubleshooting the DC PEM Installation

Removing and Replacing a DC PDU

Troubleshooting the DC PDU Installation

Cleaning and Replacing the Air Filter

Removing the Air Filter

Installing the Air Filter

Removing and Replacing the Fan Tray Assembly

Troubleshooting the Fan Tray Assembly Installation

Removing and Replacing an RP or Line Card

Removing an RP or Line Card

Installing a Route Processor or Line Card

Attaching an RP and Line Card Cable Management Bracket

Connecting RP and Line Card Cables

Removing and Replacing a Consolidated Switch Fabric Card

Removing a Consolidated Switch Fabric Card

Installing a Consolidated Switch Fabric Card

Removing and Replacing the Chassis

Before You Begin

Preparing the Replacement Chassis

Preparing the Defective Chassis

Disconnecting Power from the Router

Removing the CSF Card

Disconnecting RP Cables

Disconnecting Line Card Cables

Transferring System Components

Transferring the Fan Tray

Transferring the Power Entry Modules

Reinstalling the Power Entry Modules

Transferring RP and Line Cards

Transferring the Consolidated Switch Fabric Card

Removing the Chassis from the Equipment Rack

Detaching the Supplemental Bonding and Grounding Connection

Removing the Chassis from the Equipment Rack

Removing the Chassis from Center-Mount Brackets

Installing the Replacement Chassis

Installing the Chassis on a Tabletop or Flat Surface

Reattaching the Supplemental Bonding and Grounding Connection

Reconnecting Power to the Router

Reconnecting Line Card Network Interface Cables

Reconnecting the Route Processor Cables

Reconnecting the Fan Tray

Installing a DC Power Distribution Unit

Restarting the Cisco 12404 Internet Router

Upgrading the RP and Line Card Memory


Maintaining the Cisco 12404 Internet Router


Overview

This chapter contains safety at the field replaceable unit (FRU) level, removal and replacement instructions for FRUs and procedures to troubleshoot the FRUs.

Your Cisco 12404 Internet Router is equipped as ordered and is ready for installation and startup when it leaves the factory. After you install and configure your router, you will need maintenance. These procedures are designed to help you replace a FRU and to ensure that your Cisco 12404 Internet router continues to operate properly.

Most Cisco 12404 router FRUs can be removed and replaced with the power on and the system operating, the online insertion and removal of components with the power on, is known as hot swappable.

The FRU parts in Table 5-1 are described in this chapter. Table 5-1 shows the FRUs that are hot swappable and those that are not.

Table 5-1 FRU Online Insertion and Removal Chart 

FRU
Hot Swappable

DC power entry module (PEM)

Yes (if redundant PEMs installed)

DC Power distribution unit (PDU)

No

AC PEM

Yes (if redundant PEMs installed)

Air filter

Yes

Line cards

Yes

Route processor

Yes (if redundant RPs installed)

CSF card

No

Fan tray assembly

Yes

Cable management bracket

n/a

Center mount brackets

n/a


As your networking requirements change, you will want to upgrade your system by adding or changing components. The following sections describe tools and instructions to assist you in performing upgrades and periodic maintenance on your Cisco 12404 router.

Tools and Equipment

Powering Off an AC Powered Router

Powering Off a DC Powered Router

Removing and Installing the Front Door on Cisco 12404 Enhanced Series Router

Removing and Replacing an AC Power Entry Module

Removing and Replacing a DC Power Entry Module

Removing and Replacing a DC PDU

Cleaning and Replacing the Air Filter

Removing and Replacing the Fan Tray Assembly

Removing and Replacing an RP or Line Card

Removing and Replacing a Consolidated Switch Fabric Card

Removing and Replacing the Chassis

Transferring System Components

Removing the Chassis from the Equipment Rack

Installing the Replacement Chassis

Restarting the Cisco 12404 Internet Router

Upgrading the RP and Line Card Memory

Before you perform the procedures in this chapter, review the following safety information in the Regulatory Compliance and Safety Information for the Cisco 12000 Internet Routers, Publication Number 78-4347-09). This document is shipped with your Cisco 12404 router.

Tools and Equipment

The following section lists tools and equipment for unpacking, performing maintenance, and setting up your Cisco 12404 router.

ESD-preventive strap

3/16-inch flat-blade screwdrivers

1/4-inch flat-blade screwdrivers

9/15-inch (14-mm) wrench

3/4-inch (19-mm) socket and ratchet wrench

2-mm allen wrench

Vacuum cleaner

Antistatic bag (or similar ESD-preventive container)

Number 2 Phillips screwdriver

Powering Off an AC Powered Router

To power off an AC powered router:


Step 1 Turnoff the AC PEM power switch for each AC PEM installed (Figure 5-1).

Step 2 Turn off all circuit breakers for AC source power.

Step 3 Unplug all power cords from all AC power source outlets.

Step 4 Attach an ESD-preventive strap to your wrist or ankle. Attach the ESD clip to the chassis or to a bare metal surface.

Figure 5-1 AC PEM

1

AC PEM handle

4

Power cord receptacle

2

On/Off switch

5

LEDs

3

Bail Latch

6

Captive screws


Step 5 Release the bail latch holding the AC power cord to the power receptacle.

Step 6 Unplug the power cord from the AC PEM receptacle.

Step 7 Verify that the green AC PEM Input OK, Output OK, and amber Output Fail LEDs are all off.

Step 8 Visually check that the AC PEM fans are all off.

Step 9 Visually check that the fan tray assembly fans are all off.

Step 10 Visually check that all RP and line card LEDs are all off.

Step 11 Visually check that the CSF LEDs are all off.


Caution In a noisy environment, place your hand in front of the fan compartment on each part with a fan, to ensure the fans are all off.


Powering Off a DC Powered Router

To power off a DC-powered router:


Step 1 Turn off the DC PEM power switch for each DC PEM installed (Figure 5-2).

Step 2 Turn off all circuit breakers for DC source power.

Step 3 Attach an ESD-preventive strap to your wrist or ankle; and attach the ESD clip to the chassis or to a bare metal surface.

Step 4 Verify that the green DC PEM Input OK, Output OK, and amber Output Fail LEDs are all off.

Step 5 Visually check that the fan tray assembly fans are all off.

Step 6 Visually check that the DC PEM fans are all off.

Figure 5-2 DC PEM and PDU

1

DC PDU

5

On/Off switch

2

DC PEM

6

PDU captive screws

3

PEM captive screws

7

Terminal Block

4

LEDs

   

Step 7 Visually check that all RP and line card LEDs are all off.

Step 8 Visually check that the CSF LEDs are all off.


Caution In a noisy environment, place your hand in front of the fan compartment on each part with a fan, to ensure the fans are all off.

Step 9 Remove all power lines positive (+), negative (-) and ground wires connected to the DC PDU block.

Removing and Installing the Front Door on Cisco 12404 Enhanced Series Router

The Cisco 12404 enhanced series router has a new one-piece front door. The router ships with the door hinge mounted on the left side of the chassis so that it opens from right-to-left. This section describes how to change the front door to open from left-to-right by installing the hinge on the opposite side.

Use the following procedure to change the location of the hinge.


Step 1 Open the front door by pressing the right latch button (Figure 5-3).

Figure 5-3 Opening the Front Door

1

Front Door Latch


Step 2 Remove the front door by lifting the (top and bottom) hinge pins to free the door from the chassis (Figure 5-4).


Caution Make sure you are holding the front door securely so it does not drop when you release it from the chassis.

Step 3 Reinstall the hinge pins into the chassis hinge brackets.

Figure 5-4 Removing or Installing Hinge Pins

Step 4 Remove the bumpers and pivot blocks from the door as shown in Figure 5-5.

Figure 5-5 Removing the Bumpers and Pivot Blocks

1

Bumpers

2

Pivot Blocks


Step 5 Reinstall the hardware to the opposite sides of the front door:

a. Mount pivot blocks to the left side and tighten the screws until snug.

b. Mount the bumpers to the right side and tighten the screws until snug.

Step 6 Attach the front door to the chassis:

a. Remove the hinge pins from the hinges on the right side of the chassis.

b. Align the pivot blocks on the front door with the hinges on the right side of the chassis and install the hinge pins to hold the door in place (see Figure 5-4).

c. Close the front door by pressing the latch button allowing the door latch to engage with the hinge pins on the chassis.


Removing and Replacing an AC Power Entry Module

The AC PEM supports online insertion and removal (OIR), so you can remove and install the PEM while the system remains powered on without presenting an electrical hazard or damage to the system. This feature lets you replace the AC PEM while the system maintains all routing information and ensures session preservation.


Caution Although an AC PEM supports OIR and can be replaced without interruption to system operation, do not operate the system without the PEM for more than a few minutes.


Note The power supplies PWR-GSR4-AC, PWR-GSR4-AC= do not electrically store unit detials like serial number, firmware version, and part number. Hence, the software is unable to display serial number, firmware version, and part number details for the power supplies PWR-GSR4-AC, PWR-GSR4-AC=. While the enhanced power supply 12000/4-AC can read and display serial number, firmware version, and part number details of the units as they can electronically store this information.


Refer to Figure 5-6 and use the following procedure to remove and replace an AC PEM.


Step 1 Power off the faulty PEM.

Step 2 Unplug the power supply cord from its AC outlet.

Step 3 Power off the circuit breaker assigned to that AC outlet.

Step 4 Release the bail latch and unplug the power cord from its receptacle.

Verify that all status LEDs are off.

Step 5 Loosen the two captive screws that secure the PEM to the chassis.

Step 6 Remove the PEM from the chassis using the finger grips to pull it out.


Warning An AC PEM weighs approximately 11.0 lbs. (4.98 kg.). Use both hands to remove it from the chassis.


Figure 5-6 AC PEM Components

1

AC PEM finger grips

4

Power cord receptacle

2

On/Off switch

5

Status LEDs

3

Bail latch

6

Captive screws



Tip If you plan to return the defective PEM to the factory, repackage it in the shipping container you received with the replacement PEM.


Step 7 Slide the replacement PEM into the bay until it is seated to the backplane connector.

Make sure the power switch is in the off (0) position.

Step 8 Tighten the two captive screws to secure the PEM to the chassis.

Electrical connections between the PEM the backplane connector are made automatically when the PEM is fully seated and the captive screws are tightened.

Step 9 Connect the power cord into the receptacle and place the bail latch over the power cord to secure it in place.

Step 10 Plug the power cord into its AC outlet.

Step 11 Power on the circuit breaker assigned to that AC outlet.

Step 12 Power on the PEM.

The green INPUT OK and OUTPUT OK LEDs are on.

The amber OUTPUT FAIL LED is off.

See the "Troubleshooting an AC PEM Installation" section if the PEM does not power on correctly.


Troubleshooting an AC PEM Installation

Refer to Figure 5-7 and use the following procedure to troubleshoot the PEM installation.

Figure 5-7 AC PEM Status LEDs

1

INPUT OK

Green On

The PEM is powered on and operating correctly.

2

OUTPUT OK

Green On

The AC power source is present and operating within the specified limit.

3

OUTPUT FAIL

Amber On

The PEM detects a fault condition causing it to shutdown.



Step 1 If the INPUT OK and OUTPUT OK LEDs are off, or if the OUTPUT FAIL LED is on, check that the:

PEM is firmly seated in the bay and the captive screws are tightened securely.

AC power source circuit breaker is switched on.

Power cord is firmly plugged into the AC power source receptacle.

Power cord is firmly plugged into the PEM and the bail latch is secure over the plug.

Power switch is set to the on (1) position.

Step 2 If the problem still exists after checking the items in Step 1, replace the PEM.

Step 3 If replacing the PEM does not correct the problem, contact a Cisco service representative for assistance.


Removing and Replacing a DC Power Entry Module

The DC PEM supports online insertion and removal (OIR), so you can remove and install the PEM while the system remains powered on without presenting an electrical hazard or damage to the system. This feature lets you replace the AC PEM while the system maintains all routing information and ensures session preservation.


Caution Although a DC PEM supports OIR and can be replaced without interruption to system operation, do not operate the system without the PEM for more than a few minutes .


Note The power supplies PWR-GSR4-DC, PWR-GSR4-DC= do not electrically store unit detials like serial number, firmware version, and part number. Hence, the software is unable to display serial number, firmware version, and part number details for the power supplies PWR-GSR4-DC, PWR-GSR4-DC=. While the enhanced power supply 12000/4-DC can read and display serial number, firmware version, and part number details of the units as they can electronically store this information.


Refer to Figure 5-8 and use the following procedure to remove and replace a DC PEM.


Step 1 Power off the faulty PEM.

Step 2 Power off the circuit breaker assigned to the DC power source.

Verify that all LEDs are off.

Step 3 Loosen the three captive screws that secure the PEM to the chassis.

Step 4 Remove the PEM from the chassis using the finger grips to pull it out.


Warning A DC PEM weighs approximately 11.0 lbs. (4.98 kg.). Use both hands to remove it from the chassis.


Figure 5-8 DC PEM and PDU Components

1

DC PDU

5

On/Off switch

2

DC PEM

6

PDU captive screws

3

PEM captive screws

7

PDU terminal block

4

Status LEDs

   


Tip If you plan to return the defective PEM to the factory, repackage it in the shipping container you received with the replacement PEM.


Step 5 Slide the replacement PEM into the bay until it is seated to the backplane connector.

Make sure the power switch is in the off (0) position.

Step 6 Tighten the three captive screws to secure the PEM to the chassis.

Electrical connections between the PEM the backplane connector are made automatically when the PEM is fully seated and the captive screws are tightened.

Step 7 Power on the circuit breaker assigned to the DC source power.

Step 8 Power on the PEM.

The green INPUT OK and OUTPUT OK LEDs are on.

The amber OUTPUT FAIL LED is off.

See the "Troubleshooting the DC PEM Installation" section if the PEM does not power on correctly.


Troubleshooting the DC PEM Installation

Refer to Figure 5-9 and use the following procedure to troubleshoot the PEM installation.

Figure 5-9 DC PEM Status LEDs

1

DC PDU

 
2

DC PEM

3

INPUT OK
(Green)

On

DC PEM is operating normally in a power-on condition

4

OUTPUT OK
(Green)

On

DC power source is present and within specified limit

5

OUTPUT FAIL
(Amber)

On

PEM is operating in a fault condition and shutdown has occurred



Step 1 If the INPUT OK and OUTPUT OK LEDs are off, or if the OUTPUT FAIL LED is on, check that the:

PEM is firmly seated in the bay and the captive screws are tightened securely.

DC power source circuit breaker is switched on.

Power switch is set to the on (1) position.

Step 2 If the problem still exists after checking the items in Step 1, replace the PEM.

Step 3 If replacing the PEM does not correct the problem, contact a Cisco service representative for assistance.


Removing and Replacing a DC PDU

The DC PDU does not support online insertion and removal (OIR) and cannot be replaced while the system is operating. You must power off the router before replacing the PDU.


Warning To remove and replace the DC PDU, the system must be powered off. Notify the network administrator and other appropriate personnel that all routing traffic stops while the PDU is replaced.


Refer to Figure 5-10 and use the following procedure to remove and replace a DC PDU.

Figure 5-10 DC PEM and PDU Components

1

DC PDU

5

On/Off switch

2

DC PEM

6

PDU captive screws

3

PEM captive screws

7

PDU terminal block

4

Status LEDs

   


Step 1 Power off both PEMs.

Step 2 Power off the circuit breakers assigned to the DC power source.

Verify that all status LEDs on both PEMs are off.

Step 3 Loosen the terminal block screws to disconnect the positive, negative, and ground wires from the DC PDU terminal block of the faulty PEM.


Caution Before removing wires, be sure to note the color for each type of wire (positive, negative, and ground). Because there is no color code standard for source DC wiring, you must be sure which power wires are connected to the proper positive (+) and negative (-) terminal ports. Typically, green (or green and yellow) indicate a ground wire, while power wire leads may be labeled positive (+) or negative (-). Because this is not always the case, the safest way to indicate the polarity of a wire is to note its color and identify it as described in this procedure.


Warning When disconnecting source DC power wires, always disconnect the ground wire last.


Step 4 Loosen the captive screws securing the PDU and the PEM to the chassis.

Step 5 Remove the PDU/PEM from the chassis using the finger grips to pull it out.


Warning A DC PEM and PDU weigh more than 11.0 lbs. (4.98 kg.). Use both hands to remove it from the chassis.


Place the PDU/PEM on a table or other flat surface.

Step 6 Disconnect the PDU from the PEM.

Step 7 Connect the new PDU to the PEM (Figure 5-11).

Figure 5-11 Connector for DC PEM and DC PDU (DC PEM Rear view)

Step 8 Slide the PDU/PEM into the bay until the PEM is seated to the backplane connector.

Make sure the power switch is in the off (0) position.

Step 9 Tighten the captive screws to secure the PDU and PEM to the chassis.

Electrical connections between the PEM the backplane connector are made automatically when the PEM is fully seated and the captive screws are tightened.

Step 10 Connect the ground, positive, and negative wires to the PDU terminal block in the following order (Figure 5-12):

a. Reconnect the ground wire.


Warning When reconnecting source DC power wires, always connect the ground wire first.


b. Reconnect the positive wire.

c. Reconnect the negative wire.


Caution Be sure to connect the wires according to the color coding notes and labels you made in Step 3.

Figure 5-12 DC PDU Terminal Block

1

Negative port

3

Ground port

2

Positive port

4

Terminal port connector screws


Step 11 Power on the circuit breakers assigned to the DC power source.

Step 12 Power on both PEMs.

The green INPUT OK and OUTPUT OK LEDs are on.

The amber OUTPUT FAIL LED is off.

See the "Troubleshooting the DC PDU Installation" section if the PEM does not power on correctly.


Troubleshooting the DC PDU Installation

Refer to Figure 13 and use the following procedure to troubleshoot the PDU installation.

Figure 13 DC PDU, PEM, and Status LEDs

1

DC PDU

 
2

DC PEM

3

INPUT OK
(Green)

On

DC PEM is operating normally in a power-on condition

4

OUTPUT OK
(Green)

On

DC power source is present and within specified limit

5

OUTPUT FAIL
(Amber)

On

PEM is operating in a fault condition and shutdown has occurred



Step 1 If the INPUT OK and OUTPUT OK LEDs are off, or if the OUTPUT FAIL LED is on, check that the:

PEM is firmly seated in the bay and the captive screws are tightened securely.

DC power source circuit breakers are switched on.

DC power cables are securely attached to the PDU terminal block.

Power switch is set to the on (1) position.

Step 2 If the problem still exists after checking the items in Step 1, replace the PEM.

Step 3 If replacing the PEM does not correct the problem, contact a Cisco service representative for assistance.


Cleaning and Replacing the Air Filter

The Cisco 12404 Internet router has a serviceable air filter. Facing the rear of the chassis, the air filter is housed on the left side of the chassis. The air filter location is shown in Figure 5-14. Air flow through the air filter is shown in Figure 5-15.

The air filter removes dust from the room air drawn into the router by the cooling fans. One time per month (or more often in dusty environments), you should examine the air filter. If the filter appears dirty, you can either vacuum or replace it. If the filter appears worn or torn, dispose of it in a responsible manner and install a replacement air filter.

Cleaning and replacing the air filter is presented in the following sections:

Removing the Air Filter

Installing the Air Filter


Note You can perform these procedures with the router power on.


Removing the Air Filter

To remove and clean an air filter (Figure 5-14):


Note Do not damage the air filter. Damage to the air filter can restrict the airflow and cause an overtemperature condition in the router.


Figure 5-14 Cisco 12404 Internet Router Air Filter Location


Step 1 Attach an ESD-preventive strap to your wrist or ankle; and attach the ESD clip to the chassis or to a bare metal surface.

Step 2 Grasp the small tab on the edge of the air filter and pull the tab to remove the air filter from the housing.


Tip If you are unable to lift the tab on the edge of the air filter, use a 3/16-inch flat-blade screwdriver to lift the tab, then grasp it.


Step 3 Move the air filter away from the chassis (Figure 5-15).

Figure 5-15 Cisco 12404 Internet Router Air Filter Direction of Air Flow

Step 4 Visually check the condition of the air filter.


Caution When cleaning or replacing the air filter keep it away from the RP and line card cage so that any dislodged dust will not be drawn into the cage. Do not vacuum the air filter while it is installed in the housing.

If the filter appears dirty, you can either vacuum or replace it.

If the filter appears worn or torn, dispose of it in a responsible manner and install a replacement air filter.


Caution Never wash an air filter and immediately reinstall it in the chassis, because moisture drawn inside the chassis can damage the components. Allow the air filter to become completely dry.


Installing the Air Filter

Instructions for installing the air filter in the air filter housing, at the left rear side of the chassis, are presented in the following steps. Use Figure 5-15 as a reference for installing the air filter.


Step 1 Attach an ESD-preventive strap to your wrist or ankle; and attach the ESD clip to the chassis or to a bare metal surface.


Timesaver The arrows on the top edge of the air filter note the direction of air flow. Insert the air filter into its housing with the arrows pointing toward the card cage.


Step 2 Slide the air filter completely into the air filter housing.


Caution Do not damage the air filter. Damage to the air filter can restrict the airflow, cause an overtemperature condition in the router and degrade EMI performance.


Removing and Replacing the Fan Tray Assembly

The fan tray assembly supports online insertion and removal (OIR), so you can remove and install the fan tray assembly while the system remains powered on without presenting an electrical hazard or damage to the system. This feature lets you replace the fan tray assembly while the system maintains all routing information and ensures session preservation.


Caution Although the fan tray assembly supports OIR and can be replaced without interruption to system operation, do not operate the system without the fan tray assembly for more than a few minutes to prevent overheating.

Use the following procedure to remove and replace the fan tray assembly.


Step 1 Loosen the two captive screws on the fan tray assembly (item 3 in Figure 5-16).

Figure 5-16 Cisco 12404 Internet Router Fan Tray Assembly Location

1

Chassis

3

Fan tray assembly

2

AC PEM

   

Step 2 Grasp the handle and pull the fan tray assembly out of the fan tray housing (Figure 5-17).

Support the bottom of the assembly with your other hand when removing the fan tray.

Electrical connection for the fans are automatically disconnected when the fan tray is removed from the housing.

Figure 5-17 Cisco 12404 Router Fan Tray Assembly

Step 3 Hold the fan tray assembly with both hands and insert the connector end of the fan try into the fan tray assembly housing channel.


Note The fan try is designed to install only one way. Excessive force is not necessary when installing the fan tray assembly in the housing channel.


Step 4 Tighten the two captive screws on the fan tray assembly.

Electrical and control line connections for the fan tray assembly are made automatically when the fan tray is properly seated in the fan tray housing.


Troubleshooting the Fan Tray Assembly Installation

After the fan tray assembly is connected to a power source, follow these steps to verify that the fan tray assembly is operating properly.


Step 1 Verify that the fans are operating when the connectors are properly mated at the backplane and the captive screws are tightened. If the fans are not operating check that:

The fan tray assembly is seated properly and is flush against the chassis.

The captive screws are tightened securely.

Step 2 If the AC or DC power source was disconnected to remove and replace the fan tray assembly, make sure the router is powered on.

Step 3 If the fan tray assembly does not operate after verifying the items in steps 1 and 2, replace the fan tray assembly.


Caution If the replacement fan assembly does not operate, shut down your router and contact a Cisco service representative for assistance.


Removing and Replacing an RP or Line Card

The process to remove and replace a card in the RP and line card cage is presented in this section.

Line cards can occupy any slot, zero (0) through 3 in the RP and line card cage. Your Cisco 12404 router is configured with the RP in slot 0 (Figure 5-18).

Redundant RPs can be placed in any slot and requires a line card spacer to comply with EMI emission standards.

Additional line card information can be found in the respective installation and configuration note for each type of line card. Installation and configuration notes accompany every line card that ships from the factory as a field-replaceable unit (FRU).

Figure 5-18 CSF Location and RP and Line Card Slot Numbers

Removing an RP or Line Card

RP and line cards are hot swappable modules of the Cisco 12404 router. Removing an RP or line card from the RP and line card cage is presented in the following steps.


Step 1 Attach an ESD-preventive strap to your wrist or ankle; and attach the ESD clip to the chassis or to a bare metal surface.

Step 2 Identify the RP or line card to be replaced and write down the following information:

The RP cable connections on the RP.

The number and type of RP or line card, so that you will know the location of the card when you re-install it or the replacement, in the card cage.

The network interface cable connection ports, on the RP or line card.

Step 3 On RPs, and line cards with multiple ports, start with the left port on the card and disconnect the interface cable connectors from each of the ports.

Step 4 After all of the interface cables are disconnected, loosen the two captive screws on the cable-management bracket and pull the bracket away from the card.

Step 5 Loosen the two ejector lever captive screws at each end of the RP or line card faceplate.

Step 6 Simultaneously pivot the ejector levers away from each other to unseat the RP or line card from the backplane connector and rotate each ejector lever outward away from the faceplate. See Figure 5-19.


Caution Fully remove each RP or line card from the slots. Do not allow the line card to rest partially inserted into the slots as this will damage the EMI shielding on the RP or line card in the slot directly below.

Step 7 Grasp the edges of the card carrier with both hand to support it and fully remove the RP or line card from the slots.

Step 8 Immediately place the RP or line card in an antistatic bag to protect it against ESD and to prevent dust from getting to the fiber-optic connectors on fiber-optic line cards.

If you plan to return the defective unit to the factory, repackage it in the shipping container you received with the replacement RP or line card.


Figure 5-19 Removing an RP or Line Card from the Card Cage

Installing a Route Processor or Line Card

This section contains the procedure to install an RP or line card in the card cage.


Note Installing a card in slot 1 when all other slots are filled may require additional effort to properly seat the card. Because of the tight fit you have to either apply extra pressure to properly seat the card, or you can remove the card in slot 2 before installing the card in slot 1. After you install the card in slot 1 you can reinstall the card in slot 2.


To replace an RP or line card follow the steps in this procedure.


Step 1 Attach an ESD-preventive strap to your wrist or ankle; and attach the ESD clip to the chassis or to a bare metal surface.

Step 2 Check your notes on the slot assignment and network interface cable information that you wrote down before removing the other RP or line card.


Caution Handle the RPs and line cards by the metal card carrier edges only; avoid touching the board itself or any connector pins.

Step 3 Remove the RP or line card from its shipping package and antistatic bag.

Step 4 Set both edges of the RP or line card carrier into the card slot carrier alignment grooves on either side of the card cage.


Caution Do not allow the line card to rest partially inserted into the slots as this will damage the EMI shielding on the RP or line card in the slot directly below.

Step 5 Pivot the ejector levers away from each other; rotate each ejector lever outward away from the faceplate.

Step 6 Grasp the edges of the metal card carrier with both hands to support and guide the RP or line card into the slot alignment grooves in the card cage.


Caution One edge of the card carrier faceplate is lined with an EMI-preventive gasket consisting of many raised, conductive contacts. Be careful not to damage the gasket contacts, because a damaged card carrier gasket can result in reduced EMI performance.

Step 7 Use both thumbs to slide the card carrier into the RP or line card slot until the ejector levers make contact with the front of the card cage, then stop.

Step 8 Grasp the two RP or line card ejector levers and pivot them toward the card faceplate until they are perpendicular to the faceplate; this action will seat the RP or line card in the backplane connector.


Note The line card will not boot properly if not fully seated.


Step 9 Tighten the captive screws on each side of the card faceplate to prevent the RP or line card from becoming partially dislodged from the backplane and to ensure proper EMI shielding.


Note The line card captive screws must be tightened to meet EMI specification standards.


Repeat Step 1 through Step 9 for any additional replacement RPs or line cards, and then proceed to the next section.


Attaching an RP and Line Card Cable Management Bracket

When you install a new RP or line card, you must attach the line card cable-management bracket to the faceplate of the card before connecting cables. The type of line card cable-management bracket used by a line card is determined by the line card type and the number of network interface ports on the card faceplate.

Cisco 12000 series router line cards use cable-management brackets for the following.

Organize the network interface cables

Keep the network interface cables out of the way

Position connectors at their respective ports on the faceplate of the line card

Keep the cables free of sharp bends (excessive bending in a network interface cable can cause performance degradation)

Attaching the line card cable-management bracket to a line card is presented in the following steps.


Step 1 Attach an ESD-preventive strap to your wrist or ankle; and attach the ESD clip to the chassis or to a bare metal surface.

Step 2 Take the RP and line card cable-management bracket from the shipping carton.

Step 3 Orient the top of the line card cable-management bracket with the top of the RP or line card faceplate. See Figure 5-20.

Step 4 Align the two captive screws on the bracket with the threaded insert holes near the ejector levers on each side of the RP or line card faceplate.

Step 5 Finger tighten the two captive screws.


Caution Do not overtighten the captive screws; you might strip the threads on the screw or in the insert in the line card faceplate.

Step 6 Use a 3/16-inch flatblade screwdriver to further tighten the two captive screws.

Step 7 Repeat Step 2 through Step 6 for any remaining RPs or line cards.


Connecting RP and Line Card Cables

When you replace an existing RP or line card in the RP and line card cage, you must re-attach the line card cable management bracket to the RP or line card faceplate and reconnect the network interface cables to the replacement RP or line card.

If you have added a new RP or line card, you must connect the network interface cables to the RP or line card.


Note If a line card slot in the card cage is not populated with a line card, a blank line card must be installed to avoid an over temperature condition and to ensure electromagnetic compliance (EMC).


To reconnect network interface cables to a replacement RP or line card in the card cage follow these steps:


Step 1 Attach an ESD-preventive strap to your wrist and to the chassis; or to a bare metal surface.

Step 2 Attach an appropriate number of velcro straps to support the interface cables, through the slots in the cable management bracket (Figure 5-20).

Figure 5-20 Line Card or RP Cable Management Bracket with Velcro Strap

Step 3 Pull the small end of the velcro strap through the slot in the cable management bracket.

Step 4 Insert the small end of the velcro strap into the slot in the wide end of the velcro strap.

Step 5 Pull the small end through the velcro strap slot to secure it to the cable management bracket. See Figure 5-20.

Step 6 Proceed from the left port on the RP or line card, to the right port, identify the network interface cable for the RP or line card port and insert the cable connector into the RP or line card port.

Step 7 Align each RP or line card interface cable with the cable management bracket to which it belongs.

Step 8 Adjust the interface cable in the cable management bracket to prevent any kinks or sharp bends in the interface cable.


Note Allow adequate strain relief and avoid excessive bending of a network interface cables; these conditions can cause performance degradation.


Step 9 Repeat steps 1 through 8 for the remainder of the interface cables for each line card.

Step 10 Secure the interface cables to the cable management bracket by wrapping the velcro around them. Do not wrap the velcro too tight.

Step 11 Press the velcro strap against itself to secure it. Figure 5-20 offers a generic cable management bracket and velcro strap assembly.


Removing and Replacing a Consolidated Switch Fabric Card

Removing and replacing a CSF card instructions are presented in this section. The CSF card occupies the bottom slot in the card cage (Figure 5-21).


Caution The CSF card is not hot-swappable component of the Cisco 12404 router.

Figure 5-21 CSF Slot Location

Removing a Consolidated Switch Fabric Card

The CSF occupies the bottom slot in the cage. The CSF card is not hot swappable you cannot remove and replace a CSF card while the system remains powered up.

To remove a CSF from the card cage follow these steps.


Step 1 Attach an ESD-preventive strap to your wrist or ankle; and attach the ESD clip to the chassis or to a bare metal surface.

Step 2 Power down your router.

Use the "Powering Off an AC Powered Router" section for AC powered routers.

Use the "Powering Off a DC Powered Router" section for DC powered routers.

Step 3 After you have powered off your router, re-attach an ESD-preventive strap to your wrist or ankle; attach the ESD clip to the chassis or to a bare metal surface and proceed to step 4.

Step 4 Loosen the two captive screws on each side of the CSF card.

Step 5 Grasp the card ejector levers and pivot them away from the CSF card faceplate (Figure 5-22).

Figure 5-22 Installing a CSF Card

Step 6 Slide the CSF half-way out of the slot, then stop.

Step 7 Touching only the metal card carrier, use your free hand to support the bottom of the CSF.

Step 8 Slide the card out of the slot and place it directly into an antistatic bag or other ESD-preventive container.

Step 9 If you plan to return the defective CSF to the factory, repackage it in the shipping container you received with the replacement card.


Installing a Consolidated Switch Fabric Card

To replace or install a CSF in the line card and CSF cage, refer to Figure 5-22 and follow these steps:


Step 1 Attach an ESD-preventive strap to your wrist and to the chassis; or to a bare metal surface.

Step 2 Power down your router.

Use the "Powering Off an AC Powered Router" section for AC powered routers.

Use the "Powering Off a DC Powered Router" section for DC powered routers.

Step 3 After you have powered down your router re-attach an ESD-preventive strap to your wrist or ankle; attach the ESD clip to the chassis or to a bare metal surface and proceed to step 4.

Step 4 Remove the CSF card from its antistatic bag or ESD-preventive container. Touch only the metal card carrier


Note There are card slot alignment grooves on each side of the CSF cage. When you reinstall a card in an CSF slot, make sure you carefully align both edges of the card carrier in the corresponding card slot grooves.



Caution Avoid touching the card circuitry or any connectors.

Step 5 Set both edges of the CSF carrier into the card slot carrier alignment grooves on either side of the CSF cage.

Step 6 Pivot the ejector levers away from each other; rotate each ejector lever outward away from the faceplate.

Step 7 Use both thumbs to slide the card carrier into the CSC slot until the ejector levers make contact with the front of the card cage, then stop.

Step 8 Pivot the ejector levers toward the faceplace until the connector seats in the backplane.


Caution CSF ejector levers may not fit flush against the CSF faceplate.

Step 9 Tighten the captive screws on each side of the CSF faceplate.


Removing and Replacing the Chassis

This section describes how to remove and replace a Cisco 12404 Internet router chassis. The router chassis is an integrated, sheet metal assembly that includes:

1 CSF card slot

1 Air filter housing

1 Fan tray assembly housing

1 Backplane with connectors

2 AC PEM bays

2 DC PEM and DC power distribution bays

4 Slot RP and line card cage

The chassis can be rack mounted or placed on a stable flat surface.

Before You Begin

Because you will remove all of the components (except the air filter) from the defective chassis and reinstall them in the replacement chassis, during the process of removing the defective chassis, the procedures that follow are based on these prerequisites:

1. The replacement chassis has been removed from its shipping packaging and has been placed temporarily within reach of the rack in which the defective chassis is installed or near the surface where the defective chassis rests.

2. The replacement chassis has been temporarily connected to the same grounding system as the defective chassis.

3. You have prepared a place to set the defective chassis when it is removed from the equipment rack or stable flat surface.

4. Components are transferred from the defective chassis to the replacement chassis.

5. The replacement chassis and all the components now installed in it are inserted into the same equipment rack in place of the defective chassis.

6. The replacement chassis and all the components now installed in it are placed on a stable flat surface in place of the defective chassis.

This approach has the advantage of protecting against damage, the system components such as line cards, RPs and CSFs by eliminating the need to store them temporarily, outside their cages, bays and slots.

By transferring components from one chassis to the other, it will help to ensure that the physical configuration of the Cisco 12404 router is maintained, because each transferred component is installed in the same location in the replacement chassis that it occupied in the defective chassis.

Preparing the Replacement Chassis

Move the replacement chassis near the defective chassis site, temporarily connect the central office grounding system or interior equipment grounding system to the NEBS supplemental bonding and grounding receptacles on the replacement chassis. See Figure 5-24.

For more information, see the bonding and grounding cable and connector requirements, described in the "Supplemental Unit Bonding and Grounding Guidelines" section on page 3-9.

Preparing the Defective Chassis

Information on how to prepare the defective chassis for component removal is presented here.

Disconnecting Power from the Router

You must first power down the Cisco 12404 router as instructed in the "Powering Off an AC Powered Router" section or the "Powering Off a DC Powered Router" section before performing the process of removing the components from the defective chassis to the replacement chassis. Although many of the components in this procedure are hot swappable, you must power down the router before you remove a DC PDU.


Warning Power off your router.


Removing the CSF Card

To remove the CSF card from the fabric slot follow the instructions in the "Removing the CSF Card" section.

Disconnecting RP Cables

To remove the RP cables from the RP card follow the instructions in the "Removing an RP or Line Card" section.

After you disconnect the cables and the RP cable-management bracket from each card, carefully pull the cables bundles out of the way until the cables can be reinstalled on the replacement chassis and reconnected to the RP.

Disconnecting Line Card Cables

Disconnect the line card network interface cables from each line card as instructed in the "Removing an RP or Line Card" section.

After you disconnect the cables and the line card cable-management bracket from each card, carefully pull the cables bundles out of the way until the cables can be reinstalled on the replacement chassis and reconnected to the RP or line card.

Transferring System Components

Transferring components are presented in the following procedures.

Transferring the Fan Tray

Transferring the Power Entry Modules

Reinstalling the Power Entry Modules

Transferring RP and Line Cards

Transferring the Consolidated Switch Fabric Card

Transferring the Fan Tray

Remove and transfer the fan tray assembly from the chassis as instructed in the "Removing and Replacing the Fan Tray Assembly" section.

Transferring the Power Entry Modules

If your system is equipped with AC PEMs, remove each PEM as instructed in the "Removing and Replacing an AC Power Entry Module" section.

As you remove each PEM, move it away from the chassis and set it aside. You will reinstall the PEMs in the replacement chassis AC PEM bay.

If your system is equipped with DC PDUs and DC PEMs, remove each PEM and PDU as instructed in the "Removing and Replacing the Chassis" section.

As you remove each PEM and PDU, move them away from the chassis and set them aside. You will reinstall both units in the replacement chassis DC PEM and DC PDU bay.

Reinstalling the Power Entry Modules

If your replacement router is to be equipped with AC PEMs, reinstall the AC PEMs as instructed in the "Removing and Replacing an AC Power Entry Module" section.

If your replacement router is to be equipped with DC PEMs and DC PDUs, reinstall the DC PEMs and DC_PDUs as instructed in the "Removing and Replacing a DC Power Entry Module" section and "Removing and Replacing a DC PDU" section.

Transferring RP and Line Cards

You must remove the line cards and RPs from the RP and line card cage so that you can install them in the card cage in the replacement chassis.


Caution One edge of the card carrier faceplate is lined with an EMI-preventive gasket consisting of many raised, conductive contacts. Be careful not to damage the gasket contacts, because a damaged card carrier gasket can result in reduced EMI performance.


Caution You must remove any card slot blanks installed in the card cage and transfer them to the same card slots in the replacement chassis. Card slot blanks must be installed in slots without cards to maintain proper air flow and for EMI performance.


Note RP and line card captive screws must be tightened on the replacement chassis to ensure electromagnetic compliance (EMC)


Remove each line card in the card cage as instructed in the "Removing and Replacing an RP or Line Card" section.

As you remove each line card, transfer it to the same card slot in the replacement chassis. You must install the line cards in the same slots in the replacement chassis to match the router's existing software configuration. Reinstall the line cards as instructed in the "Installing a Route Processor or Line Card" section.


Note You must install the RP in the same slot in the replacement chassis to match the router's existing software configuration.


After removing the RP, transfer it to the same card slot in the replacement chassis. Reinstall the RP as instructed in the "Installing a Route Processor or Line Card" section.

Transferring the Consolidated Switch Fabric Card

The slot labeled FABRIC ALARM holds the CSF card. This is the bottom slot of the card cage.

To transfer the CSF card from the defective chassis to the replacement chassis reinstall the CSF as instructed in the "Installing a Consolidated Switch Fabric Card" section.


Note Switch Fabric captive screws must be tightened on the replacement chassis to ensure electromagnetic compliance (EMC)


Remove each card from the CSF cage, as instructed in the "Removing a Consolidated Switch Fabric Card" section, and install it immediately in the same slot of the replacement chassis according to the instructions.

Removing the Chassis from the Equipment Rack

This section contains the following procedures.

Detaching the Supplemental Bonding and Grounding Connection

Removing the Chassis from the Equipment Rack

Removing the Chassis from Center-Mount Brackets

Detaching the Supplemental Bonding and Grounding Connection

You must detach the supplemental bonding and grounding cables from the defective chassis. See the "Supplemental Unit Bonding and Grounding Guidelines" section on page 3-9.

Removing the Chassis from the Equipment Rack

To remove the defective chassis from the equipment rack, follow these steps.


Step 1 Ensure all cables are disconnected and moved out of the way.

Step 2 Loosen, but do not remove, the bolts that secure the chassis to the equipment rack.

Step 3 With one person positioned on each side of the chassis have a third person remove the bolts securing the chassis to the equipment rack.

Step 4 Use the guidelines in the "Lifting Guidelines" section on page 2-6 to lift the chassis out of the rack and set it aside.


Removing the Chassis from Center-Mount Brackets

Instructions for removing the equipment from a rack, where the chassis is installed using the center-mount bracket method, are presented here.


Step 1 Ensure all cables are disconnected and moved out of the way.

Step 2 Loosen, but do not remove, the screws that attach the chassis to the center-mount brackets.

Step 3 Use the procedure in the "Installing the Chassis in a Rack" section on page 3-6.

Step 4 Use the guidelines in the "Lifting Guidelines" section on page 2-6 to lift the chassis out of the rack and set it aside (Figure 5-23).

Figure 5-23 Center-Mount Brackets


Installing the Replacement Chassis

Installing your replacement Cisco 12404 Internet router is presented in the following sections:

Installing the Chassis on a Tabletop or Flat Surface

Reattaching the Supplemental Bonding and Grounding Connection

Reconnecting Power to the Router

Reconnecting Line Card Network Interface Cables

Reconnecting the Route Processor Cables

Reconnecting the Fan Tray

Installing a DC Power Distribution Unit

Installing the Chassis on a Tabletop or Flat Surface

Install the replacement chassis according to the procedures in the "Installing the Chassis in a Rack" section on page 3-6.

Reattaching the Supplemental Bonding and Grounding Connection

Reattach the bonding and grounding cable lugs to the bonding and grounding receptacles (Figure 5-24) as described in the "Supplemental Unit Bonding and Grounding Guidelines" section on page 3-9.

Figure 5-24 Grounding the Cisco 12404 Chassis

Reconnecting Power to the Router

Connect the AC power or DC power at the rear of the chassis as described in:

"Removing and Replacing an AC Power Entry Module" section

"Removing and Replacing a DC Power Entry Module" section

"Removing and Replacing a DC PDU" section


Warning Do not turn on source power until instructed to do so.


Reconnecting Line Card Network Interface Cables

Reconnect line card network interface cables as instructed in the "Reconnecting Line Card Network Interface Cables" section.

Reconnecting the Route Processor Cables

Reconnect the cables to the RP as instructed in the "Installing a Route Processor or Line Card" section.

Reconnecting the Fan Tray

Reconnect the fan tray assembly as instructed in the procedure "Removing and Replacing the Fan Tray Assembly" section.

Installing a DC Power Distribution Unit

Use the instructions in the "Removing and Replacing a DC PDU" section to reinstall the DC PDU into the replacement chassis.


Warning Power to your router must be off and all cables disconnected.



Caution The DC PDU is not a FRU.

Restarting the Cisco 12404 Internet Router

Turn on power to your router.

To restart the router and verify that it has restarted successfully after replacing the chassis follow the instruction in the "Powering On the Router" section on page 3-31.

Upgrading the RP and Line Card Memory

Upgrading the RP and line card memory is presented in the Cisco 12000 Series Internet Router Memory Replacement Instructions, Part Number: 78-4338-xx, which is available online and on the Cisco CD-ROM This document contains the latest information about memory requirements and replacing memory on the Cisco 12000 Internet router and line cards. Use that document before replacing or adding memory to your RP or line card.

You can find Cisco 12000 series router memory replacement instructions at Cisco.com.