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Cisco 12000 Series Routers

Cisco 12404 Internet Router Chassis and Backplane Replacement Instructions

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Cisco 12404 Internet Router Chassis and Backplane Replacement Instructions

Table Of Contents

Cisco 12404 Internet Router Chassis and Backplane Replacement Instructions

Overview

Preparing the Chassis for Replacement

Tools and Equipment

Safety

General Safety Guidelines

Lifting Guidelines

Unfastening the Chassis from a Rack or Enclosure

Detaching the Supplemental Bonding and Grounding Connection

Removing the Chassis from the Equipment Rack

Removing the Chassis from Center-Mount Brackets

Removing Parts from the Chassis

Powering Down the Router

Powering Down the AC Powered Router

Removing an AC PEM

Powering Down the DC Powered Router

Removing a DC PDU and DC PEM

Removing the Air Filter from the Chassis

Tools and Equipment

Removing the Air Filter

Removing the Fan Tray Assembly

Tools and Equipment

Removing the Fan Tray

Removing the Router Processor and Line Cards

Removing a CSF and Alarm Card from the Card Cage

Tools and Equipment

Removing a CSF and Alarm Card

Removing the Router Cable-Management Systems

Removing the Chassis Cable-Management Bracket

Removing a Chassis Cable-Management Bracket

Removing the RP and Line Card Cable-Management Brackets

Tools and Equipment

Removing an RP or Line Card Cable-Management Bracket

Installing the Router Components in a Chassis

Installing the Fan Tray Assembly

Tools and Equipment

Installing the Fan Tray

Checking the Fan Tray Assembly Installation

Installing the Air Filter

Installing an AC or DC Power Supply

Installing a DC PDU and DC PEM

Checking the DC PDU and DC PEM Installation

Installing a CSF and Alarm Card

Installing an RP or Line Card

Installing the Cable-Management Brackets

Installing the Chassis Cable-Management Bracket

Tools and Equipment

Installing a Chassis Cable-Management Bracket

Installing an RP or Line Card Cable-Management Bracket

Tools and Equipment

Installing the RP and Line Card Cable-Management Bracket

Installing the Chassis

Power On the Router

Connecting to an AC Power Source

Checking the Startup

Connecting to a DC Power Source

Tools and Equipment

Connecting a DC PDU and DC PEM Assembly

Checking the Startup

DC Power Entry Module LEDs

Obtaining Documentation

World Wide Web

Documentation CD-ROM

Ordering Documentation

Documentation Feedback

Obtaining Technical Assistance

Cisco.com

Technical Assistance Center

Contacting TAC by Using the Cisco TAC Website

Contacting TAC by Telephone


Cisco 12404 Internet Router Chassis and Backplane Replacement Instructions


Product Number: GSR04-CHASSIS=
Document Order Number: DOC-7813612=

Overview

This document gives you instructions for replacing the chassis with a backplane for a Cisco 12404 Internet Router. The Cisco 12404 Internet Router is able to be disassembled at your location and a new chassis with backplane installed using new or existing field replaceable units (FRUs). The chassis can be rack mounted or placed on a stable flat surface. The router weighs 103 pounds (46.7 kg) fully configured, and 73 pounds (33.1 kg) without line cards. Always use the Lifting Guidelines for lifting your router.

The Cisco 12404 Internet Router chassis is an integrated, sheet metal assembly that includes.

1 Consolidated switch fabric card slot

4 Slot route processor and line card cage

1 Air filter housing

1 Fan tray assembly housing

1 Chassis with backplane

Preparing the Chassis for Replacement

This entire procedure gives you step-by-step instructions that will enable you to disassemble your old router from its chassis and install the components in a new or replacement chassis. If you are replacing the entire chassis both the old and new router should be on a stable flat surface with all sides easily accessible on both routers.

This process includes the following sections:

Safety

Lifting Guidelines

Unfastening the Chassis from a Rack or Enclosure

Removing Parts from the Chassis

Powering Down the Router

Removing an AC PEM

Removing a DC PDU and DC PEM

Removing the Air Filter from the Chassis

Removing the Fan Tray Assembly

Removing the Router Processor and Line Cards

Removing a CSF and Alarm Card from the Card Cage

Removing the Router Cable-Management Systems

Installing the Router Components in a Chassis

Installing the Fan Tray Assembly

Installing the Air Filterr

Installing an AC or DC Power Supply

Installing a CSF and Alarm Card

Installing an RP or Line Card

Installing the Cable-Management Brackets

Power On the Router

Tools and Equipment

You will need the following tools and equipment.

3/16-inch flat-blade screwdriver

3/16-inch flat-blade screwdriver, long shaft

1/4-inch flat-blade screwdriver

1/4-inch flat-blade screwdriver, long shaft

3/16-inch Phillips screwdriver, long shaft

1/4-inch Phillips screwdriver, long shaft

Number 1 Phillips screwdriver

9/16-inch (14-mm) wrench

10-mm wrench (open-end or socket)

ESD-preventive strap

Antistatic mat or antistatic strap

Light or flashlight

Optional: If the component is hot, you may need protection for your hands.

Safety

Before attempting to remove or replace parts from your router review the safety guidelines in Chapter 2 of the "Cisco 12404 Internet Router Installation and Configuration Guide." These guidelines will help to ensure your safety and protect the equipment. The following guidelines are not inclusive of all potentially hazardous situations, so be alert.

General Safety Guidelines

Never attempt to lift an object that might be too heavy for you to lift by yourself.

Always disconnect the power source and unplug all power cables before lifting, moving or working on the router.

Keep the work area clear and dust free during and after installation.

Keep tools and router components away from walk areas.

Do not wear loose clothing, jewelry (including rings and chains), or other items that could get caught in the router.

Fasten your tie or scarf and sleeves.

The Cisco 12404 Internet Router operates safely when it is used in accordance with its electrical ratings and product usage instructions. See Chapter 2, "Cisco 12404 Internet Router Installation and Configuration Guide".

Do not work alone if potentially hazardous conditions exist.

Always unplug the power cables when performing maintenance or working on the router, unless the replacement part is capable of online insertion and removal, hot swappable.

The installation of your Cisco 12404 Internet Router should be in compliance with national and local electrical codes: in the United States, National Fire Protection Association (NFPA) 70, United States National Electrical Code; in Canada, Canadian Electrical Code, part I, CSA C22.1; in other countries, International Electrotechnical Commission (IEC) 364, part 1 through part 7. See Chapter 2 of the "Cisco 12404 Internet Router Installation and Configuration Guide" for more information.

Before installing, configuring, or maintaining the router, review the safety warnings listed in the document Regulatory Compliance and Safety Information for the Cisco 12000 series Internet Routers (Document Number 78-4347-09) that accompanied your Cisco 12404 Internet Router.

Lifting Guidelines

A fully configured Cisco 12404 Internet Router weighs approximately 100 lbs (45.36 kg). Before you begin any replacement process for your router, ensure that your site is properly prepared so you can avoid having to move the chassis while you are in the process of removing and/or installing a field replaceable unit (FRU).

Whenever you lift any heavy assembly refer to these lifting guidelines.

Never attempt to lift an object that might be too heavy for you to lift by yourself

Have a second person available to help lift the assembly

Ensure that your footing is solid; balance the weight of the object between your feet

Lift the assembly slowly; never move suddenly or twist your body as you lift

Keep your back straight and lift with your legs, not your back

If you must bend down to lift the assembly, bend at the knees, not at the waist, to reduce the strain on your lower back muscle

Always disconnect the power source and unplug all power cables before lifting, moving or working on the router.

Figure 1 Lifting a Cisco 12404 Internet Router

For more safety and regulatory information consult the "Cisco 12404 Internet Router Installation and Configuration Guide" which can be found by consulting Obtaining Documentation.

Unfastening the Chassis from a Rack or Enclosure

This procedure guides you through the process of unfastening your router from a rack or enclosure.

Detaching the Supplemental Bonding and Grounding Connection

You must detach the supplemental bonding and grounding cables from the chassis. If your router was not installed in a NEBS environment, you can bypass these guidelines.

Bonding and grounding receptacles are intended to satisfy the Telcordia NEBS requirements for supplemental bonding and grounding connections. The Cisco 12404 Internet Router chassis requires a safety earth ground connection as part of the power cabling to the router. See Figure 2.

Figure 2 Supplemental Bonding and Grounding Port for NEBS Compliance

We strongly recommend that you connect the central office (CO) ground system or interior equipment grounding system to the chassis. Grounding to the CO system or your interior equipment grounding system meets the network equipment building system (NEBS) bonding and grounding requirement.

Removing the Chassis from the Equipment Rack

To remove the defective chassis from the equipment rack, use Figure 3 and follow these steps.


Step 1 Ensure all cables are disconnected from the chassis and the rack and are 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 "Lifting Guidelines" to lift the chassis out of the rack

Step 5 Move the chassis to the location where the replacement chassis is located.


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 from the chassis and the rack and are moved out of the way

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

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 "Lifting Guidelines" to lift the chassis out of the rack

Step 5 Move the chassis to the location where the replacement chassis is located.

Figure 3 Center-Mount Brackets

1

Chassis center mount brackets.



Caution Secure the center mount bracket to the chassis so that it does not block air flow.


Removing Parts from the Chassis

Use the following illustrations and procedures to remove all of the components from the Cisco 12404 Internet Router chassis.

Powering Down the Router

Use the following procedures and illustrations to power down your AC or DC powered router.

Powering Down the AC Powered Router

The AC power entry modules (PEMs) are located at the rear of the chassis. Use Figure 5, Figure 4 and the following procedure to power down your AC powered router.

Figure 4 AC PEM Location (Rear of chassis)


Caution Turn the AC PEM power switch Off for each AC PEM installed


Step 1 Turn off all circuit breakers for AC source power

Step 2 Unplug all power cords from all AC power source outlets

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 Release the bail latch holding the AC power cord to the power receptacle

Step 5 Unplug the power cord from the AC PEM power cord receptacle

Step 6 Verify that the green AC PEM INPUT OK, OUTPUT OK and amber OUTPUT FAIL LEDs are all Off

Step 7 Visually check that the AC PEM fans are all Off

Step 8 Visually check that the fan tray assembly fans are all Off

Step 9 Visually check that all route processor (RP) and line card LEDs are all Off

Step 10 Visually check that the consolidated switch fabric (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.


Removing an AC PEM

Use Figure 4 and the following instructions to remove all AC PEMs installed in the router.


Note The AC PEM is hot-swappable, weighs 11.0 lbs. (4.98 kg.) and should be lifted with both hands.



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 Verify which AC PEM is faulty and mark it for later identification.


Step 2 Turn the AC PEM power switch Off

Figure 5 AC-Power Entry Module

1

AC PEM finger grips

4

Power cord receptacle

2

On/Off power switch

5

LEDs

3

Bail latch

6

Captive screws


Step 3 Release the bail latch holding the AC power cord to the power receptacle

Step 4 Unplug the power cord from the AC PEM receptacle on the PEM

Step 5 Verify that the green INPUT OK, OUTPUT OK and amber OUTPUT FAIL LEDs are all Off

Step 6 Visually check that the AC PEM fans are all Off

Step 7 Loosen the two captive screws that attach the PEM to the chassis


Caution The AC PEM may be hot, use caution when handling a hot PEM.

Step 8 Use the finger grips to pull the AC PEM out of the PEM bay

Step 9 Set the PEM aside.


Tip If the AC PEM is defective mark it for later identification.



Powering Down the DC Powered Router

The DC power distribution units (PDUs) and DC power entry modules (PEMs) are located at the rear of the chassis. Use Figure 6, Figure 7 and the following procedure to power down your DC powered router.


Caution Turn Off the DC PEM power switch for each DC PEM installed.


Step 1 Turn Off all circuit breakers for DC source power

Figure 6 DC PDU and DC PEM Location (Rear of chassis)

Step 2 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 3 Turn the DC PEM power switch Off for each DC PEM installed

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

Step 7 Visually check that all route processor (RP) and line card LEDs are all Off

Step 8 Visually check that the consolidated switch fabric (CSF) LEDs are all Off.

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


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.


Removing a DC PDU and DC PEM

The DC PDU and DC PEM are located at the rear of the chassis on the power supply shelves, see Figure 6. The following procedure describes how to turn Off and remove all of the DC PDUs and DC PEMs installed in the router.


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 Turn Off the switch on the DC PEM. See Figure 7.

Figure 7 DC PEM and DC PDU Assembly

1

DC PDU

5

On/Off switch

2

DC PEM

6

PDU captive screws

3

System captive screws

7

Terminal Block

4

LEDs

   

Step 3 Verify that the green INPUT OK, OUTPUT OK and amber OUTPUT FAIL LEDs are all Off

Step 4 Visually check that the DC PEM fans are all Off

Step 5 Loosen the system captive screw that secure the PEM to the chassis

Step 6 Loosen the two captive screws that secure the PEM to the PDU


Caution The DC power supply may be hot, use caution when handling a hot PEM or PDU.

Step 7 Use the finger grips to pull the DC PDU and PEM off the power supply shelf

Step 8 Set the PDU and PEM unit aside.


Tip If a DC PDU and/or DC PEM is defective mark it for later identification.



Removing the Air Filter from the Chassis

The air filter is located at the rear of the chassis, on the left side in a slot next to the power supplies. Use Figure 8, Figure 9 and the following procedure to remove the air filter from your chassis.

Figure 8 Air Filter Location

Tools and Equipment

You will need an ESD-preventive strap and leash to remove an air filter from the chassis.

Removing the Air Filter

Use Figure 8, Figure 9 and the following procedure to remove the air filter from your router.


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


Figure 9 Cisco 12404 Internet Router Air Filter Direction of Air Flow

Step 3 Move the air filter away from the chassis


Note When removing the air filter keep it away from the RP and line card cage so that any dislodged dust will not get into the card cage.


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


Removing the Fan Tray Assembly

The fan tray assembly is located at the rear of the chassis, on the right side in a slot next to the power supplies. Use Figure 10, Figure 11 and the following procedure to remove the fan tray assembly.

Figure 10 Fan Tray Assembly Location

1

Chassis

3

Fan tray assembly

2

Power supply AC or DC (AC shown)

   

Tools and Equipment

These tools and equipment are needed to remove and replace a fan tray.

ESD-preventive strap

3/16-inch flat-blade screwdriver

Number 1 Phillips screwdriver

Removing the Fan Tray

Use Figure 10, Figure 11 and the following procedure to power down your DC powered router.


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 Loosen the two captive screws on the fan tray assembly faceplate

Figure 11 Cisco 12404 Internet Router Fan Tray Assembly

Step 3 Use the handle to pull the fan tray assembly out of the fan tray assembly housing

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


Removing the Router Processor and Line Cards

The route processor (RP) and line cards are located at the front of the chassis and are hot swappable components of the Cisco 12404 Internet Router. The following procedure describes how to remove all of the RP and line cards installed in the router.


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

Figure 12 Removing an RP or Line Card from the Card Cage

Step 2 Identify each RP and line card then write down the following information

The slot number in which the RP and line card is installed

The RP cable connections on the RP

The line card cable connections on the line card

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

The network interface cable connection ports on all RPs and line cards

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 from the same RP or line card, loosen the two captive screws on the cable-management bracket and pull the bracket away from the RP or line 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, then stop

Step 7 Grasp the edges of the RP or line card carrier with both hand and support it to avoid damaging the EMI shielding on the RP or line card in the slot directly below

Step 8 Rotate each ejector lever outward away from the faceplate. See Figure 12.


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

Step 9 Remove the RP or line card from its slot

Step 10 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.


Removing a CSF and Alarm Card from the Card Cage

This procedure provides the information needed to remove and replace a consolidated switch fabric (CSF) and alarm card (fabric alarm). The CSF and alarm card occupies the bottom slot in the card cage. See Figure 13.

Figure 13 CSF and Alarm (Fabric Alarm) Card Slot Location

Tools and Equipment

You will need the following items to remove and replace a CSF card:

ESD-preventive strap

3/16-inch flat-blade screwdriver

Antistatic bag (or similar ESD-preventive container)

Removing a CSF and Alarm Card

The CSF card is located at the front of the chassis, in the CFS, RP and line card cages. The CSF card occupies the bottom slot in the card cage. The CSF card is not hot swappable you cannot remove a CSF card with your system powered On.

Use Figure 14 and this procedure to remove a CSF card from the card cage.


Warning Power must be Off to the router to remove the CSF card. The CSF card is not a hot-swappable component of the Cisco 12404 Internet Router.



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 Loosen the two captive screws on each side of the CSF card

Step 3 Grasp the card ejector levers and pivot them away from the CSF card faceplate

Figure 14 CSF Card Location

Step 4 Slide the CSF half way out of the slot, then stop

Step 5 Touching only the metal card carrier, use your free hand to support the bottom of the CSF card

Step 6 Slide the card out of the slot and place it directly into an antistatic bag or other ESD-preventive container


Removing the Router Cable-Management Systems

The Cisco 12404 Internet Router has two types of cable-management systems, a chassis cable-management bracket, and an RP and line card cable-management bracket.

Chassis Cable-Management Bracket

The chassis cable-management bracket is attached to the chassis and routes the RP and line card cables away from the chassis.

RP and Line card Cable-Management Bracket

The RP and line card cable-management bracket is attached to each RP and line card and routes the line card cables to the chassis cable-management bracket.

Removing the Chassis Cable-Management Bracket

The chassis cable-management bracket is located at the front of the chassis on the upper left side.

Figure 15 Chassis Cable-Management Bracket Location

Removing a Chassis Cable-Management Bracket

Use Figure 16 and this procedure to remove the chassis cable-management bracket. This bracket keeps the interface cables free of sharp bends and out of the way. Excessive bending in an interface cable can cause performance degradation.


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 Ensure all cables have been removed from the fingers on the chassis cable-management bracket

Step 3 Loosen the screws that secure the bracket to the chassis and set the bracket aside.

Figure 16 Chassis Cable-Management Bracket


Removing the RP and Line Card Cable-Management Brackets

The RP and line cards are located at the front of the chassis and can occupy any slot, zero (0) through 3 in the RP and line card cage. Your router is configured with the RP in slot 0. See Figure 13. Each RP and line card has network interface cables (NICs) and a cable-management bracket attached to it.

Figure 17 RP or Line Card Cable-Management Bracket

Tools and Equipment

You will need the following items to remove and replace an RP or line card cable-management bracket.

ESD-preventive strap

3/16-inch flat-blade screwdriver

Number 1 Phillips screwdriver

Removing an RP or Line Card Cable-Management Bracket

Use Figure 13, Figure 17 and this procedure to remove each RP and line card cable-management bracket.


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 each RP and line card and write down the following information for each one

The cable connections on the card

The location number, the card number and type of card, so that you will know this information when you re-install it in the replacement chassis' card cage

The network interface cable connection ports on each card

Step 3 On 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 RP and line card cable-management bracket and pull the bracket away from the card


Installing the Router Components in a Chassis

This section of the Cisco 12404 Internet Router Chassis and Backplane Replacement Instructions document gives you the information needed to install the FRUs into a new or replacement chassis at your location. The Cisco 12404 Internet Router chassis is an integrated, sheet metal assembly that includes.

1 Consolidated switch fabric card slot

4 Slot route processor and line card cage

1 Air filter housing

1 Fan tray assembly housing

1 Chassis with backplane

Installing the Fan Tray Assembly

The fan tray assembly housing is located at the rear of the chassis and fits in a channel at the right, rear side of the chassis. Two captive screws secure the fan tray assembly to the chassis. Installing the fan tray assembly is presented in the following sections.

Tools and Equipment

These tools and equipment are needed to remove and replace a fan tray.

ESD-preventive strap

3/16-inch flat-blade screwdriver

Number 1 Phillips screwdriver

Fan tray assembly.

Installing the Fan Tray

Use Figure 10, Figure 11 and this procedure to install a fan tray assembly.


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



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

A channel in the bottom of the fan tray assembly housing is provided to guide the fan tray base into the fan tray assembly housing.

Step 2 Hold the fan tray assembly with both hands and insert the connector end of the fan tray into the fan tray housing channel

Electrical and control line connections for the fan tray assembly are made automatically when the connectors mate.

Step 3 Tighten the two captive screws on the fan tray assembly.


Checking the Fan Tray Assembly Installation

When you power On your router follow these steps to verify that the fan tray assembly is operating properly.


Step 1 Verify that the fan tray assembly is seated properly in its channel

Step 2 Verify the faceplate of the fan tray assembly is seated against the chassis

Step 3 Verify the two fan tray assembly captive screws are tight

The fans should come On once the connectors are properly mated and the captive screws are tightened.

Step 4 Visually check that the fans are on

In a noisy environment, place your hand in front of the fans to ensure they are running

Step 5 If the fans do not come on, check for the following conditions:

Ensure the fan tray assembly is completely seated in its channel

Ensure the fan tray assembly faceplate is flush against the chassis

Ensure the two fan tray assembly captive screws are tightened

Step 6 If the AC  or DC power source was disconnected to the router, turn the power On and repeat steps 1 through 4.

Step 7 If after you have verified the items in step 5 the fans do not come on, suspect a faulty fan tray assembly.

Step 8 Replace the existing fan tray assembly with a spare, and start over at Step 1.


Caution If the replacement fans do not come on, shut down your router and contact a Cisco service representative for assistance.


Installing the Air Filter

Use Figure 8, Figure 9 and this procedure to 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. See Figure 9.


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.


Installing an AC or DC Power Supply


Warning Do not operate the router with both an AC PEM and a DC PEM installed at the same time. The Cisco 12404 Internet Router must be equipped with either AC PEMs installed in both power shelves or DC PEMs and DC PDUs installed in both power shelves.



Warning DC power distribution units (PDUs) are not hot-swappable and as such, power to the router must be turned Off to remove and replace either DC PDU.


Installing a DC PDU and DC PEM

Use Figure 6, Figure 7 and this procedure to install a DC PEM and DC PDU onto each power supply shelf in the router. The DC PDU and DC PEM weighs 11.0 lbs. (4.98 kg.) and should be lifted with both hands.


Warning Ensure each of the DC PEM power switches is Off.



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 Turn the DC PEM power switch Off

Step 3 Grasp the DC PDU and PEM unit with both hands and slide the unit into the vacant PEM bay


Warning Do not operate the router with both an AC PEM and a DC PEM installed at the same time. The Cisco 12404 Internet Router must be equipped with either AC PEMs installed in both power shelves or DC PDUs and DC PEMs installed in both power shelves.


Step 4 Ensure the PDU and PEM are secure on the power shelf and the PEM connector is seated to the PDU connector

Electrical connections between the PDU and the PEM are made automatically when the PEM is fully seated on the power shelf, and the system screws and captive screws are tightened. See Figure 7.


Caution Ensure the DC PEM power switch is in the Off position

Step 5 With a flat-blade screwdriver, tighten all of the captive screws

Step 6 Once you have applied power to your router, turn On the DC PEM power switch

Step 7 Visually check that the green INPUT OK and OUTPUT OK LEDs are both On

Step 8 Visually check that the amber OUTPUT FAIL LED is Off

Step 9 Visually check that the DC PEM fans are On


Checking the DC PDU and DC PEM Installation

After installing the DC PDU and DC PEM in the chassis and you have applied power to your router. Use Figure 7 and this procedure to check that the power supply has been installed correctly and is operating properly.


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 Ensure the DC PDU and DC PEM are completely inserted in the power shelf

Step 3 Ensure the On/Off power switch is turned On.

Step 4 If the INPUT OK and OUTPUT OK LEDs on the PEM are off, verify the following:

DC PEM and DC PDU are firmly seated in the power shelf

DC PEM power switch is On

All PDU and PEM captive screws are tight.

Step 5 If the amber OUTPUT FAIL LED is On, verify the following:

DC PEM and DC PDU are firmly seated in the power shelf

DC power source circuit breaker is switched On

DC power cables are firmly attached to the terminal block

DC PEM power switch is On

All PDU and PEM captive screws are tight.

Step 6 If the amber OUTPUT FAIL LED on the PEM remains On, after you have verified the items in step 5, suspect a faulty PEM.

Step 7 Replace the existing PEM with a spare PEM, and start over at Step 1. If the amber OUTPUT FAIL LED on the replacement PEM stays on:

Contact a Cisco service representative for assistance

Step 8 If the green INPUT OK and OUTPUT OK LEDs on the spare PEM goes on, return the faulty PEM for replacement.


Installing a CSF and Alarm Card

Use Figure 13, Figure 14 and this procedure to install a CSF and alarm card in your chassis.


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 should be Off to your router; if not Power down your router.

Use the AC power down procedure "Powering Down the AC Powered Router" for AC powered routers

Use the DC power down procedure "Removing an AC PEM 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

Touching 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


Installing an RP or Line Card

Use Figure 12 and this procedure to install an RP or line card in your chassis.


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 line car d and RP slot assignment and network interface cable information that you wrote down when you were removing the other RP or line card. Use those notes as a guide when installing the RP and line cards in the replacement chassis


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

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

Step 9 Tighten the captive screws on each side of the 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 each additional RP or line card you wish to install.


Installing the Cable-Management Brackets

The Cisco 12404 Internet Router has two types of cable-management systems, a chassis cable-management bracket, and an RP and line card cable-management bracket.

Chassis Cable-Management Bracket

The chassis cable-management bracket is attached to the chassis and routes the RP and line card cables away from the chassis.

RP and Line card Cable-Management Bracket

The RP and line card cable-management bracket is attached to each RP and line card and routes the line card cables to the chassis cable-management bracket.

Installing the Chassis Cable-Management Bracket

The chassis cable-management bracket is located at the front of the chassis on the upper left side.

Tools and Equipment

You will need the following items to install the chassis cable-management bracket.

ESD-preventive strap

3/16-inch flat-blade screwdriver

Number 2 Phillips screwdriver

Chassis cable-management bracket.

Installing a Chassis Cable-Management Bracket

Use Figure 15, Figure 16 and this procedure to install a chassis cable-management bracket to the chassis. This bracket keeps the network interface cables (NICs) free of sharp bends and out of the way. Excessive bending in an interface cable can cause performance degradation.


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 Hold the chassis cable-management bracket in place and insert the screws through the holes in the bracket and into the holes in the chassis

Step 3 Tighten the screws that secure the bracket to the chassis.


Installing an RP or Line Card Cable-Management Bracket

Use Figure 12, Figure 13 and this procedure to install an RP or line card cable-management bracket.

Tools and Equipment

To remove and replace an RP or line card you will need the following items.

ESD-preventive strap

3/16-inch flat-blade screwdriver

Number 2 Phillips screwdriver

Route processor or line card.

Installing the RP and Line Card Cable-Management Bracket

When you install an RP or line card in the RP and line card cage, you must attach the line card cable-management bracket to the RP or line card faceplate and reconnect the network interface cables (NIC) to the RP or line card.

Use Figure 18 and this procedure to connect NICs to an RP or line card.


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

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

Figure 18 Line Card or RP Cable-Management Brackets with Velcro Straps

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.

Step 6 Proceed from the left port on the RP or line card, to the right port, identify the NIC 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 18 shows a generic cable-management bracket and velcro strap assembly


Installing the Chassis


Caution When re-installing the chassis in a rack or enclosure, secure the center mount bracket to the chassis so that it does not block the air flow. See Figure 3.

If you are installing your chassis in a rack enclosure, a table top or on a flat surface, you will find these procedures in the "Cisco 12404 Internet Router Installation and Configuration Guide" Chapter 3, "Installing the Cisco 12404 Internet Router."

We strongly recommend that you connect the central office (CO) ground system or interior equipment grounding system to the chassis. Grounding to the CO system or your interior equipment grounding system meets the network equipment building system (NEBS) bonding and grounding requirement.

Power On the Router

Use the following procedures and illustrations to power On your AC or DC powered router. Power on the router by switching on all the circuit breakers, connecting all required power cables and/or plugging the power cord into an active power source that controls power to the AC PEM or DC PDU.

Connecting to an AC Power Source

This section provides the procedure for connecting your router to an AC power source. A power factor corrector (PFC) allows the PEM to accept AC power source voltage from an AC power source operating between 100-120 VAC, 15-Amp service in North America; and a range of 85-264 VAC, 10-Amp service in an international environment.


Caution The AC PEM weighs 14.0 pounds (6.35 kg.). Use two hands when handling a PEM.


Step 1 Attach an ESD-preventive strap to yourself and to either the chassis, or to a bare metal surface

Step 2 Using two hands to support and guide the PEM, slide it into the PEM bay

Step 3 Push the PEM all the way into the bay until the PEM connector engages the backplane connector

Step 4 Tighten the captive screws on the PEM faceplate. See Figure 5.

All electrical connections between the power supply and the backplane are made automatically when the power supply is fully inserted in the power supply bay

Step 5 Insert the AC power cord into the power cord receptacle on the PEM. See Figure 5.


Caution Turn the AC PEM power switch OFF.

Step 6 Connect the other end of the AC power cord to the AC power source outlet

We recommend attaching each AC PEM to an independent power source for full redundancy. We also recommend that you use an uninterruptable power source (UPS) to protect against power failures at your site.

Step 7 Verify that the AC power source circuit breaker servicing the AC PEM is switched On

Step 8 Turn On the AC PEM power switch.


Note When operating your router on an AC power source, both PEM shelves must have all AC PEMs installed to ensure compliance with regulatory EMI standards.



Checking the Startup

Check the startup banner and displays to ensure that the system has restarted properly and that all the interfaces reinitialize properly. You should observe the PEM LEDs shown in figures Figure 19. Also, listen for the fans in the fan tray, you should immediately hear them operating. In a noisy environment, the fans might be difficult to hear; therefore, place your hand in front of the exhaust vents at the side of the chassis to verify that the fans are operating.

Figure 19 AC PEM LEDs

1

INPUT OK

Green

AC is present and within specified limits

2

OUTPUT OK

Green

Power supply module is operating normally in a powered up condition

3

OUTPUT FAIL

Amber

Power supply module is operating in a fault condition and shutdown has occurred


Visually check the following LED and console display items:

CSF LEDs

MBus LEDs on the CSF

RP LEDs on the RP

Console terminal display.

Consolidated Switch Fabric LEDs

The MBus and CSF LEDs are located at one end of the CSF faceplate, near an ejector lever. Figure 20 shows the CSF and MBus LEDs.

Figure 20 CSF and MBus LEDs Location

Route Processor LEDs

RP LEDs are located at one end of the RP faceplate, near the ejector lever. Figure 21 shows the RP alphanumeric LED displays.

Figure 21 RP Alphanumeric LED Displays

Each four-digit display shows part of a two-line system message. During the RP boot process, the LED displays present a sequence of messages that may not be readable due to the limited amount of time they flash in the display. For LED display information see the "Cisco 12404 Internet Router Installation and Configuration Guide" Chapter 3, "Installing the Cisco 12404 Internet Router."

If the power supplies do not power up or if the system or any interfaces do not initialize properly, see the "Cisco 12404 Internet Router Installation and Configuration Guide," Chapter 4, "Troubleshooting the Installation".

If you are still unable to resolve the problem, contact your Cisco service representative for assistance at "Obtaining Technical Assistance."

Connecting to a DC Power Source

This section provides the procedure for connecting your router to a DC power source. A power factor corrector (PFC) allows the PEM to accept DC power source voltage from an AC power source operating between 100-120 VAC, 15-Amp service in North America; and a range of 85-264 VAC, 10-Amp service in an international environment.

We recommend each DC PDU be connected to an independent power source for full redundancy. We also recommend that you use an uninterruptable power source (UPS) to protect against power failures at your site.

Tools and Equipment

You will need the following items to connect DC power to your router.

ESD-preventive strap

3/16-inch flat-blade screwdriver

1/4-inch flat-blade screwdriver

Number 1 Phillips screwdriver

Connecting a DC PDU and DC PEM Assembly

Each DC PDU should be connected to separate DC sources using six threaded terminals. Two terminals for negative (source DC), two terminals for positive (source DC return), and two terminals for ground. The DC power cable leads should be 4 American Wiring Gauge (AWG) high strand count wire. The DC PEM and DC PDU assembly weighs 14.0 pounds (6.35 kg.). Use two hands when handling the power supply.


Warning Power to your router must be Off and all cables disconnected before you install the DC power assembly. The DC PDU and DC PEM when connected, is not a hot-swappable, field replaceable unit.


Use Figure 6, Figure 7, Figure 22 and this procedure to install the DC PEM and DC PDU in your router. The DC PDU and PEM install at the rear of the chassis.


Step 1 Attach an ESD-preventive strap to yourself and to either the chassis, or to a bare metal surface.


Caution If recently removed from another chassis, the DC power supply may be hot, use caution when handling a hot PEM and PDU.

Step 2 Insert the DC power module into the power shelf at the rear of the chassis

Step 3 Press the power supply against the backplane until the connectors are seated against the backplane receptacles

Step 4 Tighten all of the captive screws on the faceplate

All electrical connections between the power supply and the backplane are made automatically when the power supply is fully inserted in the power shelf.

Step 5 Use a 1/4-inch screwdriver to tighten the captive screws on the DC PDU.

Figure 22 DC PDU Power Block

1

Negative Terminal Port

3

Ground Terminal Port

2

Positive Terminal Port

4

Terminal Port Connector Screws


Step 6 Secure each lead to the proper terminal port by tightening the terminal port connector screws with a 3/16-inch flat-blade screw driver.

Step 7 Verify that the DC power source circuit breaker servicing the DC PDU and PEM is switched On

Step 8 Turn On the DC PEM power switch.


Note When operating your router on DC power source, both PEM shelves must have all DC PDUs and DC PEMs installed to ensure compliance with regulatory EMI standards.



Checking the Startup

Check the startup banner and displays to ensure that the system has restarted properly and that all the interfaces reinitialize properly. You should observe the power module LEDs shown in figure Figure 23. Also, listen for the fans in the fan tray, you should immediately hear them operating. In a noisy environment, the fans might be difficult to hear; therefore, place your hand in front of the exhaust vents at the side of the chassis to verify that the fans are operating.

Visually check the CSF LEDs, MBus LEDs on the CSF, and the RP LEDs on the RP. RP LEDs are located at one end of the RP faceplate, near the ejector lever. Figure 21 shows the RP LED displays.

On the console terminal, verify that the console displays the system banner and that the system and all interfaces initialize successfully.

DC Power Entry Module LEDs

Verify the DC PEM LEDs are On and their status is OK.

Figure 23 DC PEM LEDs

1

DC PDU

n/a

n/a

2

DC PEM

n/a

n/a

3

INPUT OK

Green

DC is present and within specified limits

4

OUTPUT OK

Green

Power supply module is operating normally in a powered Up condition

5

OUTPUT FAIL

Amber

Power module is operating in a fault condition and shutdown has occurred


If the power assembly does not power up, or if the system or any interfaces do not initialize properly, see the "Cisco 12404 Internet Router Installation and Configuration Guide," Chapter 4, "Troubleshooting the Installation." If you are still unable to resolve the problem, contact your Cisco service representative for assistance "Obtaining Technical Assistance.

Obtaining Documentation

Sources for obtaining documentation from Cisco Systems and providing feedback are presented in the following sections.

World Wide Web

You can access the most current Cisco documentation on the World Wide Web at the following sites:

http://www.cisco.com

http://www-china.cisco.com

http://www-europe.cisco.com

Documentation CD-ROM

Cisco documentation and additional literature are available in a CD-ROM package, which ships with your product. The Documentation CD-ROM is updated monthly and may be more current than printed documentation. The CD-ROM package is available as a single unit or as an annual subscription.

Ordering Documentation

Cisco documentation is available in the following ways:

Registered Cisco Direct Customers can order Cisco Product documentation from the Networking Products MarketPlace:

http://www.cisco.com/cgi-bin/order/order_root.pl

Registered Cisco.com users can order the Documentation CD-ROM through the online Subscription Store:

http://www.cisco.com/go/subscription

Nonregistered Cisco.com users can order documentation through a local account representative by calling Cisco corporate headquarters (California, USA) at 408 526-7208 or, in North America, by calling 800 553-NETS(6387).

Documentation Feedback

If you are reading Cisco product documentation on the World Wide Web, you can submit technical comments electronically. Click Feedback in the toolbar and select Documentation. After you complete the form, click Submit to send it to Cisco.

You can e-mail your comments to bug-doc@cisco.com.

To submit your comments by mail, use the response card behind the front cover of your document, or write to the following address:

Attn Document Resource Connection
Cisco Systems, Inc.
170 West Tasman Drive
San Jose, CA 95134-9883

We appreciate your comments.

Obtaining Technical Assistance

Cisco provides Cisco.com as a starting point for all technical assistance. Customers and partners can obtain documentation, troubleshooting tips, and sample configurations from online tools. For Cisco.com registered users, additional troubleshooting tools are available from the TAC website.

Cisco.com

Cisco.com is the foundation of a suite of interactive, networked services that provides immediate, open access to Cisco information and resources at anytime, from anywhere in the world. This highly integrated Internet application is a powerful, easy-to-use tool for doing business with Cisco.

Cisco.com provides a broad range of features and services to help customers and partners streamline business processes and improve productivity. Through Cisco.com, you can find information about Cisco and our networking solutions, services, and programs. In addition, you can resolve technical issues with online technical support, download and test software packages, and order Cisco learning materials and merchandise. Valuable online skill assessment, training, and certification programs are also available.

Customers and partners can self-register on Cisco.com to obtain additional personalized information and services. Registered users can order products, check on the status of an order, access technical support, and view benefits specific to their relationships with Cisco.

To access Cisco.com, go to the following website:

http://www.cisco.com

Technical Assistance Center

The Cisco TAC website is available to all customers who need technical assistance with a Cisco product or technology that is under warranty or covered by a maintenance contract.

Contacting TAC by Using the Cisco TAC Website

If you have a priority level 3 (P3) or priority level 4 (P4) problem, contact TAC by going to the TAC website:

http://www.cisco.com/tac

P3 and P4 level problems are defined as follows:

P3—Your network performance is degraded. Network functionality is noticeably impaired, but most business operations continue.

P4—You need information or assistance on Cisco product capabilities, product installation, or basic product configuration.

In each of the above cases, use the Cisco TAC website to quickly find answers to your questions.

To register for Cisco.com, go to the following website:

http://www.cisco.com/register/

If you cannot resolve your technical issue by using the TAC online resources, Cisco.com registered users can open a case online by using the TAC Case Open tool at the following website:

http://www.cisco.com/tac/caseopen

Contacting TAC by Telephone

If you have a priority level 1 (P1) or priority level 2 (P2) problem, contact TAC by telephone and immediately open a case. To obtain a directory of toll-free numbers for your country, go to the following website:

http://www.cisco.com/warp/public/687/Directory/DirTAC.shtml

P1 and P2 level problems are defined as follows:

P1—Your production network is down, causing a critical impact to business operations if service is not restored quickly. No workaround is available.

P2—Your production network is severely degraded, affecting significant aspects of your business operations. No workaround is available.