Tools Required
Opening the Chassis
Removing the Power-Supply Tray Assembly
Jumper Settings
Replacing DRAM SIMMs
Flash Memory SIMMs
Replacing Flash EPROMs in the Model 3202
Replacing the Boot ROMs
Replacing the Chassis Cover and Tray
Recovering a Lost Password

Maintenance

This chapter contains information on maintenance procedures you might do as your internetworking needs change.

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Note If any upgrades requiring new firmware or software replacement should be necessary, an appropriate publication called a configuration note will be shipped to you automatically with the parts.

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This chapter contains the following sections:

• Opening the Chassis
  
  
• Removing the Power-Supply Tray Assembly
  
  
• Jumper Settings
  
  
• Replacing DRAM SIMMs
  
  
• Flash Memory SIMMs
  
  
• Replacing Flash EPROMs in the Model 3202
  
  
• Replacing the Boot ROMs
  
  
• Replacing the Chassis Cover and Tray
  
  
• Recovering a Lost Password
  
  

This chapter also contains descriptions of system card jumper settings.

Caution Before opening the chassis, ensure that you have discharged all static electricity from your body and be sure the power is OFF. Before performing any procedures described in this chapter, review the following sections in Chapter 2: "Safety Recommendations," "Safety with Electricity," "Preventing Electrostatic Discharge Damage," and "Tools and Equipment Required."

Tools Required

The following tools are required for the procedures described in this chapter:

• ESD cord and wrist strap
  
  
• Screwdrivers: No. 1 and No. 2 Phillips
  
  
• Flat-blade screwdriver
  
  
• EPROM extraction tool
  
  

Opening the Chassis

You must open the router chassis to gain access to its interior components: the system card, Flash SIMMs, Flash EPROMs, DRAM SIMMs, boot ROMs, and jumpers. This section outlines the steps required to open the router chassis. Figure 5-1 shows the internal components of the router. When performing the cover and the power-supply tray assembly removal procedures, have the router face you. (Use Figure 5-2 as a guide.)

After you take the necessary ESD precautions, you can proceed with opening the chassis.

Figure 5-1: Internal View of the Router

Removing the Chassis Cover

Warning Hazardous voltages may exist in or near the power supply, so use extreme caution when working near the power supply. Before starting any of these procedures, turn OFF power to the system, unplug the power cord, disconnect any cables at the ports, and connect ESD protection.

To remove the chassis cover, follow these steps.

Step 1 Turn OFF the unit and unplug it.

Step 2 Attach ESD protection.

Step 3 Remove all cables from the back of the router (including the power cable) to ensure that the unit is not powered on and to ensure that the cover will not get caught on the cables.

Caution Avoid damaging any cables as you remove the cover.

Step 4 Turn the unit up so that the back of the chassis is resting on a surface, and the underside of the chassis is facing you, taking care not to damage the network connectors.

Step 5 Remove the latch screw (shown in Figure 5-1) behind the latch on the right side of the underside of the chassis. The latch will not open until this screw is removed.

Step 6 Put the unit back down with the LEDs facing you. Place your fingers inside the two front latches on the underside of the chassis (see Figure 5-1) and push the latches back until they snap open.

Step 7 Lift the chassis cover from the front edge where the LEDs are located. The chassis cover will tilt up from the front toward the back. If you feel excessive resistance when opening the unit, one of the latches might still be closed. Push back on the latches again.

Step 8 Remove the ground wire (green with yellow stripes) connecting the left hinge post on the cover with the main ground stud, as shown in Figure 5-2. The ground wire is attached to the main ground stud with a slip-on lug, so the wire can be slipped off easily.

Figure 5-2: Router Tray Assembly

Step 9 Remove the chassis cover the rest of the way by pulling it up and forward so that the hinge posts come free from the notches in the bottom tray.

Step 10 Set the cover aside.

Removing the Power-Supply Tray Assembly

To access the router system card, you must remove the router power- supply tray assembly as follows:

Step 1 Locate the DC power harness on the far left edge of the power-supply tray assembly. (See Figure 5-2.) Detach the DC power harness from the system card under the power-supply tray assembly using the pull tab provided.

Caution If you lift the power-supply tray assembly without first removing the power-supply harness, you might damage the cable which provides all power to the system card.

Step 2 Remove the power-supply tray screw.

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Note The power-supply tray screw that holds down the power-supply tray assembly is not obvious. This screw must be removed before the power-supply tray assembly can be removed.

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Step 3 Place your fingers underneath the front edge of the power-supply tray assembly and pull the edge up. The latches holding the power-supply tray assembly will release.

Step 4 Slide the power-supply tray assembly toward you, lift it off the base, and remove it. The system card is now exposed. You do not need to remove the system card from the base of the chassis.

Step 5 Set the power-supply tray assembly aside.

Jumper Settings

Table 5-1 lists the interface ports on the various router models.

Network Interface Options

Model	Ethernet	Token Ring	Serial	BRI
3101 (See Figure 5-5)1	2	0	0	0
3102 (See Figure 5-5)	1	0	1	0
3103 (See Figure 5-5)	1	0	0	1
3202 (See Figure 5-7)	0	1	1	0
3104 (See Figure 5-4)	1	0	2	1
3204 (See Figure 5-3)	0	1	2	1

Refer to the appropriate figure to determine your system's jumper locations.

Figure 5-3 shows the jumper locations at J11 and J12 on the model 3204 system card, and it shows the jumpers' labels. Jumper location J1 enables or disables the writing to Flash memory.

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Note Your router will arrive with the jumper at location J11 set to write enable for Flash memory.

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Jumper location J12 is set according to the size of the boot ROMs.

Figure 5-3: Model 3204 System Card Layout

Figure 5-4 shows the jumper locations at J11 and J12 on the model 3104 system card, and it shows the jumpers' labels. Jumper location J11 enables or disables the writing to Flash memory.

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Note Your router will arrive with the jumper at location J11 set to write enable for Flash memory.

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Jumper location J12 is set according to the size of the boot ROMs.

Figure 5-4: Model 3104 System Card Layout

Figure 5-5 shows the jumper locations W1, W3, and W4 on the model 3101 system card, and it shows the labels of the jumpers.

Figure 5-5: Model 3101 System Card Layout--Typical of Models 3101, 3102, and 3103

Using the orientation of Figure 5-6, jumper location W1 (see Figure 5-6) ships with its left two pins jumpered together. At location W3, jumper the two left pins to permit writing to Flash memory, or jumper the two right pins to disable writing to Flash memory. At location W4, the two pins are jumpered to the corresponding size of the boot ROM memory.

Figure 5-6: Jumper Locations for Models 3101, 3102, and 3103

Figure 5-7 shows the jumper locations W1, W2, W3, and W4 on the model 3202 system card with Token Ring and serial interfaces, and it shows the labels of the jumpers.

Figure 5-7: Model 3202 System Card Layout

Using the orientation of Figure 5-7 for the model 3202 default jumper locations, note that W1 ships with its left two pins jumpered together. At location W3, the two left pins are jumpered to permit writing to Flash memory, or the two right pins are jumpered to disable writing to Flash memory. At location W4, the jumper corresponds to the size of boot ROM memory as shown on the ROM labels.

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Note The factory-set default jumper setting for jumper locations W3, W2, W4 on the model 3202 is for the two left pins on all jumpers to be jumpered together as shown in Figure 5-7. If you do not want your system to be writable from the net, disable the write to Flash memory option by moving the jumper on W3 to the right two jumpers.

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Note Note that the jumper ordering for the model 3202 (first W3, then W2, then W4) is not intuitive.

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Figure 5-8 shows the correct jumper setting for jumper location W1 on the model 3202 when the system card is oriented as in Figure 5-7. There should be no normal conditions under which the jumper setting on W1 should be changed.

Figure 5-8: Model 3202 Jumper Location W1 Default Setting

For information on configuring your system's Flash memory, refer to the Router Products Configuration and Reference publication.

Replacing DRAM SIMMs

The router contains primary (main memory) and secondary (shared) memory. Both primary and secondary memory size, in kilobytes (KB), are shown in the system banner on the console screen. Primary memory is implemented with dynamic random-access memory (DRAM) single in-line memory modules (SIMMs). Secondary memory, used for packet buffering, consists of a fixed 512 KB (2 megabytes [MB] for models 3104 and 3204).

After booting up, your system will indicate in the system banner the amount of memory it has. The following example shows a system with 4096 KB (4 MB) of primary memory.

System Bootstrap, Version 4.6(0.15), SOFTWARE
Copyright (c) 1986-1992 by cisco Systems
Cisco 3000/030 processor with 4096 Kbytes of memory
>

Primary memory may need to be expanded when you use very large routing tables or many protocols. This might be necessary with configurations in which the router is set up as a connection device between large external networks and your internal network.

Tools and Equipment Required for DRAM SIMM Replacement

• ESD cord and wrist strap
  
  
• Screwdriver: No. 1 Phillips
  
  
• DRAM SIMMs for your router model
  
  

Primary Memory Configurations for Models 3101, 3102, 3103, and 3202

The standard primary memory (main memory) configuration of the router models 3101, 3102, 3103, and 3202 are 4 MB of 32-bit-wide DRAM. Upgrade to 16 MB of 32-bit-wide DRAM by replacing the system's four 1 MB x 9 SIMMs. For 16-MB configurations, substitute four 4 MB x 9 DRAM SIMMs.

Memory upgrade kits for the router include four new 4 MB x 9 DRAM SIMMs.

Approved DRAM SIMMs for Models 3101, 3102, 3103, and 3202

Table 5-2 lists approved 4 MB x 9, 80-nanosecond DRAM SIMMs for models 3101, 3102, 3103, and 3202.

Approved 4 MB x 9, 80-Nanosecond DRAM SIMMs

Manufacturer's Name	Manufacturer's Part Number
Motorola	MCM94000AS80
Micron	MT9D49M-8
Texas Instruments	TM100EAD9-80

After booting up, your system will indicate in the system banner the amount of primary and secondary memory it has. The following example shows a system with 4096 KB (4 MB) of primary memory and 512 KB (1/2 MB) of secondary memory:

System Bootstrap, Version 9.1 ROUTER SOFTWARE
Copyright (c) 1986-1992 cisco Systems, Inc.
Cisco 3000/030 processor with 4608 Kbytes of memory
>

Primary Memory Configurations for Models 3204 and 3104

The standard primary memory configuration of the router models 3204 and 3104 are 4 MB and
8 MB. You can upgrade from 4 MB of DRAM (main memory) by replacing the 72-pin DRAM SIMM in the main memory socket on the system card. Memory upgrade kits for the router models 3204 and 3104 are obtainable from us. Table 5-3 lists approved 2 MB x 36, 80-nanosecond DRAM SIMMs for models for models 3204 and 3104.

Approved 2 MB x 36, 80-Nanosecond DRAM SIMMs

Manufacturer's Name	Manufacturer's Part Number
Micron	MT18D236M-8
NEC	MC-422000A36B-80

Upgrading to 8 MB Primary Memory in Router Models 3204 and 3104

You can upgrade your router, models 3204 and 3104, from the standard 4 MB of primary memory to 8 MB (see Table 5-3) using the memory upgrade kit as follows:

Step 1 Turn OFF the unit and unplug it.

Step 2 Attach ESD protection.

Step 3 Open the cover according to the procedures in the sections "Opening the Chassis" and "Removing the Power-Supply Tray Assembly."

Step 4 Locate the primary memory (DRAM SIMMs) by using Figure 5-3 or Figure 5-4.

Step 5 Remove the existing DRAM SIMMs by pulling outward on the connectors to unlatch them, as shown in Figure 5-9. Be careful not to break the holders on the SIMM connector.

Figure 5-9: Removing a SIMM from the SIMM Connector Socket

Step 6 Insert the new DRAM SIMM into the open connector by sliding the end with the metal fingers into the DRAM SIMM connector socket, at approximately a 45-degree angle to the system card. Gently rock the DRAM SIMM back into place until the latch on either side snaps into place. Do not use excessive force, or the connector could break.

Step 7 Reassemble the router following the procedures in the section "Replacing the Chassis Cover and Tray," taking care not to pinch the DC power harness.

Step 8 Connect the router to a console terminal and turn On the power. If error messages relating to memory are displayed, repeat steps 1 through 6, taking care to firmly seat the SIMM in its socket.

Upgrading to 16 MB of Primary Memory in Models 3101, 3102, 3103, and 3202

You can upgrade your router, models 3101, 3102, 3103, and 3202 from the standard 4 MB of primary memory to 16 MB using the memory upgrade kit as follows:

Step 1 Turn OFF the unit and unplug it.

Step 2 Attach ESD protection.

Step 3 Open the cover according to the procedures in the sections "Opening the Chassis" and "Removing the Power-Supply Tray Assembly."

Step 4 Locate the DRAM SIMMs by using Figure 5-5 or Figure 5-7.

Step 5 Remove the existing DRAM SIMMs by pulling outward on the connectors to unlatch them, as shown in Figure 5-9. Be careful not to break the holders on the SIMM connector.

Figure 5-10: Removing a SIMM from the SIMM Connector Socket

Step 6 Plug each new DRAM SIMM (4 MB x 9) into the open connector. To insert a new DRAM SIMM card, slide the end with the metal fingers straight down into the SIMM connector socket, at an angle perpendicular to the card. Gently rock the DRAM SIMM back toward the SIMMs already installed and snap into place. Do not use excessive force, or the connector could break.

Step 7 Repeat step 5 for each new DRAM SIMM card.

Step 8 Reassemble the router following the procedures in the section "Replacing the Chassis Cover and Tray," taking care not to pinch the DC power harness.

Step 9 Connect the router to a console terminal and turn ON the power. If error messages relating to memory are displayed, repeat steps 1 through 7, taking care to firmly seat the DRAM SIMMs in their sockets.

Flash Memory SIMMs

80-pin Flash memory SIMMs can be purchased from us or from other vendors.

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Note The Flash memory for all the router models except 3202 can be contained on either one or two 80-pin Flash memory SIMMs. If only one 80-pin Flash memory SIMM socket is populated, then it must be the socket indicated in Figure 5-3 and Figure 5-4.

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If you are replacing Flash memory with SIMMs you purchase from other vendors, be sure to use 120-nanosecond memory Flash SIMMs from the vendor listed in Table 5-4.

Approved, 4-MB, 120-Nanosecond Flash SIMMs

Manufacturer's Name	Manufacturer's Part Number
SMART Module	SM732C1024.12

Tools and Equipment Required for Flash Memory SIMM Replacement

The procedures for replacing Flash Memory SIMMs require the tools and equipment following:

• ESD cord and wrist strap
  
  
• Screwdriver: No. 1 Phillips
  
  
• Flash memory SIMMS or EPROMS for your router model
  
  

Replacing Flash Memory SIMMs

Follow these steps to upgrade the Flash memory on all models except 3202, which employs Flash EPROMs:

Step 1 Turn OFF the router and unplug it.

Step 2 Open the chassis cover according to the procedures in the sections "Opening the Chassis" and "Removing the Power-Supply Tray Assembly."

Step 3 Locate the Flash memory SIMMs on the system card. (Shown in Figure 5-3, Figure 5-4, and Figure 5-5.)

Step 4 Gently spread the Flash memory SIMM connector holddowns until they are wide enough to permit you to remove the Flash memory SIMM. (See Figure 5-11.)

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Note The connector holds the Flash memory SIMM tightly, so you will probably hear a "creaking" sound like moving a rusty hinge as you pry the Flash memory SIMM loose.

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Step 5 Repeat for all the Flash memory SIMMs to be replaced.

Caution Do not push on the Flash chips themselves. Handle the Flash SIMM and its components with care. They are fragile.

Figure 5-11: Flash SIMM Card Removal

Step 6 Plug the new Flash memory SIMM into the open connector. To insert a new SIMM, slide the end with the metal fingers straight down into the SIMM connector socket, at an angle perpendicular to the system card. Gently rock the SIMM back toward the SIMMs already installed and snap into place. Do not use excessive force, or the connector could break.

Replacing Flash EPROMs in the Model 3202

After opening the model 3202 chassis to access the system card, follow the procedures in this section to replace the Flash EPROMs.

After removing the old EPROMs, keep them separate from the new ones to avoid mixing the two sets.

Caution The correct placement of the Flash EPROMs is crucial. If improperly positioned, the EPROMs could be damaged when the system is powered on. Read through all of the instructions before proceeding. To prevent damage to the EPROMs from electrostatic discharge (when handling the system and its components) be sure to follow the ESD procedures described in Chapter 2. Also, be careful not to damage or scratch the printed circuit card under the EPROMs.

In addition to the tools listed in the section "Tools and Equipment Required for Flash Memory SIMM Replacement," you need the following tools and equipment to install Flash EPROMs in the model 3202:

• EPROM removal tool
  
  
• Eight Flash EPROMs, labeled U41 through U48
  
  

Figure 5-7 illustrates the model 3202 card layout. The card is oriented with the front panel LEDs at the bottom of the illustration. Refer to this figure to locate the EPROMs on the system card.

Installing Flash Memory EPROMs

Follow these steps to install Flash memory EPROMs in the model 3202:

Step 1 Locate the EPROMs labeled U41 through U48 at the front of the unit. (See Figure 5-7.) Note the orientation of the notches on the EPROMs to aid in inserting the new EPROMs. Do not rely on the EPROM labels for correct positioning.

Step 2 Use an EPROM removal tool to gently remove EPROMs U41 through U48. Set the EPROMs aside and keep them in case you need to use them again.

Step 3 Insert the new EPROMs in the sockets U41 through U48 in the order shown in Figure 5-7, being careful not to bend or crush any of the pins. To straighten out a bent pin, use needlenose pliers. Align the notch in the EPROM with the notch in the EPROM socket, ignoring the orientation of the label. Be sure to insert the new EPROMs using the same orientation as the EPROMs you are replacing.

Replacing the Boot ROMs

To replace the boot ROM software with a new software image, the existing boot ROMs must be replaced.

Tools and Equipment Required for Replacing the Boot ROMs

The following tools and equipment are required to replace the boot ROMs:

• EPROM extraction tool or a small flat-blade screwdriver
  
  
• Two boot ROMs
  
  

Upgrading the Boot ROMs

Follow this procedure to replace the boot ROMs:

Step 1 To open the chassis and expose the boot ROMs, follow the procedures in the sections "Opening the Chassis" and "Removing the Power-Supply Tray Assembly."

Step 2 Once the boot ROMs, FW1 and FW2, on the system card are exposed, follow the procedures in this section to replace the ROMs.

Caution The correct placement of the boot ROMs is crucial. If improperly positioned, the new components could be damaged when the system is powered on. Read through all of the instructions before proceeding. To prevent damage to the ROMs from ESD (when handling the system and its components), follow the ESD procedures described earlier. Also, be careful not to damage or scratch the printed circuit card under the ROMs.

Step 3 Locate the boot ROMs, FW1 and FW2. (See Figure 5-3, Figure 5-4, Figure 5-5, and Figure 5-7.)

Step 4 Using an EPROM extraction tool or a small flat-blade screwdriver, gently remove the boot ROMs and set them aside.

Step 5 Insert the new boot ROMs in their respective sockets in the orientation shown in Figure 5-3, Figure 5-4, Figure 5-5, and Figure 5-7, being careful not to bend or crush any of the bottom pins. To straighten out a bent pin, use needlenose pliers. Align the notch in the new ROM with the notch in the ROM socket, ignoring the orientation of the label.

Replacing the Chassis Cover and Tray

After you perform the maintenance for your system, replace the cover and component tray by following these steps.

Step 1 Replace the metal power supply and tray assembly on the chassis.

Step 2 Replace the power-supply tray screw. (See Figure 5-2.)

Step 3 Replace the ground wire by connecting the ground wire to the stud.

Step 4 Replace the DC power harness. (See Figure 5-2.)

Step 5 Replace the chassis cover.

Step 6 Replace the latch screw. (See Figure 5-1.)

Step 7 Replace the chassis cables.

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Note The power cable is designed so that if it is installed backwards or offset, +5V is shorted to ground. This enables the protective circuitry on the power supply to protect the system card from reversed voltage. If this happens, you will hear a quiet clicking from the power supply, but you will not hear other noises, such as the fan, and no LEDs will light.

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Recovering a Lost Password

An overview to recovering a lost password follows:

• Enter the show version command to note existing virtual configuration value
  
  
• Break to the bootstrap program prompt (ROM monitor)
  
  
• Change the configuration register to 0x141 (boot from ROM)
  
  
• Enter the privileged mode in the system bootstrap program (the boot ROM software image)
  
  
• Enter the show configuration command to display the enable password
  
  
• Change the configuration register value back to its original setting
  
  

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Note To recover a lost password if Break is disabled on the router, it is necessary to have physical access to the router.

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To recover a lost password, follow this procedure:

Step 1 Attach an RS-232 ASCII terminal to the router console port which is located at the rear of the router.

Step 2 Configure the terminal to operate at 9600 baud, 8 data bits, no parity, 1 stop bit (or to whatever settings the router is set).

Step 3 Enter the command show version to display the existing configuration register value. Note this value for later use in step 14.

Step 4 If Break is disabled, power cycle the router. (Turn the router OFF, wait 5 seconds, and then turn it ON again.) If Break is enabled on the router, send a Break and then proceed to step 5.

Step 5 Within 60 seconds of turning the router on, press the Break key. This action causes the terminal to display the bootstrap program prompt (>).

Step 6 To reset the configuration register to boot from the boot ROMs, enter o/r at the bootstrap prompt as follows:

Step 7 Initialize the router by entering the i command as follows:

The router will power cycle, the configuration register will be set to 0x141, and the router will boot the boot ROM system image and prompt you with the system configuration dialog as in the follows:

         --- System Configuration Dialog --- 
                                  

Step 8 Enter no to the system configuration dialog prompts until the following system message is displayed:

Step 9 Press Return. The boot ROM prompt appears as follows:

Step 10 Enter the enable command to enter the EXEC mode in the boot ROM image. The prompt changes to the following:

Step 11 Enter the show configuration EXEC command to display the enable password in the router's configuration file.

Step 12 Enter the configure terminal command at the EXEC prompt. You are prompted as follows:

Step 13 Using the config-reg 0xvalue command, change the configuration register value back to its original value (from step 3) or change it to a value of 0x102, which in the absence of a boot system command in the configuration file, causes the router to boot from Flash memory.

Step 14 Exit configuration mode by entering Ctrl-Z.

Step 15 Reboot the router and enable using the recovered password.