Cisco 5814 Dial Shelf Packaging Replacement Instructions

Required Tools and Parts

Powering Off the Cisco AS5800

Preparing to Repackage the Cisco 5814 Dial Shelf

Repackaging the Cisco 5814 Dial Shelf

Cisco 5814 Dial Shelf Packaging Replacement Instructions

This appendix provides packaging material information for the Cisco 5814 dial shelf. It explains how to prepare the dial shelf for repackaging and how to package the dial shelf for shipping. This appendix assumes that you are returning your entire Cisco 5814 dial shelf. If you are returning an empty chassis, use these instructions as applicable.

The Cisco 5814 dial shelf is a large, heavy chassis; it measures 19-in. (48.3 cm) wide, 21-in. (53.3 cm) deep, and 56-in. (142.2 cm) high. A fully configured dial shelf weighs approximately 278 lb (126.1 kg). In order to ship the chassis safely, a packaging kit has been engineered to prevent shock damage. This is the same packaging kit originally used to ship the dial shelf. If your original system packaging is damaged or was discarded, you must order a replacement packaging kit (PKG-5814=).

Figure C-1 shows the dial shelf packaging detail.

Figure C-1: Cisco 5814 Packaging Detail

Required Tools and Parts

You will need the following tools and parts to remove the Cisco 5814 dial shelf components and to repackage the Cisco 5814 dial shelf:

Your own ESD-preventive wrist strap
Cable ties (recommended, but not essential)
An antistatic mat
No. 2 Phillips screwdriver
1/4-in. flat-blade screwdriver
Standard strapping tool and strap or banding material
Cisco 5814 repackaging kit (PKG-5814=), which includes:
- Wooden pallet and base tray assembly (corrugated tray, foam cushions, corrugated chassis platform
- Plastic bag
- Top perimeter foam
- Accessory box
- Master shipper

Powering Off the Cisco AS5800

You must power off the Cisco AS5800 before attempting to dismantle the dial shelf for repackaging.

Powering off the access server involves the following components:

Router shelf
Dial shelf
AC-input power shelf, if applicable

To power off the Cisco AS5800, follow these steps:

Warning Before working on equipment that is connected to power lines, remove jewelry (including rings, necklaces, and watches). Metal objects will heat up when connected to power and ground and can cause serious burns or weld the metal object to the terminals. To see translations of the warnings that appear in this publication, refer to the Regulatory Compliance and Safety Information document that accompanied this device.

Step 1 Power OFF (O) the power switches located on the router shelf rear panel. (See Figure C-2.)

Figure C-2: Router Shelf Power Switches

Step 2 Power OFF (O) the power switches located on each dial shelf PEM front panel. (See Figure C-3.)

Figure C-3: Dial Shelf Power Switches on the PEMS

Step 3 If you are using the optional AC-input power shelf, power OFF (O) the power switches located on the AC-input power shelf front panel. (See Figure C-4.)

Figure C-4: AC-Input Power Shelf

Step 4 Power OFF the central office main circuit breaker.

Caution If you are using the optional AC-input power shelf, you must power off both AC-input power supplies before you disconnect the DC cables from the DC terminal blocks.

Step 5 Loosen the screws in the DC-input power terminal blocks and the alarm terminal blocks using a 1/4-in. flat-blade screwdriver, and disconnect power cables and alarm cables to the dial shelf PEMs. Figure C-5 shows the location of the terminal blocks.

Figure C-5: PEM DC Terminal Block

Step 6 Disconnect the DC power cables from your DC power source.

The last two steps refer to the optional AC-input power shelf. If you are using a DC power source, you can skip Step 7 and Step 8 and proceed to the section "Preparing to Repackage the Cisco 5814 Dial Shelf."

Step 7 Disconnect the monitor cable DB-9 connector from the base of the filter module. (See Figure C-6.)

Figure C-6: Filter Module Monitor Cable DB-9 Connector

Step 8 Disconnect power cables to the optional AC-input power shelf. (See Figure C-7.)

Figure C-7: AC-Input Power Shelf Cable Connections

Step 9 Disconnect incoming CE1 or CT1 trunk line cables and secure them out of the way using cable ties, if necessary. On the dial shelf controller card, disconnect the dial shelf interconnect cable and the BNC connection if applicable.

This completes the power-off sequence. Proceed to the following section, "Preparing to Repackage the Cisco 5814 Dial Shelf."

Preparing to Repackage the Cisco 5814 Dial Shelf

The Cisco 5814 dial shelf is equipped with a blower assembly, dial shelf cards (trunk and modem cards) and dial shelf controller cards configured in the chassis. Fully loaded, the dial shelf weighs 278 lb (126.1 kg).

Before removing the Cisco 5814 from the rack, we recommend that you remove the dial shelf cards, dial shelf controller cards, and the blower assembly from the dial shelf to decrease the chassis weight (see the "Removing the Blower Assembly" section and the "Removing Dial Shelf Cards and Dial Shelf Controller Cards" section), then reinstall the components (See the "Replacing the Dial Shelf Components" section) after the dial shelf is seated on the shipping pallet/base tray assembly.

Repackaging the Cisco 5814 Dial Shelf

To repackage the Cisco 5814 dial shelf, follow these steps:

Step 1 Lay the opened plastic bag, with sides rolled down, on the pallet/base tray assembly. (See Figure C-1.)

Step 2 Remove the screws securing the rear mounting brackets on the dial shelf to the rear rack posts. Next, remove the rear brackets from the dial shelf chassis.

Caution If the dial shelf is suspended in the rack, install the two support brackets that were included in your original rack-mount kit under the chassis to prevent it from falling while you are removing the rack-mount screws and brackets.

Step 3 Remove the screws securing the front of the dial shelf chassis to the rack.

Step 4 Lift and slide the chassis out of the rack.

Warning Two people are required to lift the chassis. Use the handles on the chassis sides. To prevent injury, keep your back straight and lift with your legs, not your back. To prevent damage to the chassis and components, never attempt to lift the chassis with the handles on the power supplies, the filter module, or on the blower assembly. These handles are not designed to support the weight of the chassis. To see translations of the warnings that appear in this publication, refer to the Regulatory Compliance and Safety Information document that accompanied this device.

Step 5 Seat the dial shelf on the pallet/base tray assembly, and remove the front rack-mount brackets from the chassis sides, if applicable.

Step 6 Place all accessories (including power cords, cables, documentation, and mounting hardware) in the accessories box and tape the box closed.

Step 7 Replace the blower assembly, dial shelf cards, and dial shelf controller cards you removed into the dial shelf chassis.

Step 8 Pull the sides of the plastic bag up over the dial shelf chassis and seal the bag.

Step 9 Position the foam around the top chassis perimeter.

Step 10 Place the accessories box on top of the dial shelf chassis.

Step 11 Slide the master shipper over the top of the chassis and base tray; close the top flaps and seal with tape. (See Figure C-1.)

Step 12 Secure the container to the pallet and base tray using a standard strapping tool and banding.

The Cisco 5814 dial shelf is now packaged and ready to be transported. Use a forklift or pallet jack to move the dial shelf container.

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