Removing Components from the Chassis Before Installing the M40e Router Without a Lift

You can install the router into a rack either with or without the help of a mechanical lift. Because the router weighs between 190 lb (86 kg) and about 360 lb (164 kg) depending on configuration, using a mechanical lift is recommended; for instructions, see Installing the M40e Router Using a Mechanical Lift.

If you do not use a mechanical lift, you must remove components from the chassis to reduce its weight before lifting it into the rack. The reduced chassis weight is approximately 115 lb (52 kg), so installing it safely still requires three people to lift and another person to insert the mounting screws.

To make the router light enough to install without a mechanical lift, you must remove most of the components.

Warning: The procedures in this section apply only to initial installation and assume that you have not yet connected power to the router. If power is connected, completely disconnect it before continuing. See Disconnecting AC Power from the M40e Router or Disconnecting DC Power from the M40e Router. Do not stack components on top of one another after removing them from the chassis. Place each one individually on a flat, stable surface, either on an antistatic mat or in an electrostatic bag. Set the removed components far enough away from the installation site that they will not be in the way as you lift the chassis into the rack.

Note: Do not remove the circuit breaker box (on a DC-powered router) or the Connector Interface Panel (CIP). This topic does not include instructions for removing these components.

Perform the procedures described in the following sections to remove components from the chassis, first from the rear and then from the front:

Removing the Power Supplies

The router has two power supplies (AC or DC) located at the bottom rear of the chassis, as shown in M40e Chassis Description. An AC power supply weighs approximately 15 lb (6.8 kg). A DC power supply weighs approximately 13 lb (5.9 kg).

To remove the power supplies (see Figure 1, which shows a DC power supply):

1. Attach an electrostatic discharge (ESD) grounding strap to your bare wrist, and connect the strap to one of the ESD points on the chassis. For more information about ESD, see Preventing Electrostatic Discharge Damage to an M Series, MX Series, or T Series Router.
2. Verify that the power switch for each power supply is in the OFF (O) position. On an AC-powered router, the switch for each power supply is on the power supply faceplate. On a DC-powered router, the switches are on the circuit breaker box.
3. Loosen the thumbscrew at each corner of the power supply faceplate, using a Phillips screwdriver if necessary.
4. Grasp the handle or handles on the power supply faceplate and pull firmly to slide the unit about halfway out of the chassis.
5. Place one hand under the power supply to support it, then slide it completely out of the chassis.
6. Repeat the procedure to remove the second power supply.

Figure 1: Removing a M40e Power Supply

Removing the Rear Component Cover

The rear component cover protects the SFMs, Routing Engines, MCSs, and PCGs, as shown in M40e Chassis Description. To remove it:

1. Attach an electrostatic discharge (ESD) grounding strap to your bare wrist, and connect the strap to one of the ESD points on the chassis. For more information about ESD, see Preventing Electrostatic Discharge Damage to an M Series, MX Series, or T Series Router.
2. Loosen the thumbscrew at each corner of the component cover, using a Phillips screwdriver if necessary.
3. Pull the cover straight off the chassis.

Caution: To maintain proper airflow and provide electromagnetic shielding, do not operate the router without the rear component cover in place.

Removing the SFMs

The router can have an SFM in each of the slots labeled SFM 0 and SFM 1 at the rear of the chassis, as shown in M40e Chassis Description. Each SFM weighs approximately 5 lb (2.3 kg).

To remove an SFM (see Figure 2):

1. Place an electrostatic bag or antistatic mat on a flat, stable surface.
2. Attach an electrostatic discharge (ESD) grounding strap to your bare wrist, and connect the strap to one of the ESD points on the chassis. For more information about ESD, see Preventing Electrostatic Discharge Damage to an M Series, MX Series, or T Series Router.
3. Loosen the thumbscrew on each ejector locking tab (shown in M40e SFM LEDs), using a Phillips screwdriver if necessary.
4. Pull the end of each ejector handle outward until it is nearly perpendicular to the SFM or CFEB-E faceplate.
5. Grasp the ejector handles and pull firmly to slide the SFM or CFEB-E about halfway out of the chassis.
6. Place one hand under the SFM or CFEB-E to support it, slide it completely out of the chassis, and place it on the antistatic mat or in the electrostatic bag.

   Caution: When an SFM or CFEB-E is out of the chassis, do not hold it by the ejector handles. They cannot support its weight. Do not stack SFMs or CFEB-Es on top of or under other components. Place each one individually in an electrostatic bag or on its own antistatic mat on a flat, stable surface.

If a second SFM is installed, repeat the procedure to remove it.

Figure 2: Removing an M40e SFM

Removing the MCSs

The router can have an MCS in each of the slots labeled MCS 0 and MCS 1 at the rear of the chassis, as shown in M40e Chassis Description. Each MCS weighs approximately 2.5 lb (1 kg).

The MCS is hot-pluggable, as described in M40e Field-Replaceable Units (FRUs). For a description of the effect of removing an MCS, see M40e Host Module Description.

To remove the MCSs (see Figure 3):

1. Place an electrostatic bag or antistatic mat on a flat, stable surface.
2. Attach an electrostatic discharge (ESD) grounding strap to your bare wrist, and connect the strap to one of the ESD points on the chassis. For more information about ESD, see Preventing Electrostatic Discharge Damage to an M Series, MX Series, or T Series Router.
3. Push the end of each extractor clip (located at each end of the MCS) outward.
4. Grasp the extractor clips and slide the MCS about halfway out of the chassis.
5. Place one hand under the MCS to support it, slide it completely out of the chassis, and place it on the antistatic mat or in the electrostatic bag.

If a second MCS is installed, repeat the procedure to remove it.

Figure 3: Removing an M40e MCS

Removing the PCGs

The router has two PCGs installed in the slots labeled PCG 0 and PCG 1 at the rear of the chassis, as shown in M40e Chassis Description. Each PCG weighs approximately 1 lb (0.5 kg).

To remove the PCGs (see Figure 4):

1. Place an electrostatic bag or antistatic mat on a flat, stable surface.
2. Attach an electrostatic discharge (ESD) grounding strap to your bare wrist, and connect the strap to one of the ESD points on the chassis. For more information about ESD, see Preventing Electrostatic Discharge Damage to an M Series, MX Series, or T Series Router.
3. Loosen the thumbscrew at the lower right corner of the PCG faceplate, using a Phillips screwdriver if necessary.
4. Grasp the thumbscrew and slide the PCG about halfway out of the chassis.

   Caution: Be careful to slide the PCG straight out of the chassis to avoid bending any of the pins on the underside of the board.

5. Place one hand under the PCG to support it, slide it completely out of the chassis, and place it on the antistatic mat or in the electrostatic bag.
6. Repeat the procedure to remove the second PCG.

Figure 4: Removing a M40e PCG

Removing the Routing Engines

The router can have a Routing Engine in each of the slots labeled RE 0 and RE 1 at the rear of the chassis, as shown in M40e Chassis Description. Each Routing Engine weighs approximately 1.5 lb (0.7 kg).

The routing engine is hot-pluggable, as described in M40e Field-Replaceable Units (FRUs). For a description of the effect of removing a routing engine, see M40e Host Module Description.

To remove a Routing Engine (see Figure 5):

1. Place an electrostatic bag or antistatic mat on a flat, stable surface.
2. Attach an electrostatic discharge (ESD) grounding strap to your bare wrist, and connect the strap to one of the ESD points on the chassis. For more information about ESD, see Preventing Electrostatic Discharge Damage to an M Series, MX Series, or T Series Router.
3. Using your thumbs, push and hold the red tab on each extractor clip toward the outer edge of the unit. Push the ends of the extractor clips outward to unseat the Routing Engine from the chassis.
4. Grasp the extractor clips and slide the unit about halfway out of the chassis.

   Caution: Slide the Routing Engine straight out of the chassis. Damage can result if the Routing Engine gets lodged because of uneven movement.

5. Place one hand under the Routing Engine to support it, slide it completely out of the chassis, and place it on the antistatic mat or in the electrostatic bag.

If a second Routing Engine is installed, repeat the procedure to remove it.

Figure 5: Removing a M40e Routing Engine

Removing the Rear Upper Impeller Assembly

The rear upper impeller assembly is located at the top of the chassis rear, as shown in M40e Chassis Description. The assembly weighs approximately 4 lb (1.8 kg).

To remove the rear upper impeller assembly (see Figure 6):

1. Attach an electrostatic discharge (ESD) grounding strap to your bare wrist, and connect the strap to one of the ESD points on the chassis. For more information about ESD, see Preventing Electrostatic Discharge Damage to an M Series, MX Series, or T Series Router.
2. Loosen the thumbscrew at each corner of the impeller cover, using a Phillips screwdriver if necessary.
3. Grasp the screws at opposite corners of the impeller cover and slide the assembly out of the chassis.

Figure 6: Removing the M40e Rear Upper Impeller Assembly

Removing the Rear Lower Impeller Assembly

The rear lower impeller assembly is located to the left of the circuit breaker box on the rear of the chassis, as shown in M40e Chassis Description. The assembly weighs approximately 5 lb (2.3 kg).

To remove the rear lower impeller assembly (see Figure 7):

1. Attach an electrostatic discharge (ESD) grounding strap to your bare wrist, and connect the strap to one of the ESD points on the chassis. For more information about ESD, see Preventing Electrostatic Discharge Damage to an M Series, MX Series, or T Series Router.
2. Loosen the thumbscrew at each corner of the impeller cover, using a Phillips screwdriver if necessary.
3. Grasp the screws at opposite corners of the impeller cover and slide the assembly out of the chassis.

Figure 7: Removing the M40e Rear Lower Impeller Assembly

Removing the Fan Tray

The fan tray is located behind the cable management system on the front of the chassis, just above the air filter, as shown in M40e Chassis Description. The fan tray contains four fans and weighs approximately 13 lb (5.9 kg).

To remove the fan tray (see Figure 8):

1. Attach an electrostatic discharge (ESD) grounding strap to your bare wrist, and connect the strap to one of the ESD points on the chassis. For more information about ESD, see Preventing Electrostatic Discharge Damage to an M Series, MX Series, or T Series Router.
2. Loosen the thumbscrew at each end of the fan tray, using a Phillips screwdriver if necessary.
3. Grasp the sides of the fan tray and pull firmly to slide it out of the chassis.

Figure 8: Removing the M40e Fan Tray

Removing the FPCs

The router can have up to eight FPCs mounted vertically in the FPC card cage on the front of the chassis, as shown in M40e Chassis Description. An FPC that houses four PICs weighs about 15 lb (6.8 kg).

Note: To help you work systematically, remove FPCs starting at the left side of the card cage and working toward the right. You can remove FPCs in any order, however. As you remove each FPC, label it with its slot number and record the relevant information in the checklist in Table 1.

To remove the FPCs (see Figure 9):

1. Place an electrostatic bag or antistatic mat on a flat, stable surface.
2. Attach an electrostatic discharge (ESD) grounding strap to your bare wrist, and connect the strap to one of the ESD points on the chassis. For more information about ESD, see Preventing Electrostatic Discharge Damage to an M Series, MX Series, or T Series Router.
3. Locate the FPC or blank panel located in the leftmost slot of the card cage on the front of the chassis. It is directly below the offline button on the craft interface that is labeled FPC0.
4. If the slot is covered by a blank panel, you can leave it in place. If the slot contains an FPC:
   1. Loosen the thumbscrew at each end of the FPC, using a Phillips screwdriver if necessary.
   2. Pull the ends of the ejector levers, which are adjacent to the thumbscrews, away from the face of the FPC until they are nearly perpendicular to it.
   3. Grasp the top and bottom flanges of the card carrier and slide the FPC about halfway out of the card cage.
   4. Place one hand around the front of the FPC (the PIC housing) and the other hand under it to support it. Slide the FPC completely out of the chassis, and place it on the antistatic mat or in the electrostatic bag.

      Caution: The weight of the FPC is concentrated in the back end. Be prepared to accept the full weight—up to 15 lb (6.8 kg)—as you slide the FPC out of the chassis. When the FPC is out of the chassis, do not hold it by the ejector levers, bus bars, or edge connectors. They cannot support its weight. Do not stack FPCs on top of one another after removal. Place each one individually in an electrostatic bag or on its own antistatic mat on a flat, stable surface.

5. Repeat Step 4 for each FPC card carrier or blank cover, proceeding from left to right.

Figure 9: Removing an M40e FPC

Removing the Front Impeller Assembly

The front impeller assembly, which includes the craft interface, is located at the front of the chassis above the FPC card cage, as shown in M40e Chassis Description. The assembly weighs approximately 14.5 lb (6.6 kg).

To remove the front impeller assembly (see Figure 10):

1. Place an electrostatic bag or antistatic mat on a flat, stable surface.
2. Attach an electrostatic discharge (ESD) grounding strap to your bare wrist, and connect the strap to one of the ESD points on the chassis. For more information about ESD, see Preventing Electrostatic Discharge Damage to an M Series, MX Series, or T Series Router.
3. Using a Phillips screwdriver, loosen the captive screw at each corner of the craft interface.
4. Insert a flat-blade screwdriver into the gap around the craft interface and gently pry the impeller assembly forward until you can grasp the sides of the assembly and slide it halfway out of the chassis.
5. Place one hand under the assembly to support it, slide it completely out of the chassis, and place it on the antistatic mat or in the electrostatic bag.

Figure 10: Removing the M40e Front Impeller Assembly