Installing the T640 Chassis in the Rack Manually

To install the T640 router in the rack (see Figure 2):

Caution: If you are installing two routers in one rack, install the lower one first. Installing a router in the upper position in a rack or cabinet requires a lift.

Caution: Before front-mounting the router in a rack, have a qualified technician verify that the rack is strong enough to support the router's weight and is adequately supported at the installation site.

Caution: Lifting the chassis and mounting it in a rack requires four people. The empty chassis weighs approximately 205 lb (93 kg).

1. If you are installing the router in an open-frame rack, ensure that the rack is in its permanent location and is secured to the building. Ensure that the installation site allows adequate clearance for both airflow and maintenance. For details, see T640 Clearance Requirements for Airflow and Hardware Maintenance .
2. Attach the installation handle by tightening the captive screws of the handle into the holes previously occupied by the captive screws of the power supplies (see Figure 1). Tighten the screws, using a Phillips (+) screwdriver, number 2.

   Figure 1: Attaching the Installation Handle

   
3. Position the router in front of the rack or cabinet, centering it in front of the mounting shelves. Use a pallet jack if one is available.

   Caution: Do not lift the router using the installation handle, or the handles on the sides of the chassis. Use these handles only to help position the router.

4. With two people in the front and two people in the back, hold onto the bottom of the chassis and carefully lift it onto the mounting shelves.

   Warning: To prevent injury, keep your back straight and lift with your legs, not your back. Avoid twisting your body as you lift. Balance the load evenly and be sure that your footing is solid.

5. With one person pulling on the installation handle from the rear of the rack or cabinet while two people push on the front-mounting flanges, slide the router onto the mounting shelves until the mounting brackets or front-mounting flanges contact the rack rails or spacer bars (depending on your type of installation). The shelves ensure that the holes in the mounting brackets and the front-mounting flanges of the chassis align with the holes in the rack rails.

   If you center-mount the chassis, you use the center-mounting brackets attached to the chassis; if you front-mount the chassis, you use the front-mounting flanges.

6. If you are installing the router in a four-post rack or cabinet, install a mounting screw and a cage nut into each of the holes aligned with the threaded holes in the spacer bars. If you are installing the router in an open-frame rack, install a mounting screw into each of the open mounting holes aligned with the rack, starting from the bottom.
7. Loosen the captive screws on the installation handle completely, and remove the handle from the chassis.
8. Visually inspect the alignment of the router. If the router is installed properly in the rack, all the mounting screws on one side of the rack should be aligned with the mounting screws on the opposite side and the router should be level.

Figure 2: Installing the Router in the Rack

Note: This illustration depicts the router being installed in a four-post rack. For an illustration of the mounting hardware required for an open-frame rack, see Install the Mounting Hardware for an Open-Frame Rack.