Avici Systems Inc.

Field Replacement Procedure

SSR Replacement Packaging

04258-01 Rev. AB

Before you Begin

If you do not have the packaging the SSR arrived in, a kit is available for repackaging. In addition, a 2-wheel lift is required for rack removal and mounting. The 2-wheel lift can be purchased or leased from Avici. If using a lift other than the recommended Avici lift, follow all safety precautions when undertaking this procedure.

If leasing or purchasing a kit from Avici, carefully inspect the package to ensure no damage occurred during shipping or delivery. If you suspect any possible damage to any field replacement unit, contact Avici Support Services immediately.

This document describes the procedure to pack the SSR chassis for shipping.

NOTE This document assumes that the SSR has been de-commissioned, and that the router, server, and bay controller modules have been removed.

Refer to the following Field Replacement Procedures for the steps to remove the router, server, and bay controller modules from the rack:

Support Services

There are three ways to obtain information on customer service and training:

Supplies Needed

You will need the following supplies to pack an SSR


Table 1. Packaging Materials List 
Part Name/Description Quantity

Crate Kit:

      Plywood crate top

1

      Plywood top support

1

      Plywood sides

4

      Klimps fasteners

12

      Inner pallet bottom with anti-static foam

1

      Outer pallet top

1

36-inch plastic film

1 roll

Come-along strap

1

Removable handles

2

Shipping labels

Packing slip

1

Tip N Tells

As req.

Tools Needed

You will need the following tools to pack an SSR:

Removing the SSR from the Rack

Use the 2-wheel lift is to support the SSR in the rack while disconnecting the rack mounting ears from the rack and to move the SSR to the crating area. After removing the SSR from the rack, reattach the removable handles.

If the chassis is being removed from the front, note that the SSR is heaviest in the rear and follow safety precautions while moving.

PROCEDURE: Use the following procedure to remove an SSR from a rack:

Step 1 Using the 2-wheeled lift, position the lift underneath the SSR in the rack and lock the wheels.

Step 2 Beginning at the bottom of the rack mounting ear, and working alternately from left to right, use a 18" ratchet extension (if needed) and a #2 Phillips screwdriver to remove the twelve (12) 10-32 panhead (panel mount) screws (six per side) that secure the rack mounting ears to the rack.

WARNING (1) The SSR is heaviest at the rear of the unit. It is 165 lb empty and 242 lb with shipped components. Use safe lifting procedures when moving the unit to avoid personal injury.

Step 3 Slide the SSR onto the lift if necessary and lower the lift slowly. (At least three people are necessary to leverage the unit).

Step 4 Use a come-a-long strap to secure the chassis to the lift if moving the SSR a long distance. Unlock the wheels to move the chassis.

Moving the SSR to a Pallet

Move the chassis on the lift to the crating area. Before lifting the chassis onto the double-bottomed crate, it is necessary to reattach the removable handles to the side of the chassis. If you do not have the removable handles, please contact Customer Service to obtain the removable handles kit.

At least three people are required to move the chassis from the lift to the crate.

WARNING (2) The SSR is heaviest at the rear of the unit. It is 165 lb empty and 242 lb with shipped components. Use safe lifting procedures when moving the unit to avoid personal injury.

PROCEDURE: Use the following steps to move SSR from the 2-wheel lift onto the pallet:

Step 1 Remove the come-a-long strap if used before reattaching the removable handles.

Step 2 Use a #2 Phillips screwdriver to reinstall handles on the SSR chassis (see Figure 1).

Figure 1. Removable Handles

NOTE Before lifting the chassis, note that the indentation in the foam inside the crate is wider at one end and matches the exact shape of the bottom of the SSR.

Step 3 Position the SSR next to the double-bottomed crate, matching the indentation in the foam with the bottom of the SSR.

Step 4 Slide the SSR off the 2-wheel lift and lift it into the crate bottom (see Figure 2).

Figure 2. SSR Chassis on Crate Bottom

Step 5 Wrap the plastic wrap three times around the outside of the chassis.

Step 6 If removed during installation, use a #3 Phillips screwdriver to install the two 2" X 4" wooden pieces (supplied with the crating kit) to the front and rear of inner crate (see Figure 3).

In

Figure 3. Installation of Front and Rear 2" x 4"

Step 7 Write the serial number of the SSR on the front right side with an indelible marker if this is a new repackaging kit. Reused packaging kits are already marked with the serial number.

Step 8 Position the inner top cover on the top of the chassis. The foam protection padding fits snugly over the chassis top.

Step 9 Secure the inner cover to the chassis with the come-a-long strap as shown (see Figure 4).

Figure 4. Installation of Inner Top Crate Cover

Step 10 Position the sides of the crate around the chassis and secure the corners and sides with 2 klimps along each edge.(see Figure 5 and Figure 6).

Step 11 Position the crate top on top of the crate and secure with klimp fasteners (see Figure 5 and Figure 6). Secure the corners with 2 klimps along each edge.

Figure 5. Installation of Side and Top Crate Covers

Figure 6. Klimp Fasteners

Step 12 Complete and attach the required labelling.

Step 13 Attach Tip 'n Tell shipping monitors as required.

Figure 7. Tip N Tell Shipping Monitor

Moving the Chassis to Shipping Area

Transporting the chassis to the shipping area requires a standard pallet jack.

Using a Pallet Jack

PROCEDURE: Use the following steps to secure the pallet jack to the pallet holding the chassis, move the chassis to the shipping area, and remove the pallet jack from the pallet.

Step 1 Lower the pallet jack to just below the pallet.

Step 2 Insert the pallet jack into the rear of the pallet opening. When the SSR is fully crated, the rear can be determined by locating the serial number, which has be written on the front right side of the pallet (see Figure 8).

Figure 8. SSR Serial Number Location

NOTE The SSR chassis is heavier at the rear of the chassis; therefore, position the pallet truck toward the rear of the pallet to balance the load.

Step 3 Raise the pallet just enough to maneuver the chassis.

Step 4 Transport the chassis to the shipping area.

Step 5 Lower the pallet and remove the jack.

Copyright © 2002 Avici Systems Inc.
Avici® and TSR® is a registered trademark of Avici Systems Inc.
IPriori™, Composite Links™, SSR™, and NSR® are trademarks of Avici Systems Inc.

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    Last Updated: 11/25/02 at 11:25:27

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