HP ProCurve 4000m Fan-Array Repair

On 11 November 2005 I replaced the fan array in my HP ProCurve 4000m switch, which had been running non-stop for about five years. One of the fans had failed, and HP sent me a new fan array for free. (ProCurve equipment is warranted for life.) The following photos were taken during the removal-and-installation procedure, which lasted about 70 minutes.

For more information, see this write-up of my experience on my blog.

img_0825-wm.jpg My poor 4000m! One of its fans has failed. (Note orange fault indicator in upper-left corner.)

img_0826-wm.jpg Starting the repair, I remove the 4000m from the rack and prepare to open it up.

img_0827-wm.jpg First, I remove power supply 1.

img_0828-wm.jpg Yuck! Look at all of that dust. Time for the vacuum cleaner!

img_0829-wm.jpg Next, I remove the second side.

img_0830-wm.jpg Next, on the front panel, I remove the master control module.

img_0831-wm.jpg Then, I remove the first 8-port 10/100 Ethernet module.

img_0832-wm.jpg This is the other side of the 8-port 10/100 Ethernet module.

img_0833-wm.jpg I remove the next module.

img_0834-wm.jpg And the next.

img_0835-wm.jpg And so on...

img_0836-wm.jpg With all of the modules removed, the backplane is exposed.

img_0837-wm.jpg (I need to vacuum this out, too.)

img_0838-wm.jpg Here is the power connector for the fan array.

img_0839-wm.jpg I unplug it.

img_0840-wm.jpg And then unscrew the fan array.

img_0841-wm.jpg With the fan array removed, it's time to vacuum again. Wee!

img_0842-wm.jpg Now, I install the shiny new fan array.

img_0843-wm.jpg And screw it in place.

img_0844-wm.jpg There, now it's ready to plug in.

img_0845-wm.jpg The new connector has a fancy handle for easy gripping.

img_0846-wm.jpg It plugs in easily.

img_0847-wm.jpg I re-install the modules and run a quick smoke test.

img_0848-wm.jpg So far so good: all LEDs light, and the module-by-module tests begin.

img_0850-wm.jpg Success: all modules pass their self-tests!

img_0856-wm.jpg The rejuvenated ProCurve 4000m, back in its home and serving packets to you.

Total downtime: 1 hour, 12 minutes.