Unable to copy IOS to switch in stack

[jmorris52]

I'm upgrading a 4-switch stack and the .bin file was able to transfer to 1, 2, and 4, but not switch 3. When I manually try to copy it over, I get the following error:
flash-3:/cat9k_iosxe.17.09.04a.SPA.bin (I/O error)

I've removed and readded the file from the switches, tried to readd/install multiple times but it keeps failing on switch 3:
Any thoughts?
TIA 

[balaji.bandi]

flash-3:/cat9k_iosxe.17.09.04a.SPA.bin (I/O error)  - seems to be hardware error for me.

Remove the device from Stack and try below option and see if that fix the issue, 

# check the free space or delete any files.

#fsck flash:

check if that fix the issue,  if not still have IO error, contact TAC for RMA>

[Leo Laohoo]

Post the complete output to the following commands: 

dir flash-3:
sh log | include -3-

[jmorris52]

There were many errors that all centered around this: %BTRACE_MANAGER-3-BTRT_ERR_MSG: Switch 3 R0/0: btman: Btrace Rotate Error: Move file failed, Delete file: chasync_R0-0.7318_8517422.20240109143017.bin.gz

[jmorris52]

dir flash-3:

671771 -rw- 5242880 Jul 11 2023 14:51:48 -04:00 ssd
671748 -rw- 6216 Mar 9 2023 18:37:28 -05:00 vlan.dat
671759 drwx 4096 May 2 2022 12:18:18 -04:00 .installer
671750 -rw- 0 May 2 2022 12:13:08 -04:00 dope_hist
671782 -rw- 16929 May 2 2022 12:13:08 -04:00 rdope_out.txt
671783 -rw- 89 May 2 2022 12:13:06 -04:00 rdope.log
671773 -rwx 2049 May 2 2022 12:11:05 -04:00 svl_ipc.tcl
671763 -rw- 134458 May 2 2022 12:11:05 -04:00 memleak.tcl
671749 -rw- 395 May 2 2022 12:10:52 -04:00 boothelper.log
49153 drwx 4096 May 2 2022 12:10:51 -04:00 dc_profile_dir
671760 -rw- 370 May 2 2022 12:10:41 -04:00 bootloader_evt_handle.log
16385 drwx 4096 Jun 22 2021 06:07:53 -04:00 .prst_sync
253953 drwx 4096 Jun 22 2021 06:05:34 -04:00 .dbpersist
221185 drwx 4096 Jun 22 2021 05:58:06 -04:00 .USWAP
245761 drwx 4096 Jun 22 2021 05:58:02 -04:00 Tbot
237569 drwx 4096 Jun 22 2021 05:58:01 -04:00 .CRFT
204832 drwx 4096 Jun 22 2021 05:57:53 -04:00 sys_report
204801 drwx 4096 Jun 22 2021 05:57:52 -04:00 tech_support
40961 drwx 4096 Jun 22 2021 05:57:52 -04:00 gs_script
139265 drwx 4096 Jun 22 2021 05:57:50 -04:00 ss_disc
32769 drwx 4096 Jun 22 2021 05:55:58 -04:00 .rollback_timer
671779 -rw- 7715 Jun 22 2021 05:55:39 -04:00 packages.conf
147469 -rw- 47364227 Jun 22 2021 05:52:19 -04:00 cat9k-rpboot.17.03.03.SPA.pkg
147468 -rw- 9220 Jun 22 2021 05:51:50 -04:00 cat9k-wlc.17.03.03.SPA.pkg
147467 -rw- 14427140 Jun 22 2021 05:51:50 -04:00 cat9k-webui.17.03.03.SPA.pkg
147466 -rw- 28738568 Jun 22 2021 05:51:50 -04:00 cat9k-srdriver.17.03.03.SPA.pkg
147465 -rw- 57529348 Jun 22 2021 05:51:49 -04:00 cat9k-sipspa.17.03.03.SPA.pkg
147464 -rw- 34792456 Jun 22 2021 05:51:48 -04:00 cat9k-sipbase.17.03.03.SPA.pkg
147463 -rw- 595178500 Jun 22 2021 05:51:47 -04:00 cat9k-rpbase.17.03.03.SPA.pkg
147462 -rw- 5124 Jun 22 2021 05:51:29 -04:00 cat9k-lni.17.03.03.SPA.pkg
147461 -rw- 2262024 Jun 22 2021 05:51:29 -04:00 cat9k-guestshell.17.03.03.SPA.pkg
147460 -rw- 104428552 Jun 22 2021 05:51:29 -04:00 cat9k-espbase.17.03.03.SPA.pkg
147459 -rw- 17392652 Jun 22 2021 05:51:26 -04:00 cat9k-cc_srdriver.17.03.03.SPA.pkg
671747 -rwx 2097152 Jun 22 2021 05:47:28 -04:00 nvram_config_bkup
671746 drwx 4096 Dec 6 2018 05:10:38 -05:00 onep
671767 -rw- 51216 Jul 20 2018 15:32:15 -04:00 pnp-tech-discovery-summary
671766 -rw- 35 Jul 20 2018 15:32:13 -04:00 pnp-tech-time
671761 drwx 4096 Jul 20 2018 15:31:28 -04:00 core

[Leo Laohoo]

---

@jmorris52 wrote:
There were many errors that all centered around this: %BTRACE_MANAGER-3-BTRT_ERR_MSG: Switch 3 R0/0: btman: Btrace Rotate Error: Move file failed, Delete file: chasync_R0-0.7318_8517422.20240109143017.bin.gz

---

That's not good. 

You have two options:  

1.  Raise a TAC Case.  

2.  Remove switch 3 from the stack, reboot and force switch 3 to boot into ROMMON and manually put the firmware back into the switch via the ROMMON  command "emergency-install usbflash0:firmwware.bin".  Once switch 3 boots up, connect it back to the stack.