I faced with this issue after upgrading IOSs on my 3750 series switches stack. Stack consists of 4 catalyst 3750 series. After I have copied anf setting new IOS file as a boot file on has failed to boot and I got "Switch is not usable" error.
My solution.
- I have removed stack cables from the switch that has failed to boot
- I have set the new IOS with boot sytem .... command.
- I ensured that the switch booted up with new IOS
- I have powered off the switch.
- I have connected stack cables and power on the switch.
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