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• Part No: 300-1596
• Part Description: AC Input Type Power Supply - A185

• Part No: 300-1460
• Part Description: AC Input Type Power Supply - A153

The original handle design of the 300-1460 (A153) and 300-1596 (A185) power supplies is susceptible to failure under normal handling conditions. The press pin design of the handle can cause excessive stress fracturing within the hinge housing of the plastic handle, resulting in sudden handle failure/breakage and possible injury.

• Visual inspection is the only 100% accurate way to determine if an A153/A185 PSU is prone to this failure mode.

• Using the provided photograph, inspect the pin (old) -or- rivet (new) that attaches the handle to the power supply, to determine what type of handle the PSU is equipped with.

• Tip: The press pin has a smaller diameter (approximately 50% smaller) than the swag pin which looks more like a rivet.

The only symptoms that may alert one to this failure mode would be (i) visible cracks/fractures in the hinge region of the handle and/or (ii) plastic pieces that may have already broken off of the handle, resting in the vicinity of the PSU.

Due to the low number of confirmed handle failures of the press pin handles, it is difficult, if not impossible to specifically identify the root cause of this failure mode beyond implicating the press pin design as a whole. It may be the case that a change in manufacturing process of (i) the press pin or (ii) the plastic handle housing molding caused this failure mode to occur.

Both FDK and Tyco transitioned out of the press pin handle design and into the swag pin (rivet) handle design in late 2003/early 2004. A GSAP will be released in tandem with this FIN to ensure both RVs are screening and reworking A153 and A185s with press pin handles returned from the field in a consistent manner.

If you have cause to remove a press pin handle-equipped PSU from a system, do so with great care:

1. Ensure you have reviewed all PSU servicing and removal instructions.
2. Use the eject levers to initiate the removal (unseating) of the PSU from the system.
3. Using two hands and proper lifting technique, grasp the actual chassis (NOT the handle) of the PSU and remove it from the system.
4. Package the entire press pin handle-equipped PSU in ESD wrapping, inside an appropriate shipping receptacle.
5. Ship the package to RV where rework to rivet handle can be performed.

• In late 2003, the handle manufacturer (Southco) modified the design of the power supply handle/pivot with a stronger, more robust design to prevent failures of this type. This corrective action has been implemented for both the 300-1460 and the 300-1596 power supplies. Note however, that from November 2003 through January 2004, a phase-in occurred, during which, both types of handles were used in PSU manufacture. All 300-1460s manufactured by FDK (from 0408W16425 an onward) and Tyco (unknown SN cut-in) since February 2004 have used the stronger swag pin (rivet) handle design.
  
  

• If the press pin handle breaks during removal from the system, include all broken pieces in package.

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