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BOEING PROPRIETARY - Copyright (C) - Unpublished Work - See title page for details.
A
737-300/400/500MAINTENANCE MANUAL
 TASK 21-23-25-302-142
 9. Inner Lining Repair - Polyurethane Foam Duct (Fig. 202)
____________________________________________
 A. General
 (1)  
This procedure gives instructions for the repair of the inner lining on a polyurethane foam air conditioning duct. Use this procedure if the inner lining has peeled away from the duct but the polyurethane foam is not damaged.

 (2)  
If the polyurethane foam is damaged, do the Duct Section Replacement - Polyurethane Foam procedure below.

 B. Consumable Materials
 (1)  
Fiberglass cloth - minimum 0.007 inch thick (MIL-C-9084 Type VIII) -commercially available

 (2)  
Plastic sheet - polyethylene or vinyl - commercially available

 (3)  
Resin for repair of fiberglass duct - R109A Hetron 92 Polyester

 (4)  
Solvent - Butyl carbitol (alternative to B01011, Series 91) -commercially available (AMM 20-30-91/201)

 (5)  
Solvent - B01011, Series 91 - commercially available (AMM 20-30-91/201)

 (6)  
Wiping cloth, lint-free - commercially available

 (7)  
Squeegee - commercially available

 C. References
 (1)  AMM 36-05-00/201, Pneumatic - General
 D. Prepare for the Repair
 S 862-143
 (1)  Release the pressure from the pneumatic system (AMM 36-05-00/201).
 NOTE: This will make sure that there is no airflow in the ducts
____
 when you do the repair.

 S 862-144
 (2)  
On the bleed air control module on the pilots' overhead panel, P5, put the pack control switches in the OFF position.

 S 012-145

 (3)  
Remove the applicable ceiling, sidewall, or floor panels to gain access to the damaged air conditioning duct.

 (4)  
If insulation is installed on the duct joint, remove the insulation.

 S 012-146
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BOEING PROPRIETARY - Copyright (C) - Unpublished Work - See title page for details.
A 737-300/400/500MAINTENANCE MANUAL
 S 342-147
 (5)  Do these steps to prepare the damaged area of the duct.
 (a)  
Cut away the inner lining that has peeled away from the foam. Do not damage the polyurethane foam.

 (b)  
Examine the polyurethane foam for damage. If the polyurethane foam is damaged, then do the Duct Section Replacement -Polyurethane Foam Duct procedure below.

 WARNING: DO NOT GET SOLVENTS IN YOUR MOUTH, OR YOUR EYES, OR ON
_______ YOUR SKIN. DO NOT BREATHE THE FUMES FROM THE SOLVENTS. SOLVENTS ARE HAZARDOUS MATERIALS. SOLVENTS MAY BE FLAMMABLE OR HARMFUL TO THE ENVIRONMENT. REFER TO PRODUCT MATERIAL SAFETY DATA SHEETS (MSDS) AND LOCAL REQUIREMENTS FOR PROPER HANDLING PROCEDURES.
 (c)  
Use the solvent and a wiping cloth to clean the damaged area.

 (d)  
Sand the duct joint area to remove any remaining adhesive and contamination.

 (e)  
Use the solvent and a wiping cloth to clean the damaged area.

 S 342-148
 (6)  Prepare the fiberglass cloth.
 (a)  
Cut two pieces of the fiberglass cloth 1/2 inch larger on all sides than the damaged area.

 (b)  
Round the corners of the fiberglass cloth pieces.

 S 342-149
 (7)  Prepare the resin.
 E. Repair the Inner Lining
 S 342-150
 (1)  Apply a thin, smooth layer of the applicable resin to the damaged area of the duct.
 NOTE: Make sure the area of the resin is larger than the size and
____
 shape of the fiberglass cloth.

 S 342-151
 (2)  
Put a piece of the fiberglass cloth on the resin so that it extends beyond the damaged area a minimum of 1/2 inch on all sides.

 (3)  
Soak the fiberglass cloth with the applicable resin.

 S 342-152
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