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August 02, 2010 737-28A1227 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 1 of 204
ALERT ALERT Commercial Airplane Group 737
ALERTALERT Service Bulletin Number: 737-28A1227 Date: August 02, 2010 ATA System: 2822 SUBJECT: FUEL - Distribution - Center and Auxiliary Tank Boost Pumps Fuel Control System Un- Commanded On Relay Installation and Related Wiring Changes
BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2010 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.
This document includes proprietary information owned by The Boeing Company and/or one or more third parties. Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.
Boeing, 707, 717, 727, 737, 747, 757, 767, 777, BBJ, BOEING BUSINESS JET, DC-8, DC-9, DC-10, MD-10, MD-11, MD-80, MD-90, the Boeing logo and the Boeing livery are among the trademarks owned by Boeing or its subsidiaries. No intellectual property license (express or implied) is granted in connection with this document or otherwise.
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Table of Contents August 02, 2010 737-28A1227 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 3 of 204 BOEING SERVICE BULLETIN 737-28A1227
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Table of Contents Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . 56
3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 56 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 56
2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . 66
3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 67
3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 FIGURE 1: J2802 BOX ASSEMBLY - RELAYS AND SWITCHES INSTALLATION . . . . . . . . . . 102 FIGURE 2: WIRE BUNDLE W1760 AND W1770 IN THE J2802 BOX ASSEMBLY - INSTALLATION . 104 FIGURE 3: WIRE BUNDLE W1760 THE J2802 BOX ASSEMBLY - CONNECTION . . . . . . . . . . 105 FIGURE 4: WIRE BUNDLE W1770 THE J2802 BOX ASSEMBLY - CONNECTION . . . . . . . . . . 108 FIGURE 5: J2802 BOX ASSEMBLY - RELAYS AND SWITCHES INSTALLATION . . . . . . . . . . 111 FIGURE 6: WIRE BUNDLE W1760 AND W1770 IN THE J2802 BOX ASSEMBLY - INSTALLATION . 113 FIGURE 7: WIRE BUNDLE W1760 THE J2802 BOX ASSEMBLY - CONNECTION . . . . . . . . . . 114 FIGURE 8: WIRE BUNDLE W1770 THE J2802 BOX ASSEMBLY - CONNECTION . . . . . . . . . . 118 FIGURE 9: WIRE BUNDLE W0368, W0386, W1764 AND W1774 FROM P6 DISCONNECT PANELS TO J2802 BOX ASSEMBLY - ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 FIGURE 10: WIRE BUNDLE W0368 AND W1764 FROM P6 DISCONNECT PANELS TO J2802 BOX ASSEMBLY - WIRING CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
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FIGURE 11: WIRE BUNDLE W0386 AND W1774 FROM P6 DISCONNECT PANELS TO J2802 BOX ASSEMBLY - WIRING CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 FIGURE 12: WIRE BUNDLE W0368, W0386, W1764 AND W1774 FROM P6 DISCONNECT PANELS TO J2802 BOX ASSEMBLY - ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . 131 FIGURE 13: WIRE BUNDLE W0368 AND W1764 FROM DISCONNECT PANEL A TO J2802 BOX ASSEMBLY - WIRING CHANGES . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 FIGURE 14: WIRE BUNDLE W0386 AND W1774 FROM P6 DISCONNECT PANEL TO J2802 BOX ASSEMBLY - WIRING CHANGES . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 FIGURE 15: WIRE BUNDLE W0368, W0386, W1764 AND W1774 FROM P6 DISCONNECT PANELS TO J2802 BOX ASSEMBLY - ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . 140 FIGURE 16: WIRE BUNDLE W0368 AND W1764 FROM P6 DISCONNECT PANEL TO J2802 BOX ASSEMBLY - WIRING CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 FIGURE 17: WIRE BUNDLE W0386 AND W1774 FROM P6 DISCONNECT PANEL TO J2802 BOX ASSEMBLY - WIRING CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 FIGURE 18: WIRE BUNDLE W0368, W0386, W1034, W1046, W1764 AND W1774 FROM P6 DISCONNECT PANELS TO J2802 BOX ASSEMBLY - ROUTING . . . . . . . . . . . 149 FIGURE 19: WIRE BUNDLE W0368, W1046 AND W1764 FROM P6 DISCONNECT PANEL TO J2802 BOX ASSEMBLY - WIRING CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . 154 FIGURE 20: WIRE BUNDLE W0386, W1034 AND W1774 FROM P6 DISCONNECT PANEL TO J2802 BOX ASSEMBLY - WIRING CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . 158 FIGURE 21: WIRE BUNDLE W0368, W0386, W1034, W1046, W1764 AND W1774 FROM P6 DISCONNECT PANELS TO J2802 BOX ASSEMBLY - ROUTING . . . . . . . . . . . 162 FIGURE 22: WIRE BUNDLE W0368, W1046 AND W1764 FROM P6 DISCONNECT PANEL TO J2802 BOX ASSEMBLY - WIRING CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . 170 FIGURE 23: WIRE BUNDLE W0386, W1034 AND W1774 FROM P6 DISCONNECT PANEL TO J2802 BOX ASSEMBLY - WIRING CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . 174 FIGURE 24: WIRE BUNDLE W0368, W0386, W1034, W1046, W1764 AND W1774 FROM P6 DISCONNECT PANELS TO J2802 BOX ASSEMBLY - ROUTING . . . . . . . . . . . 178 FIGURE 25: WIRE BUNDLE W0368, W1046 AND W1764 FROM P6 DISCONNECT PANEL TO J2802 BOX ASSEMBLY - WIRING CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . 183 FIGURE 26: WIRE BUNDLE W0386, W1034 AND W1774 FROM P6 DISCONNECT PANEL TO J2802 BOX ASSEMBLY - WIRING CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . 187 FIGURE 27: WIRE BUNDLE W0368, W0386, W1034, W1046, W1764 AND W1774 FROM P6 DISCONNECT PANELS TO J2802 BOX ASSEMBLY - ROUTING . . . . . . . . . . . 191 FIGURE 28: WIRE BUNDLE W0368, W1046 AND W1764 FROM P6 DISCONNECT PANEL TO J2802 BOX ASSEMBLY - WIRING CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . 196 FIGURE 29: WIRE BUNDLE W0386, W1034 AND W1774 FROM P6 DISCONNECT PANEL TO J2802 BOX ASSEMBLY - WIRING CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . 200 FIGURE 30: J2802 BOX ASSEMBLY - CLOSE ACCESS . . . . . . . . . . . . . . . . . . . . . . . 204
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ALERT ALERT Commercial Airplanes 737
ALERTALERT Service Bulletin Number: 737-28A1227 Summary Original Issue: August 02, 2010 ATA System: 2822 SUBJECT: FUEL - Distribution - Center and Auxiliary Tank Boost Pumps Fuel Control System Un- Commanded On Relay Installation and Related Wiring Changes
THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH 1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.
CONCURRENT REQUIREMENTS Refer to Paragraph 1.B., Concurrent Requirements.
BACKGROUND This service bulletin affects the 737-200/-200C/-300/-400/-500 airplanes with line numbers 292 thru 3132 that have center and auxiliary fuel tanks. Operators with 737-100/-200/-200C airplanes with line numbers 1 thru 291 that have center and auxiliary fuel tanks should contact Boeing to obtain engineering and accomplishment instructions for this modification. This service bulletin is sent to give ’un-commanded on’ protection for the fuel pump control system. Instructions are given to add one more relay, as a fail safe, for each fuel pump in the center and auxiliary fuel tanks. If this service bulletin is not done, the fuel pumps could run dry, which increases the pumps temperature and could cause an ignition source for fuel vapor in the fuel tank. Ignition of the flammable fuel vapors in the fuel tanks, could cause a fire or explosion which will put the airplane in an unsafe condition.
The Boeing system safety assessment necessary for Special Federal Aviation Regulation (SFAR) 88, showed that electrical faults within the fuel tank pump system can cause a fuel pump to operate when the fuel pump switch is in the ’OFF’ position. Boeing has developed a new system to prevent extended operation of the fuel tank boost pumps in this condition. This new system has a second relay to prevent the operation of a pump when its switch is in the ’OFF’ position. The auto shutdown relay currently installed for each pump gives the same solution as the new additional relay, but is known to have caused in-service problems because its contacts have ’welded’ closed and continued to let power be supplied. This condition is referred to as ’un-commanded on’ (UCO) pump operation. This new second relay added to the existing fuel control circuit and interfaced with the P5-2 fuel control module, prevents UCO operation of the fuel boost pumps. The system senses if there is a voltage remaining in the fuel boost pump circuit and activates the UCO relay to remove the power. In the flight deck, the pump low pressure light in the P5-2 fuel systems module, and master caution light come on when the fuel pump is at low pressure. No additional indication is provided for dry running pumps.
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Accomplishment of this service bulletin installs new UCO relays and toggle switches in the J2802 box assembly located in the Electronic Equipment Bay (E/E bay). This service bulletin also changes and adds new wire bundles that route from the J2802 box assembly to the P5 Forward Overhead Panel and the P6 Disconnect Panels. Installation of the new UCO relays for each pump will prevent "dry running" of the fuel pumps and reduce the risk of fuel tank fire or explosion.
New Airworthiness Limitations (AWL) 28-AWL-24 (Center Tank) and 28-AWL-25 (Auxiliary Fuel Tank) for 737- 200 airplanes and AWL 28-AWL-23 (Center Tank) and 28-AWL-24 (Auxiliary Fuel Tank) for 737-300/-400/-500 airplanes will be added to section 9 of the Maintenance Planning Data (MPD) to include a functional check of the center fuel pumps and (auxiliary tank pumps for applicable airplanes) primary and secondary control relays.
Boeing Fleet Team Digest (FTD) 737 FTD 28-04004 is related to this service bulletin.
ACTION (PRR 35443-RS) Remove equipment as necessary to get access the J2802 box assembly on the E2 and E3 support posts in the E/E bay, P6 Load Control Center in the flight compartment/control cabin, and P6 disconnect panels. Remove the cover from the J2802 box assembly and install wire bundles W1760 and W1770 and relays. Change wire bundles W036, W368, W386, W1034, W1046, W1764 and W1774, as applicable, between the P6 disconnect panels and J2802 box assembly. Check the continuity of all the new and changed wires and do a functional test to make sure the changed fuel control system operates correctly.
Operators with Group 1 airplanes should contact Boeing to obtain engineering and accomplishment instructions for this modification.
EFFECTIVITY 737-100/200/200C/300/400/500 Airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.
COMPLIANCE Boeing recommends that the change given in this service bulletin be done within 60 months after the original issue date of this service bulletin.
The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.
Operators with Group 1 airplanes should contact Boeing to obtain engineering and accomplishment instructions for this modification.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the configuration changes given in this service bulletin.
MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Boeing Supplied Kits.
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Refer to Paragraph 2.A., Material - Price and Availability.
CHANGE WIRE BUNDLES W1764/W1774
CHANGE WIRE BUNDLES W0368/W0386
INSTALL NEW TOGGLE
SWITCHES, RELAYS AND WIRE BUNDLES W1760 AND W1770 IN THE J2802 BOX ASSEMBLY
CHANGE WIRE BUNDLES W0386/W1034/W1046/W1764/W1774 1308568
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Original Issue: August 02, 2010 737-28A1227 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 9 of 204
ALERT ALERT Commercial Airplanes 737
ALERTALERT Service Bulletin Number: 737-28A1227 Original Issue: August 02, 2010 ATA System: 2822 SUBJECT: FUEL - Distribution - Center and Auxiliary Tank Boost Pumps Fuel Control System Un-Commanded On Relay Installation and Related Wiring Changes
THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH 1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.
1. PLANNING INFORMATION A. Effectivity
1. Airplanes Refer to Service Bulletin Index Document D6-19567 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
This service bulletin is for the airplanes shown below. Refer to PRR 35443-RS for data about this change
GROUP CONFIGURATION DESCRIPTION 1 - 737-100/200/200C airplanes, that have a center tank but do not have a auxiliary tank, with a unique wiring configuration.
2 - 737-200/200C airplanes, that have a center tank but do not have an auxiliary tank, with a unique wiring configuration.
3 - 737-300/400/500 airplanes, that have a center tank but do not have an auxiliary tank.
4 - 737-200/200C airplanes, that have a center tank but do not have an auxiliary tank, with a unique wiring configuration.
5 - 737-300 airplanes, that have a center tank and an auxiliary tank (or provisions for an auxiliary tank).
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Airplane models:
737-100 737-200 737-200C 737-300 737-400 737-500
IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER A.P.S. TRADING SERV S.R.L (PSV) 2 PL019 AAR A/C ENG. SALES & LEASING (AFD) 3P Q 1 1 6
ADC AIRLINES (ADN) 2 PK462 PN034 4 PJ118–PJ119 AEGEAN AIRLINES S.A. (CRM) 3 PS608 PW002 PW046 PW053 PW157 PW261 PW276 PW289 PW502 PW564 AERCAP B.V. (DEA) 3P W 2 4 9
AERGO CAPITAL LIMITED (CLJ) 2 PK528 PK802 PK901 PK903 PK915 PK922 PK974 3 PP935
AERO CONTRACTORS OF NIGERIA (NCC) 3 PQ194 PQ196 PT396 PT401 PT420–PT421 PT430–PT431 PT433 PV031 PV041
AERO CONTROLS (AEO) 1P G 3 1 2 P G 6 2 9
AEROFLOT - CARGO (CGB) 3 PP825–PP826 6 - 737-400 airplanes, that have a center tank and an auxiliary tank (or provisions for an auxiliary tank).
7 - 737-200 airplanes, that have a center tank and an auxiliary tank (or provisions for an auxiliary tank), with a unique wiring configuration.
8 - 737-200 airplanes, that have a center tank and an auxiliary tank (or provisions for an auxiliary tank), with a unique wiring configuration.
GROUP CONFIGURATION DESCRIPTION
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AEROFLOT-DON (DAU) 3 PT507–PT508 PT513–PT514 PT701–PT703
AEROFLOT-NORD (CJS) 3 PR044 PT022 PT050–PT051 PT054 PT056–PT057 PT147–PT148 PT182–PT184
AEROGAL/GALAPAGOS AIRLINES (ERG) 2 PK715 PL102 PL110 PL171 PL624–PL625 PN030 PN405 3 PP946 PQ226 PQ243 4P K 8 2 7
AEROLINEAS ARGENTINAS (ARG) 1 PH705–PH708 PH742 2 PG584–PG585 PK102–PK103 PK735–PK737 PK740 PK747 PK750–PK751 PK755 PK757 PK761 PK765 PN104 PN110 PN112–PN113 3 PT023 PT042 PT044–PT045 PT047 PT101–PT102 PT212 PT214 PT220 PT303–PT306 PT309 PT509–PT510 AEROLINEAS AUSTRAL CHILE S.A. (LUT) 2 PK745 PL405 PN103 7 PM141–PM142
AEROSERVICE (SRI) 2 PL742–PL743
AEROSUCRE (SUS) 1P Y 3 4 1 2P Y 2 0 1 P Y 4 5 1
AEROSUR (REO) 2 PK594 PK713–PK714 PK716
AEROSVIT (UKA) 2P K 5 6 4 3 PP924 PQ284 PQ286 PT138 PT614–PT615 PW039 PW265 PW268 PW591–PW592 PW595–PW596
AEROVISTA GULF EXPRESS (GXP) 2 PK861–PK863 PY621
AIR ALGERIE (ALG) 2 PK633–PK634 PL722 PL724 PY051 PY053
AIR AUSTRAL (AUX) 3 PS621 PT215
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AIR CANADA (ACN) 2 PK679–PK680
AIR CARRIER ACCESSORY SERVICE (RCY) 2P N 0 8 5
AIR CHINA (BEJ) 3 PQ345–PQ346 PQ361–PQ364 PQ373 PQ438 PQ447 PQ971 PQ975 5 PS957
AIR CHINA INNER MONGOLIAN (IML) 3 PQ365–PQ366 PQ370 PQ372 PQ988 PQ990 PS614–PS617
AIR CHINA SOUTHWEST BRANCH (XIN) 3 PP632–PP633 PQ401–PQ406 PQ408–PQ410 PS811
AIR CHINA TIANJIN BRANCH (TJA) 3 PQ367–PQ369 PQ371
AIR CORRIDOR (KRD) 2 PK468 PK749
AIR DO (HIA) 3P T 8 7 4
AIR DOMINICANA (DMA) 3 PP894
AIR GUINEE (GNE) 2 PN456 PY651
AIR HORIZONS (AHZ) 1 PY004
AIR INDIA (IND) 2 PK237–PK240 PM001–PM006 PY631
AIR INUIT (AIU) 2 PY243
AIR ITALY (RIT) 3 PP393 PP903
AIR MADAGASCAR (MAD) 3 PP852 PQ297 PQ299
AIR MALAWI (AML) 3 PS602 PT397
AIR MEDITERRANEE (AMV) 1 PG028–PG029 PY301