N422JS

Part: PSEU — FAILED (WARNING SYSTEM) · airframe 19,002 hrs · 16,586 cycles

DURING CLIMBOUT, THE CREW RECEIVED A UNSAFE CABIN DOOR INDICATION AND RETURNED TO DAY. MAINTENANCE INSPECTED AND FOUND CODE A06 ON THE PSEU. MAINTENANCE THEN REPLACED THE PSEU IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 32-00-00.

Part: SHIM — DEFECTIVE (LEFT) · airframe 18,966 hrs · 16,555 cycles

THE CREW RECEIVED A LEFT HAND OIL PRESSURE CAS MESSAGE IN THE AMBER RANGE AND CALLED MAINTENANCE CONTROL. FLIGHT 4056 WAS THEN INSTRUCTED TO RETURN TO CAK. MAINTENANCE INSPECTED AND REMOVED A OIL PRESSURE REGULATOR SHIM IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 79-00-00. OPERATIONAL CHECKS WERE PERFORMED AND THE AIRCRAFT WAS RELEASED FOR SERVICE.

Part: CONTROLLER — MALFUNCTIONED (CABIN PRESSURE) · airframe 18,163 hrs · 15,875 cycles

DURING TAKEOFF, THE CREW RECEIVED A CPCS AUTO FAIL CAS MESSAGE AND ABORTED TAKEOFF. THE CPCS AUTO MODE WAS DEFERRED, 21-9-1 CODE C, AND THE FLIGHT CONTINUED TO CAE ON TIME.

Part: POWER SUPPLY — DISCHARGED (CABIN) · airframe 17,893 hrs · 15,681 cycles

THE CREW REPORTED THAT THE AFT EMERGENCY POWER SUPPLY WOULD NOT TEST. MAINTENANCE INSPECTED AND REPLACED THE AFT EMERGENCY POWER SUPPLY IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 33-00-00. OPERATIONAL CHECKS WERE PERFORMED AND THE AIRCRAFT WAS RELEASED FOR SERVICE.

Part: LEAD — DAMAGED (RT PROPELLER) · airframe 17,586 hrs · 15,450 cycles

AFTER TAKEOFF, THE RIGHT HAND PROPELLER HEAT FAILED AND FLIGHT 4147 RETURNED TO BTV. MAINTENANCE INSPECTED AND REPAIR THE DE-ICE LEAD IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 30-00-00. OPERATIONAL CHECKS WERE PERFORMED AND THE AIRCRAFT WAS RELEASED FOR SERVICE.

Part: BATTERY — FAULTY (LEFT) · airframe 16,583 hrs · 14,618 cycles

WHILE IN CRUISE JUST WEST OF CVG, THE CREW RECEIVED A BATTERY OVERHEAT INDICATION ON THE RED WARNING PANEL. THE CREW FOLLOWED THE PROCEDURE IN THE QUICK REFERENCE HANDBOOK AND THE INDICATION WENT OUT. THE CREW CALLED MAINTENANCE CONTROL AND WERE ADVISED TO DIVERT TO DAY. MAINTENANCE INSPECTED AND REPLACED THE LEFT HAND MAIN BATTERY IN ACCORDANCE WITH 24-00-00. OPERATIONAL CHECKS WERE PERFORMED AND THE AIRCRAFT WAS RELEASED FOR SERVICE.

Part: WARNING SYSTEM — MALFUNCTIONED (COCKPIT) · airframe 16,082 hrs · 14,170 cycles

POWER WAS ADVANCED FOR TAKEOFF AND THE CREW RECEIVED A TAKEOFF CONFIGURATION WARNING ON THE RED WARNING PANEL. THE CREW ABORTED TAKEOFF AND WHEN TAXIING FROM THE RUNWAY THE LIGHT EXTINGUISHED AND FLIGHT 9407 RETURNED TO THE GATE FOR ANOTHER DEPARTURE INFORMATION. FLIGHT 9407 THEN DEPARTED WITH NO FURTHER INCIDENTS.

Part: FLIGHT DIR — SHORTED (COCKPIT) · airframe 15,794 hrs · 14,106 cycles

FLIGHT 4172 WAS BOARDED AND MAINTENANCE NEEDED TO REPLACE THE VERTICAL SPEED BUTTON ON THE FLIGHT DIRECTOR PANEL. A SHORT OCCURRED AND THE COCKPIT FILLED WITH SMOKE. THE PASSENGERS WERE DEPLANED AND FLIGHT 4172 WAS CANCELED. MAINTENANCE INSPECTED AND REPLACED THE FLIGHT DIRECTOR PANEL IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 22-00-00. OPERATIONAL TESTED WERE COMPLETED AND THE AIRCRAFT WAS RELEASED FOR SERVICE.

Part: BRUSH BLOCK — DIRTY (RT PROPELLER) · airframe 14,625 hrs · 12,888 cycles

DURING THE TAKEOFF ROLL THE RIGHT HAND PROPELLOR DEICE HEAT FAILED. THE FLIGHT CREW ABORTED THE TAKEOFF. MAINTENANCE INSPECTED AND CLEANED THE PROPELLOR SLIP RING AND BRUSHBLOCK IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 30-60-00. OPERATIONAL CHECKS WERE COMPLETED AND THE AIRCRAFT RETURNED TO SERVICE.

Part: ENGINE — DAMAGED (LEFT) · airframe 14,092 hrs · 12,458 cycles

DURING TAKE OFF, THE CREW RECEIVED LOW NP INDICATIONS AND A OVERTORQUE EXCEDENCE. THE CREW ABORTED TAKE OFF AND RETURNED TO THE GATE. THE AIRCRAFT WAS THEN FERRIED TO DAYTON. MAINTENANCE PERFORMED A RIGGING CHECK IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 76-11-00. MAINTENANCE ALSO PERFORMED A OVERTORQUE INSPECTION IN ACCORDANCE WITH TR 05-075, NO DEFECTS WERE FOUND. OPERATIONAL CHECKS WERE PERFORMED AND THE AIRCRAFT WAS RELEASED FOR SERVICE.

Part: ENGINE — DAMAGED (LEFT) · airframe 14,092 hrs · 12,458 cycles

DURING TAKE OFF, THE CREW RECEIVED LOW NP INDICATIONS AND A OVERTORQUE EXCEDENCE. THE CREW ABORTED TAKE OFF AND RETURNED TO THE GATE. THE AIRCRAFT WAS THEN FERRIED TO DAYTON. MAINTENANCE PERFORMED A RIGGING CHECK IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 76-11-00. MAINTENANCE ALSO PERFORMED A OVERTORQUE INSPECTION IN ACCORDANCE WITH TR 05-075, NO DEFECTS WERE FOUND. OPERATIONAL CHECKS WERE PERFORMED AND THE AIRCRAFT WAS RELEASED FOR SERVICE.

Part: SENSOR — FAILED (BATTERY TEMP) · airframe 13,209 hrs · 11,734 cycles

FLIGHT 4118 WAS CLIMBING THROUGH FL180 AND THE CREW RECEIVED A NR 1 BATTERY FAIL LIGHT ON THE RED WARNING PANEL. THE CREW CONSULTED THE QUICK REFERENCE HANDBOOK AND RETURNED BACK TO CAK. MAINTENANCE INSPECTED AND REPLACED THE BATTERY TEMPERATURE SENSOR IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 24-32-00. OPERATIONAL CHECKS WERE PERFORMED AND THE AIRCRAFT WAS RELEASED FOR SERVICE.

Part: LEVER — FAILED (MLG) · airframe 13,169 hrs · 11,701 cycles

DURING CLIMBOUT, THE LANDING GEAR WOULD NOT RETRACT. FLIGHT 4155 RETURNED TO THE FIELD. MAINTENANCE INSPECTED AND REPLACED THE GEAR CONTROL LEVER IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 32-31-01. OPERATIONAL CHECKS WERE PERFORMED AND THE AIRCRAFT WAS RELEASED FOR SERVICE.

Part: OUTFLOW VALVE — FAILED (FUSELAGE) · airframe 12,965 hrs · 11,527 cycles

DURING CLIMB OUT, THE CREW WAS UNABLE TO PRESSURIZE THE AIRCRAFT. THE CREW CALLED MAINTENANCE CONTROL WHO INSTRUCTED THEM TO RETURN TO DCA. MAINTENANCE INSPECTED AND REPLACED THE FORWARD OUTFLOW VALVE IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 21-00-00. OPERATIONAL CHECKS WERE PERFORMED AND THE AIRCRAFT WAS RELEASED FOR SERVICE.

Part: BLEED VALVE — FAILED (RT ENGINE)

DURING THE TAKEOFF, THE RIGHT HIGH PRESSURE BLEED VALVE FAILED IN THE CLOSED POSITION. THE CREW ABORTED TAKEOFF AND CLEARED THE RUNWAY. MAINTENANCE CONTROL DIFFERED THE RIGHT HIGH PRESSURE BLEED VALVE IN ACCORDANCE WITH THE MINIMUM EQUIPMENT LIST.. THE AIRCRAFT DEPARTED WITH NO FURTHER INCIDENT.

Part: LAMP — FAILED (RT MLG)

ON APPROACH TO PIT FLIGHT 4172 HAD A GEAR INTRANSIT INDICATION BUT NO GREEN LIGHT INDICATION ON THE RT MAIN LANDING GEAR. THE CREW DID A TOWER FLY-BY TO CONFIRM GEAR DOWN. THE AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE INSPECTED AND REPLACED THE RT MAIN LANDING GEAR DOWN AND LOCKED INDICATION BULBS IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 32-61-12. OPERATIONAL CHECKS WERE COMPLETED AND AIRCRAFT RELEASED FOR SERVICE.

Part: FLUX VALVE — DAMAGED (VERT STAB)

THE CREW REPORTED A POSSIBLE LIGHTNING STRIKE TO THE AIRCRAFT ON THE DESCENT INTO PIT. MAINTENANCE COMPLIED WITH A LIGHTNING STRIKE INSPECTION AND FOUND DAMAGE ON THE RIGHT ELEVATOR TRAILING EDGE. THE ELEVATOR DAMAGE WAS REPAIRED PER 51-77-10. ALSO, MAINTENANCE NOTED A TEN DEGREE HEADING SPLIT ON THE AIRCRAFT. THE AIRCRAFT WAS INSPECTED FOR A FERRY FLIGHT TO DAYTON FOR REPAIR. DAYTON MAINTENANCE INSPECTED AND REPLACED THE NR 1 FLUX VALVE, AND PERFORMED OPERATIONAL CHECKS IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 34-21-12. OPERATIONAL CHECKS WERE SATISFACTORY, AND THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: WINDSHIELD — CRACKED (LT COCKPIT)

THE LEFT SIDE COCKPIT WINDOW CRACKED, DURING THE TAXI PRIOR TO TAKEOFF. THE AIRCRAFT RETURNED TO THE GATE. OUTSTATION MAINTENANCE INSPECTED AND APPROVED THE AIRCRAFT FOR A FERRY FLIGHT TO PIT. THE FERRY FLIGHT TOOK PLACE WITHOUT ANY PROBLEMS. PIT MAINTENANCE INSPECTED AND REPLACED THE LEFT SIDE WINDSCREEN, IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 56-12-00. OPERATIONAL CHECKS WERE COMPLETED, AND THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: SKIN — BIRD STRIKE (FWD FUSELAGE)

DURING ROLLOUT, HEARD 2 THUMPS AND SAW BIRDS STRIKE THE AIRCRAFT BELOW THE CO-PILOTS WINDSHIELD. MAINTENANCE INSPECTED THE AIRCRAFT PROPELLERS, INLETS, FUSELAGE AND FLIGHT CONTROLS FOR DAMAGE, NO DAMAGED FOUND. CLEANED AIRCRAFT AND APPROVED FOR RETURN TO SERVICE.

Part: GOVERNOR — DEFECTIVE (LT PROP)

WHILE TAXIING TO RUNWAY, CREW PERFORMED PROPELLER OVERSPEED TEST. TEST FAILED. AIRCRAFT RETURNED TO GATE. MAINTENANCE INSPECTED THE AIRCRAFT AND FOUND THE PROPELLER OVERSPEED GOVERNOR DEFECTIVE. REPLACED GOVERNOR IN ACCORDANCE WITH THE DORNIER MAINTENANCE MANUAL 61-21-04. OPERATIONAL AND LEAK CHECKS GOOD. AIRCRAFT APPROVED FOR RETURN TO SERVICE.

Part: STRUCTURE — LIGHTNING STRIKE (AIRFRAME)

WHILE EN ROUTE, THE CREW SUSPECTED THAT THE AIRCRAFT WAS STRUCK BY LIGHTNING. THEY DID NOT RECEIVE ANY ABNORMAL INDICATIONS, AND CONTINUED THE FLIGHT INTO PIT. THE AIRCRAFT LANDED NORMALLY IN PIT. MAINTENANCE INSPECTED AND PERFORMED OPERATION CHECKS IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 05-51-02. NO DEFECTS WERE NOTED.

Part: TRANSCEIVER — FAILED (AVIONICS RACK)

DURING TAXI, THE NUMBER ONE COMM UNIT FAILED TO OPERATE. THE AIRCRAFT RETURNED TO THE GATE. MAINTENANCE INSPECTED AND REPLACED THE NUMBER ONE COMM UNIT, IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 23-10-00. OPERATIONAL CHECKS WERE COMPLETED, AND THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: BATTERY — DISCHARGED (CABIN)

THE EMERGENCY LIGHTS AT ROWS FIVE AND SIX FAILED TO OPERATE, DURING PREFLIGHT INSPECTION. MAINTENANCE INSPECTED AND REPLACED THE EMERGENCY BATTERY AT POSITION 5LK, IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 33-51-01. OPERATION CHECKS WERE COMPLIED.

Part: BATTERY — DISCHARGED (CABIN)

PRIOR TO TAXI, ON ENGINE STARTUP AND SUBSEQUENT TEST, THE EMERGENCY FLOOR LIGHTS AT ROW 4, 5 AND 6, WERE FOUND TO BE INOPERATIVE. MAINTENANCE INSPECTED AND REPLACED THE 5 LK EMERGENCY BATTERY PACK IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 33-51-01. OPERATIONAL CHECKS WERE COMPLETED.

Part: STATIC WICK — FAILED (RT WINGTIP)

WHILE EN ROUTE, THE ACFT WAS STRUCK BY LIGHTNING. CONTINUED ON TO RDG. MX INSPECTED AND APPROVED THE ACFT FOR A FERRY FLIGHT TO PIT. THE FERRY FLIGHT WAS COMPLETED WITHOUT INCIDENT. PIT MX COMPLIED WITH A LIGHTNING STRIKE INSPECTION IAW DORNIER MM 05-51-02. MX INSPECTED AND REPAIRED BURNT PAINT ON THE RIGHT HAND WING TIP AND REPLACED THE RIGHT HAND OUTBOARD WING TIP STATIC WICK. ALSO, DAMAGE WAS NOTED ON THE LEFT HAND MAIN LANDING GEAR FAIRING SPONSON. A REPAIR WAS CARRIED OUT ON THE AREA IAW DORNIER SRM 51-77-31.

Part: PWR SUPPLY — INOPERATIVE (CABIN)

DURING PREFLIGHT INSPECTION, IT WAS DISCOVERED THAT THE EMERGENCY FLOOR LIGHTS LOCATED AT THE MIDDLE SECTION, WERE INOPERATIVE. MAINTENANCE INSPECTED AND REPLACED THE EMERGENCY LIGHT POWER SUPPLY AT 5 LK, IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 33-51-01. FUNCTION CHECKS WERE COMPLIED WITH AND THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: DAU — FAILED (NR 1)

ON CLIMB, DATA ACQUISITION UNIT CHANNEL 1B FAILED. AIRCRAFT LANDED IN PIT WITHOUT INCIDENT. MAINTENANCE FOUND DATA ACQUISITION UNIT NR 1 TO BE DEFECTIVE. MAINTENANCE REMOVED AND REPLACED THE UNIT, IN ACCORDANCE WITH MAINTENANCE MANUAL JOB CARD 31-42- 00, OPERATION CHECKED GOOD.

Part: STRUCTURE — BIRDSTRIKE (AIRFRAME)

JUST AFTER TAKEOFF, FLEW THROUGH A FLOCK OF BIRDS, HEARD 3 STRIKES. RETURNED TO FIELD WITHOUT FURTHER INCIDENT. MAINTENANCE PERFORMED A BIRD STRIKE AND OVERWEIGHT LANDING INSPECTION. NO DEFECTS WERE NOTED AND THE AIRCRAFT WAS APPROVED FOR RETURN TO SERVICE.

Part: T/O WARNING — ACTIVATED (COCKPIT)

CREW RECEIVED A TAKEOFF, CONFIGURATION WARNING ASSOCIATED WITH AN AMBER CAS MESSAGE DURING THE TAKEOFF ROLL. CREW ABORTED THE TAKEOFF AND RETURNED TO THE TAXIWAY. CREW THEN CLEARED ALL CAS MESSAGES, CONDUCTED A POWER ASSURANCE RUN, EVERYTHING CHECKED GOOD. AIRCRAFT CONTINUED ON WITH THE FLIGHT. SUSPECT ELEVATOR TRIM MAY HAVE BEEN OUT OF CONFIGURATION FOR TAKEOFF, THIS CAUSING THE WARNING.

Part: UPLOCK ROLLER — LACK OF LUBE (MLG WW)

FLT 4014 - AFTER TAKEOFF, LT MLG INTRANSIT LIGHT REMAINED ILLUMINATED AFTER THE GEAR WAS SELECTED 'UP'. AIRCRAFT RETURNED TO FIELD, LANDED WITHOUT FURTHER INCIDENT. PIT MX CLEANED AND LUBRICATED THE MLG LOCK ROLLERS IAW MM 32-00-00 AND STD MX PRACTICES. GROUND CHECKED 'GOOD'. AIRCRAFT RETURNED TO SERVICE. (X)

Part: ENGINE COWL — BIRD STRIKE (LT NACELLE)

PIT - FLT 4041 - DURING APPROACH, THE FLIGHT CREW HEARD SEVERAL AUDIBLE THUMPS FROM THE LEFT SIDE OF THE AIRCRAFT. THE AIRCRAFT LANDED WITH NO FURTHER INCIDENT. PIT MX CONDUCTED A BIRD STRIKE INSPECTION IAW MM 05-57-07. ALSO REMOVED AND REPLACED THE LT ENGINE COWL IAW MM 71-01-00 WHICH WAS DAMAGED AS A RESULT OF THE BIRD STRIKE. AIRCRAFT WAS THEN RETURNED TO SERVICE.

Part: CONNECTORS — DIRTY (RT ENGINE)

FLT 4008 - SHORTLY AFTER TAKEOFF AT APPROXIMATELY 12,000 FEET MGL, RIGHT ENGINE BEGAN TO SURGE (ALL PARAMETERS). CREW ELECTED TO SHUT DOWN RIGHT ENGINE AND RETURN TO FIELD. AN EMERGENCY WAS DECLARED. THE AIRCRAFT LANDED WITHOUT FURTHER INCIDENT. OUT-STATION MAINTENANCE REMOVED, CLEANED, AND RE-INSTALLED ENGINE ELECTRICAL HARNESS CANNON CONNECTORS FROM THE FOLLOWING ENGINE SENSORS, ECU, NP, NH AND TQ IAW MM 71-10-00. ENGINE GROUND RUNS CHECKED GOOD. AIRCRAFT RETURNED TO SERVICE.