N438JS

Part: DOOR — OPEN (NLG) · airframe 21,471 hrs · 18,751 cycles

DURING FLIGHT, THE CREW REPORTED THE NOSE LANDING GEAR DOOR WAS OPEN AND RETURNED TO LEX. MAINTENANCE INSPECTED AND LATCHED THE NOSE LANDING GEAR DOOR IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 32-00-00. OPERATIONAL CHECKS WERE PERFORMED AND THE AIRCRAFT WAS RELEASED FOR SERVICE.

Part: LEAD — FAILED (RT PROP DEICE) · airframe 21,377 hrs · 18,666 cycles

DURING FLIGHT, THE CREW RECEIVED A RIGHT HAND PROP DE-ICE FAIL INDICATION AND RETURNED TO PIT. MAINTENANCE INSPECTED AND ADJUSTED THE BRUSHBLOCK THEN REPLACED THE PROP LEAD IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 30-00-00. OPERATIONAL CHECKS WERE PERFORMED AND THE AIRCRAFT WAS RELEASED FOR SERVICE.

Part: COMPUTER — FAILED (LEFT) · airframe 20,977 hrs · 18,295 cycles

DURING TAKEOFF, THE CREW RECEIVED A TAKEOFF CONFIGURATION AND A LEFT HAND PROP OVERSPEED CAS INDICATION AND ABORTED TAKEOFF. MAINTENANCE INSPECTED AND CYCLED THE INTEGRATED AVIONICS COMPUTER CIRCUIT BREAKERS IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 61-00-00. OPERATIONAL CHECKS WERE PERFORMED AND THE AIRCRAFT WAS RELEASED FOR SERVICE.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 20,106 hrs · 17,532 cycles

THE CREW REPORTED THAT SOME OF THE EMERGENCY FLOOR LIGHTING WAS NOT ILLUMINATING. THE AIRCRAFT WAS THEN FERRIED TO PIT. MAINTENANCE INSPECTED AND REPLACED THE FLOOR EMERGENCY LIGHTING STRIPS IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 33-00-00. OPERATIONAL CHECKS WERE PERFORMED AND THE AIRCRAFT WAS RELEASED FOR SERVICE.

Part: WARNING LIGHT — ILLUMINATED (EMER BRAKE) · airframe 19,947 hrs · 17,410 cycles

EN ROUTE, THE CREW HAD A EMERGENCY PARKING BRAKE ACCUMULATOR CAS MESSAGE THAT WOULD NOT EXTINGUISH. THE CREW FOLLOWED THE QUICK REFERENCE HANDBOOK AND DIVERTED TO ELM. AT 50 FEET ABOVE GROUND ON LANDING THE MESSAGE EXTINGUISHED. OUTSTATION MAINTENANCE INSPECTED AND SERVICED THE EMERGENCY PARKING BRAKE ACCUMULATOR IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 12-12-00. THE SYSTEM WAS CHARGED AND OPERATIONAL CHECKS WERE PERFORMED. THE AIRCRAFT WAS THEN RELEASED FOR SERVICE.

Part: POWER SUPPLY — FAILED (FORWARD) · airframe 18,842 hrs · 16,493 cycles

THE CREW REPORTED THAT THE EMERGENCY POWER SUPPLY FAILS TO TEST. MAINTENANCE INSPECTED AND REPLACED THE FORWARD EMERGENCY POWER SUPPLY IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 31-00-00. OPERATIONAL CHECKS WERE PERFORMED AND THE AIRCRAFT WAS RELEASED FOR SERVICE.

Part: CLAMP — LOOSE (A/C BAY) · airframe 18,344 hrs · 16,071 cycles

THE FLIGHT ATTENDANT REPORTED SMELLING SMOKE IN THE CABIN. THE CREW PERFORMED THE SMOKE REMOVAL CHECK LIST AND THE SMOKE CLEARED. AS A PRECAUTION THE CREW DECLARED AN EMERGENCY AND REQUESTED PRIORITY HANDLING. AFTER LANDING THE FLIGHT ATTENDANT AGAIN REPORTING A SMOKE SMELL IN THE CABIN. THE CREW THEN EVACUATED THE PASSENGERS. MAINTENANCE INSPECTED, REPOSITIONED, AND RESECURED THE LEFT HAND PACK CLAMPS AT THE HEAT EXCHANGER. OPERATIONAL CHECKS WERE PERFORMED AND THE AIRCRAFT WAS RELEASED FOR SERVICE.

Part: CONTROL UNIT — FAILED (NLG STEERING) · airframe 18,241 hrs · 15,984 cycles

ON SHORT FINAL, THE CREW RECEIVED A NOSE WHEEL STEERING FAIL CAS MESSAGE AND DECIDED TO DO A MISSED APPROACH. THE CREW RESET THE SYSTEM IN ACCORDANCE WITH THE QUICK REFERENCE HANDBOOK AND LANDED WITHOUT INCIDENT. MAINTENANCE INSPECTED AND REPLACED THE NOSE WHEEL STEERING CONTROL UNIT IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 32-00-00. OPERATIONAL CHECKS WERE PERFORMED AND THE AIRCRAFT WAS RELEASED FOR SERVICE.

Part: CONTROL UNIT — FAILED · airframe 18,241 hrs · 15,984 cycles

ON SHORT FINAL, THE CREW RECEIVED A NOSE WHEEL STEERING FAIL CAS MESSAGE AND DECIDED TO DO A MISSED APPROACH. THE CREW RESET THE SYSTEM IN ACCORDANCE WITH THE QUICK REFERENCE HANDBOOK AND LANDED WITHOUT INCIDENT. MAINTENANCE INSPECTED AND REPLACED THE NOSE WHEEL STEERING CONTROL UNIT IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 32-00-00. OPERATIONAL CHECKS WERE PERFORMED AND THE AIRCRAFT WAS RELEASED FOR SERVICE.

Part: CONTROL UNIT — MALFUNCTIONED (NLG STEERING) · airframe 18,213 hrs · 15,961 cycles

DURING LANDING, FLIGHT 4180 EXPERIENCED A NOSE WHEEL STEERING FAIL CAS MESSAGE AND EXECUTED A MISSED APPROACH. THE CREW FOLLOWED THE QUICK REFERENCE HANDBOOK AND TURNED OFF THE NOSE WHEEL STEERING AND ANTI-SKID. FLIGHT 4180 THEN LANDED WITH NO FURTHER INCIDENTS. MAINTENANCE INSPECTED AND RERACKED THE NOSE WHEEL STEERING CONTROL UNIT THEN PERFORMED TAXI CHECKS IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 32-00-00. THE PROBLEM COULD NOT BE DUPLICATED DURING THESE OPERATIONAL CHECKS AND THE AIRCRAFT WAS RELEASED FOR SERVICE.

Part: TIRE — VIBRATION (NLG) · airframe 18,025 hrs · 15,818 cycles

AFTER TAKEOFF, THE CREW REPORTED A SEVERE NOSE GEAR VIBRATION AND RETURNED TO PIT. MAINTENANCE INSPECTED AND REPLACED THE NOSE WHEEL TIRE ASSEMBLIES IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 32-00-00. OPERATIONAL CHECKS WERE PERFORMED AND THE AIRCRAFT WAS RELEASED FOR SERVICE.

Part: BATTERY — DISCHARGED (CABIN) · airframe 18,025 hrs · 15,818 cycles

THE CREW REPORTED THAT THE EMERGENCY FLOOR LIGHTING A ROWS 1 TO 6 WERE NOT ILLUMINATING. MAINTENANCE INSPECTED AND REPLACED THE EMERGENCY BATTERIES AT THE 4LK AND 5LK POSITIONS IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 33-00-00. OPERATIONAL CHECKS WERE PERFORMED AND THE AIRCRAFT WAS RELEASED FOR SERVICE.

Part: BATTERY — DISCHARGED (CABIN) · airframe 17,982 hrs · 15,786 cycles

THE CREW REPORTED THAT THE ROW 4 TO 6 OF EMERGENCY FLOOR LIGHTING WAS NOT ILLUMINATING. MAINTENANCE INSPECTED AND REPLACED THE 5LK EMERGENCY BATTERY IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 33-00-00. OPERATIONAL CHECKS WERE PERFORMED AND THE AIRCRAFT WAS RELEASED FOR SERVICE.

Part: BATTERY — DISCHARGED (CABIN) · airframe 17,895 hrs · 15,714 cycles

THE CREW REPORTED THAT THE FIRST SECTION OF EMERGENCY FLOOR LIGHTING WAS NOT ILLUMINATING. MAINTENANCE INSPECTED AND REPLACED THE 4LK EMERGENCY BATTERY IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 33-00-00. OPERATIONAL CHECKS WERE PERFORMED AND THE AIRCRAFT WAS RELEASED FOR SERVICE.

Part: WARNING SYSTEM — MALFUNCTIONED (COCKPIT) · airframe 17,761 hrs · 15,611 cycles

DURING TAKEOFF, THE CREW RECEIVED A NOSE WHEEL STEERING FAIL MESSAGE AND ABORTED TAKEOFF. THE CREW CALLED MAINTENANCE CONTROL AND WERE ABLE TO RESET THE SYSTEM. FLIGHT 4147 WAS CLEARED FOR ANOTHER TAKEOFF ATTEMPT AND DEPARTED WITH NO FURTHER INCIDENTS.

Part: WARNING SYSTEM — MALFUNCTIONED (COCKPIT) · airframe 17,474 hrs · 15,395 cycles

DURING TAKEOFF, THE CREW RECEIVED A NOSE WHEEL STEERING FAIL CAS MESSAGE AND ABORTED TAKEOFF. WHEN THE POWER WAS REDUCED THE MESSAGE CLEARED. THE CREW CALLED MAINTENANCE CONTROL WHO HAD THE CREW RUN UP THE AIRCRAFT AT TAKEOFF POWER IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 71-01-00 AND NO FURTHER PROBLEMS OR DISCREPANCIES WERE NOTED. FLIGHT 8640 WAS THEN RELEASED FOR ANOTHER TAKEOFF ATTEMPT AND DEPARTED WITH NO FURTHER INCIDENTS.

Part: CONTROL UNIT — FAILED · airframe 17,291 hrs · 15,246 cycles

DURING TAKE OFF, THE CREW RECEIVED A FLIGHT GUIDANCE COMPUTER FAIL CAS MESSAGE AND ABORTED TAKE OFF. THE AIRCRAFT RETURNED TO THE GATE AND MAINTENANCE CONTROL DEFERRED THE FLIGHT GUIDANCE COMPUTER AND THE FLIGHT THEN CONTINUED ON TO RDU.

Part: PANEL — FAULTY (RT WING) · airframe 17,264 hrs · 15,223 cycles

DURING TAKEOFF, THE CREW RECEIVED A FUEL QUANTITY FAIL CAS MESSAGE AND ABORTED TAKEOFF. MAINTENANCE INSPECTED AND REPLACED THE REFUELING PANEL IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 28-00-00. OPERATIONAL CHECKS WERE PERFORMED AND THE AIRCRAFT WAS RELEASED FOR SERVICE.

Part: CONNECTOR — DIRTY (FUEL SYSTEM) · airframe 17,258 hrs · 15,217 cycles

DURING TAKEOFF, THE CREW RECEIVED A RIGHT HAND FUEL QUANTITY FAIL CAS MESSAGE AND ABORTED TAKEOFF. MAINTENANCE INSPECTED AND CLEANED THE COAX CONNECTORS THEN PERFORMED A HIGH SPEED TAXI WITH THE CREW, IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 28-00-00, NO DEFECTS WERE NOTED AT THIS TIME. AFTER PERFORMING THESE OPERATIONAL CHECKS THE AIRCRAFT WAS RELEASED FOR SERVICE.

Part: BATTERY — DISCHARGED (CABIN) · airframe 17,139 hrs · 15,125 cycles

THE AIRCRAFT RETURNED TO THE GATE AFTER DISCOVERING THAT THE EMERGENCY LIGHTING AT ROWS 2, 3, AND 4 WERE NOT ILLUMINATING. MAINTENANCE INSPECTED AND REPLACED THE EMERGENCY BATTERY IN THE 4LK POSITION IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 33-00-00. OPERATIONAL CHECKS WERE PERFORMED AND THE AIRCRAFT WAS RELEASED FOR SERVICE.

Part: FMC — MALFUNCTIONED (COCKPIT) · airframe 16,969 hrs · 14,984 cycles

DURING TAKEOFF, THE HEADING MODE OF THE FLIGHT MANAGEMENT SYSTEM FAILED AND THE CREW ABORTED TAKEOFF. THE CREW CALLED MAINTENANCE CONTROL AND RESET THE SYSTEM. FLIGHT 4032 ATTEMPTED A SECOND TAKEOFF AND DEPARTED WITHOUT ANY OTHER INCIDENTS.

Part: COMPUTER — MALFUNCTIONED (COCKPIT) · airframe 16,798 hrs · 14,856 cycles

DURING TAKEOFF, THE CREW RECEIVED A FLIGHT GUIDANCE COMPUTER FAIL CAS MESSAGE AND ABORTED TAKEOFF. AFTER EXITING THE RUNWAY THE MESSAGE CLEARED AND FLIGHT 4099 WAS CLEARED FOR ANOTHER TAKEOFF ATTEMPT. FLIGHT 4099 THEN DEPARTED WITH NO FURTHER INCIDENTS.

Part: VALVE — FAILED (PARK BRAKE) · airframe 16,617 hrs · 14,701 cycles

DURING CLIMBOUT, THE CREW RECEIVED A EMERGENCY PARKING BRAKE ACCUMULATOR BRAKE CAS MESSAGE. THE CREW FOLLOWED THE QUICK REFERENCE HANDBOOK AND LANDED AT THE NEAREST SUITABLE AIRPORT. OUTSTATION MAINTENANCE INSPECTED AND SERVICED THE MAIN SYSTEM PRECHARGE IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 12-00-00. THE AIRCRAFT WAS THEN FERRIED TO CAK WHERE MAINTENANCE INSPECTED AND REPLACED THE EMERGENCY PARK BRAKE VALVE IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 32-00-00. OPERATIONAL CHECKS WERE COMPLETE AND THE AIRCRAFT WAS RELEASED FOR SERVICE.

Part: WARNING SYSTEM — MALFUNCTIONED (COCKPIT) · airframe 16,588 hrs · 14,673 cycles

THE CREW RECEIVED A FLIGHT GUIDANCE COMPUTER FAIL CAS MESSAGE AND ABORTED TAKEOFF. AS THE AIRCRAFT CLEARED THE RUNWAY THE MESSAGE CLEARED. FLIGHT 4030 WAS THEN CLEARED FOR ANOTHER TAKEOFF ATTEMPT. FLIGHT 4030 THEN DEPARTED WITH NO FURTHER INCIDENTS.

Part: CHECK VALVE — FAILED · airframe 16,554 hrs · 14,648 cycles

TWENTY MINUTES INTO THE FLIGHT, THE CREW RECEIVED A CAS MESSAGE STATING THE EMERGENCY PARKING BRAKE ACCUMULATOR PRESSURE WAS LOW. THE CREW FOLLOWED THE QUICK REFERENCE HANDBOOK AND TURNED ON THE STAND BY PUMP TO MANUAL AND SET THE PARKING BRAKE FOR 10 SECONDS. THE LIGHT WENT OUT. AFTER ANOTHER TWENTY MINUTES THE CREW RECEIVED THE SAME INDICATION AND FLIGHT 4063 RETURNED TO PIT. MAINTENANCE INSPECTED AND REPLACED THE HYDRUALIC CHECK VALVE IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 29-00-00. OPERATIONAL CHECKS WERE PERFORMED AND THE AIRCRAFT WAS RELEASED FOR SERVICE.

Part: COMPUTER — MALFUNCTIONED (COCKPIT) · airframe 16,524 hrs · 14,622 cycles

DURING THE TAKEOFF ROLL, THE CREW RECEIVED A FLIGHT GUIDANCE COMPUTER FAIL INDICATION AND ABORTED TAKEOFF. THE CREW WAS TAXIING TO THE GATE AND THE MESSAGE CLEARED BY ITSELF. MAINTENANCE CONTROL MEL'D THE FLIGHT GUIDANCE COMPUTER AND THE FLIGHT DEPARTED WITH NO FURTHER INCIDENTS.

Part: WARNING SYSTEM — MALFUNCTIONED (COCKPIT) · airframe 16,462 hrs · 14,573 cycles

DURING TAKEOFF, THE CREW RECEIVED A FLIGHT GUIDANCE CONTROL UNIT FAIL MESSAGE AND ABORTED TAKEOFF. THE MESSAGE CLEARED AS FLIGHT 4168 TAXIED ONTO THE TAXI WAY. THE CREW CALLED MAINTENANCE WHO SUGGESTED ANOTHER TAKEOFF ATTEMPT.

Part: COMPUTER — FAULTY (E/E BAY) · airframe 16,462 hrs · 14,573 cycles

DURING TAKEOFF, THE CREW RECEIVED A FLIGHT GUIDANCE CONTROL UNIT FAIL MESSAGE AND ABORTED TAKEOFF. MAINTENANCE INSPECTED AND REPLACED THE INTEGRATED AVIONICS COMPUTER IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 31-00-00. OPERATIONAL CHECKS WERE PERFORMED AND THE AIRCRAFT WAS RELEASED FOR SERVICE.

Part: SENSOR — FAILED (ELECTRICAL SYS) · airframe 16,330 hrs · 14,463 cycles

DURING TAKEOFF, THE CREW RECEIVED A RIGHT HAND GENERATOR FAIL MESSAGE AND ABORTED TAKEOFF. THE AIRCRAFT WAS THEN FERRIED TO DAY WHERE MAINTENANCE INSPECTED AND REPLACED THE HALL EFFECT SENSOR IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 24-00-00. OPERATIONAL CHECKS WERE PERFORMED AND THE AIRCRAFT WAS RELEASED FOR SERVICE.

Part: ENGINE — FAILED (LEFT) · airframe 16,285 hrs · 14,405 cycles

DURING FLIGHT, THE LEFT HAND ENGINE SHUT DOWN. THE CREW DECLARED AN EMERGENCY AND DIVERTED TO MDT. THE LEFT HAND PROPELLER DID NOT FEATHER. OUT STATION MAINTENANCE INSPECTED THE AIRCRAFT AND TROUBLESHOT THE FUEL PUMP AND HYDRO MECHANICAL UNIT, THIS DID NOT CORRECT THE PROBLEM. DAY MAINTENANCE SENT MECHANICS AND AN ENGINE TO MDT. DAY MAINTENANCE INSPECTED AND REPLACED THE LEFT HAND ENGINE IAW DORNIER MM 72-00-00. OPERATIONAL CHECKS WERE PERFORMED AND CHECKED GOOD. MAINTENANCE THEN INSPECTED AND REPLACED FUSE 11KD IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 61-00-00. OPERATIONAL CHECKS WERE PERFORMED AND THE AIRCRAFT WAS RELEASED FOR SERVICE.

Part: WARNING SYSTEM — MALFUNCTIONED (COCKPIT) · airframe 16,152 hrs · 14,294 cycles

DURING THE TAKEOFF ROLL, THE FLIGHT CREW RECEIVED MULTIPLE WARNING MESSAGES FOR THE MAIN CABIN DOOR, THE MICRO AIR DATA COMPUTERS AND THE FLIGHT GUIDANCE COMPUTER. THE FLIGHT CREW ABORTED THE TAKEOFF AND RETURNED TO THE GATE. THE AIRCRAFT WAS INSPECTED AND FERRIED TO CAK WHERE MAINTENANCE PERFORMED OPERATIONAL CHECKS IN ACCORDANCE WITH THE DORNIER MAINTENANCE MANUALS AND NO ABNORMALITIES WERE FOUND. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: CONTROL PANEL — FAILED (COCKPIT) · airframe 16,034 hrs · 14,192 cycles

AS FLIGHT 4078 WAS READY FOR TAKEOFF THE CREW RECEIVED A RIGHT HAND GENERATOR FAIL CAS MESSAGE AND ABORTED TAKEOFF. FLIGHT 4078 RETURNED TO THE GATE WHERE MAINTENANCE INSPECTED AND SWAPPED 1VE PANELS WITH N427JS IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 24-00-00. OPERATIONAL CHECKS WERE PERFORMED AND THE AIRCRAFT WAS RELEASED FOR SERVICE.

Part: CONNECTOR — DIRTY (GENERATOR) · airframe 16,007 hrs · 14,166 cycles

DURING TAKEOFF, THE CREW RECEIVED A ELECTRONIC CONTROL UNIT FAIL MESSAGE AND ABORTED TAKEOFF. THE CAPTAIN REPORTED AN INTERMITTENT FAILURE DURING TAXI. MAINTENANCE CONTROL HAD OUTSTATION MAINTENANCE CLEAN THE CANNON PLUGS ON THE DIRECT CURRENT GENERATOR IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 24-00-00. OPERATIONAL CHECKS WERE PERFORMED AND THE AIRCRAFT WAS RELEASED FOR SERVICE.

Part: WARNING SYSTEM — MALFUNCTIONED (COCKPIT) · airframe 15,654 hrs · 13,856 cycles

AT 50 KNOTS THE CREW RECEIVED A BLEED VALVE SHUT OFF AND APU SHUT OFF VALVE CAS MESSAGE AND ABORTED TAKEOFF. AS THE CREW CLEARED THE RUNWAY THE MESSAGE CLEARED AND FLIGHT 4177 WAS CLEARED FOR ANOTHER TAKEOFF ATTEMPT. FLIGHT 4177 THEN DEPARTED WITH NO FURTHER INCIDENTS.

Part: SIGNAL COND UNIT — FAILED (LT ENGINE) · airframe 15,566 hrs · 13,777 cycles

DURING DESCENT, THE LEFT HAND ENGINE TORQUE WAS 35 PERCENT THEN JUMPED TO AN INDICATED 85 PERCENT. FLIGHT 4012 CONTINUED AND LANDED WITHOUT FURTHER INCIDENT. MAINTENANCE INSPECTED AND REPLACED THE TORQUE SIGNAL CONDITIONER IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 77-00-00. OPERATIONAL CHECKS WERE PERFORMED AND THE AIRCRAFT WAS RELEASED FOR SERVICE.

Part: DISPLAY — MALFUNCTIONED (COCKPIT) · airframe 15,522 hrs · 13,738 cycles

DURING THE TAKEOFF ROLL, FLIGHT 4021 LOST REFERENCE DATA AND ABORTED TAKEOFF. WHILE DEPARTING THE RUNWAY AND ENTERING THE TAXI WAY THE REFERENCE DATA RE-APPEARED. FLIGHT 4021 WAS APPROVED FOR ANOTHER TAKEOFF ATTEMPT AND DEPARTED WITHOUT ANY FURTHER INCIDENTS.

Part: VALVE — FAILED (LH) · airframe 15,484 hrs · 13,704 cycles

DURING CLIMB THE LEFT BLEED VALVE NEVER OPENED. AFTER TROUBLESHOOTING WITH MAINTENANCE CONTROL THE CREW WAS ASKED TO RETURN TO PIT. UPON ARRIVAL AT PIT, MAINTENANCE INSPECTED AND REPLACED THE FLOW CONTROL SHUT OFF VALVE IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 36-00-00. OPERATIONAL CHECKS WERE PERFORMED AND THE AIRCRAFT WAS RELEASEDFOR SERVICE.

Part: COMPUTER — MALFUNCTIONED (COCKPIT) · airframe 15,383 hrs · 13,619 cycles

DURING THE TAKEOFF ROLL, THE CREW RECEIVED A FLIGHT GUIDANCE COMPUTER FAIL MESSAGE AND ABORTED TAKEOFF. THE MESSAGE CLEARED BY ITSELF AND THE CREW CALLED MAINTENANCE CONTROL WHO ADVISED THE CREW TO ATTEMPT ANOTHER TAKEOFF. FLIGHT 4094 THEN DEPARTED WITH NO FURTHER INCIDENTS.

Part: WARNING SYSTEM — MALFUNCTIONED (COCKPIT) · airframe 15,300 hrs · 13,545 cycles

DURING THE TAKEOFF ROLL, THE CREW RECEIVED A TAKE OFF CONFIGURATION CAS MESSAGE AND ABORTED TAKEOFF. THE CREW RESET THE ELEVATOR TRIM AND ATTEMPTED ANOTHER TAKEOFF. FLIGHT 4082 DEPARTED WITH NO FURTHER INCIDENTS.

Part: COMPUTER — MALFUNCTIONED (COCKPIT)

PIT - FLT 4066 - DURING THE TAKEOFF ROLL, THE CREW RECEIVED A FGC LAP FAIL CAS MESSAGE. THE CREW ABORTED TAKEOFF. AS FLIGHT 4066, EXITED THE RUNWAY THE MESSAGE CLEARED AND MAINTENANCE CONTROL REQUESTED THAT THE FLIGHT CONTINUE TO CAE. FLIGHT THEN DEPARTED WITH NO FURTHER INCIDENTS. (M)

Part: BATTERY — DISCHARGED (CABIN) · airframe 15,170 hrs · 13,434 cycles

THE CREW REPORTED THAT THE EMERGENCY LIGHTING WAS NOT ILLUMINATING AT ROWS 8 TO 10. MAINTENANCE INSPECTED AND REPLACED THE EMERGENCY BATTERY AT THE 7LK POSITION IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 33-00-00. OPERATIONAL CHECKS WERE PERFORMED AND THE AIRCRAFT WAS RELEASED FOR SERVICE.

Part: BATTERY — DISCHARGED (CABIN) · airframe 14,770 hrs · 13,089 cycles

THE CREW REPORTED THAT THE EMERGENCY BATTERIES WERE DRAINED. THE AIRCRAFT WAS FERRIED TO PIT WHERE MAINTENANCE REPLACED THE EMERGENCY BATTERIES IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 33-00-00. OPERATIONAL CHECKS WERE PERFORMED AND THE AIRCRAFT WAS RELEASED FOR SERVICE.

Part: ACCUMULATOR — LACK OF LUBE (HYD SYSTEM) · airframe 14,519 hrs · 12,868 cycles

THE FLIGHT LEVELED OFF AT 27,000 FEET AND THE CREW RECEIVED AN EMERGENCY PARKING BRAKE ACCUMULATOR LOW CAS MESSAGE. THE CREW REFERENCED THE QUICK REFERENCE HANDBOOK AND WERE DIRECTED TO RETURN TO CHS. AS FLIGHT 4069 DESCENDED THROUGH 8000 FEET THE CAS MESSAGE EXTINGUISHED AND FLIGHT 4069 LANDED WITH NO FURTHER INCIDENT. MAINTENANCE INSPECTED AND SERVICED THE EMERGENCY PARKING BRAKE ACCUMULATOR IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 12-00-00. OPERATIONAL CHECKS WERE PERFORMED AND THE AIRCRAFT WAS RELEASED FOR SERVICE.

Part: BATTERY — DISCHARGED (CABIN) · airframe 14,338 hrs · 12,703 cycles

THE FLIGHT CREW REPORTED THAT THE EMERGENCY LIGHTS WOULD NOT OPERATE IN THE AFT SECTION OF THE CABIN. MAINTENANCE INSPECTED AND REPLACED THE 7LK BATTERY IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 33-51-00. OPERATIONAL CHECKS WERE COMPLETED AND THE AIRCRAFT RETURNED TO SERVICE.

Part: CONTROL HANDLE — FAILED (COCKPIT) · airframe 13,841 hrs · 12,276 cycles

WHILE ON FINAL, THE CREW RECEIVED NO INDICATION WHETHER THE LANDING GEAR WAS DOWN OR NOT. THE CREW EXECUTED A GO AROUND AND REVIEWED THE QUICK REFERENCE HANDBOOK AND MANUALLY EXTENDED THE GEAR. THE CREW THEN RECEIVED THREE GREEN LIGHTS AND LANDED WITH NO FURTHER INCIDENTS. MAINTENANCE INSPECTED AND REPLACED THE LANDING GEAR CONTROL LEVER IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 32-00-00. OPERATIONAL CHECKS WERE PERFORMED AND THE AIRCRAFT WAS RELEASED FOR SERVICE.

Part: BATTERY — FAILED (CABIN) · airframe 12,806 hrs · 11,402 cycles

THE CREW REPORTED THAT THE FORWARD EMERGENCY LIGHTS WOULD NOT ILLUMINATE. MAINTENANCE INSPECTED AND REPLACED THE EMERGENCY BATTERY IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 33-51-01. OPERATIONAL CHECKS WERE PERFORMED AND THE AIRCRAFT WAS RELEASED FOR SERVICE.

Part: BULB — FAILED (ROW 9) · airframe 12,456 hrs · 11,118 cycles

THE CREW REPORTED THAT THE EMERGENCY EXIT SIGN AT ROW 9A WAS NOT ILLUMINATING. MAINTENANCE INSPECTED AND REPLACED THE EMERGENCY EXIT SIGN LIGHT BULBS IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 33-00-00. OPERATIONAL CHECKS WERE PERFORMED AND THE AIRCRAFT WAS RELEASED FOR SERVICE.

Part: BATTERY — FAILED (CABIN) · airframe 12,321 hrs · 11,002 cycles

THE CREW REPORTED THAT THE EMERGENCY LIGHTING DID NOT WORK AT THE 6 LK & 7 LK POSITIONS. MAINTENANCE INSPECTED AND REPLACED THE 7 LK EMERGENCY BATTERY IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 33-51-01, OPERATIONAL CHECKS WERE PERFORMED AND THE AIRCRAFT WAS RELEASED FOR SERVICE.

Part: BATTERY — FAILED (ROW 9) · airframe 11,836 hrs · 10,598 cycles

THE CREW REPORTED, THE EMERGENCY LIGHTS AT ROW 9A DID NOT ILLUNIMATE. MAINTENANCE INSPECTED AND REPLACED THE BATTERY AT THE 6LK POSITION IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 33-51-00. OPERATIONAL CHECKS WERE COMPLETED AND THE AIRCRAFT WAS RELEASED FOR SERVICE.

Part: GENERATOR — FAILED (STARTER/GEN)

DURING CRUISE, FLIGHT 4168 EXPERIENCED A RIGHT GENERATOR FAILURE. THE AIRCRAFT WAS 20 MILES FROM CAK, SO MAINTENANCE CONTROL DIVERTED THE AIRCRAFT TO CAK. MAINTENANCE INSPECTED AND REPLACED THE RIGHT STARTER GENERATOR IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 29-31-01. OPERATIONAL CHECKS WERE PERFORMED AND THE AIRCRAFT WAS RELEASED AND CONTINUED ON TO AZO WITHOUT FURTHER INCIDENT.

Part: HMU — FAILED (RT ENGINE)

DURING TAKEOFF, THE RIGHT HAND ENGINE WOULD ONLY PRODUCE 86 PERCENT TORQUE. THE AIRCRAFT RETURNED TO THE FIELD WITHOUT FURTHER INCIDENT. THE AIRCRAFT WAS FERRIED TO PIT WHERE MAINTENANCE INSPECTED AND REPLACED THE HYDRO MECHANICAL UNIT IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 73-22-00. OPERATIONAL CHECKS WERE PERFORMED AND THE AIRCRAFT WAS RELEASED FOR SERVICE.

Part: SIGNAL COND — FAILED (LT PROP)

THE LEFT PROPELLER WOULD NOT COME OUT OF FEATHER WHEN THE AUTOFEATHER TEST WAS ATTEMPTED PRIOR TO DEPARTURE. THE AIRCRAFT RETURNED TO THE GATE. MAINTENANCE INSPECTED THE AIRCRAFT AND FERRIED THE AIRCRAFT TO PIT. MAINTENANCE REPLACED THE LEFT TORQUE SIGNAL CONDITIONER IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 77-11-02. OPERATIONAL CHECKS WERE COMPLETED AND THE AIRCRAFT RETURNED TO SERVICE.

Part: BATTERY PACK — DSCHARGED (ROW 7LK)

A SECTION OF THE EMERGENCY FLOOR LIGHTING WAS FOUND TO BE INOPERATIVE. MAINTENANCE INSPECTED AND REPLACED THE 7LK EMERGENCY BATTERY PACK IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 33-51-00. OPERATIONAL CHECKS WERE COMPLETED AND THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: BATTERY — DISCHARGED (FUSELAGE)

THE EMERGENCY FLOOR LIGHTING AT SEAT 4D AND 4F WAS NOTED TO BE INOPERATIVE BY THE CREW ON THE PREFLIGHT INSPECTION. MAINTENANCE INSPECTED AND REPLACED THE EMERGENCY LIGHT BATTERY PACK AT SEAT 4D AND 4F, IN ACCORDANCE WITH DORNIER MM 33-51-00. OPERATIONAL CHECKS WERE COMPLETED, AND THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: BATTERY — DISCHARGED (ROW 5LK)

A SECTION OF EMERGENCY LIGHTING WAS NOTED TO BE INOPERATIVE DURING THE PREFLIGHT INSPECTION. MAINTENANCE INSPECTED AND REPLACED THE 5LK EMERGENCY BATTERY PACK, IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 33-51-01. OPERATIONAL CHECKS WERE COMPLETED, AND THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: PWR SUPPLY — INOP (ROW 5LK)

ROW FOUR EMERGENCY FLOOR LIGHTING WAS NOTED TO BE INOPERATIVE DURING THE PREFLIGHT INSPECTION. MAINTENANCE INSPECTED AND REPLACED THE EMERGENCY POWER SUPPLY UNIT AT THE 5LK POSITION, IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 33-51-00. OPERATIONAL CHECKS WERE COMPLETED, AND THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: BATTERY — DISCHARGED (CABIN)

A SECTION OF EMERGENCY LIGHTS WERE NOTED TO BE INOPERATIVE DURING THE POST-FLIGHT INSPECTION. MAINTENANCE INSPECTED AND REPLACED THE EMERGENCY BATTERY PACK AT THE 5LK POSITION. OPERATIONAL CHECKS WERE COMPLETED, AND THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: ADC — FAILED (E & E COMPT)

A RED O2 FAIL WARNING MESSAGE ILLUMINATED DURING THE FLIGHT. THE AIRCRAFT RETURNED TO DCA. OUTSTATION MAINTENANCE INSPECTED THE OXYGEN SYSTEM IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 12-19-01. THE AIRCRAFT WAS RETURNED TO SERVICE. LATER THAT DAY, THE WARNING MESSAGE OCCURRED AGAIN. MAINTENANCE INSPECTED AND REPLACED THE AIR DATA COMPUTER, IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 34-11-01. OPERATIONAL CHECKS, INCLUDING A FLIGHT CHECK WERE COMPLETED. THE RESULTS WERE SATISFACTORY, AND THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: METERING UNIT — FAILED (MLG BRAKES)

THE CREW REPORTED THAT THE BRAKES WOULD PULSATE ON AND OFF, WHEN THEY WERE APPLIED DURING TAXI. THE AIRCRAFT RETURNED TO THE GATE. MAINTENANCE INSPECTED AND REPLACED THE BRAKE METERING UNIT, IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 32-42-03. OPERATIONAL AND LEAK CHECKS WERE SATISFACTORY AND THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: METERING UNIT — FAILED (RT MLG BRAKES)

THE RIGHT HAND BRAKE PEDALS ON THE PILOT AND FIRST OFFICERS POSITIONS, PULSATED WHEN BRAKES WERE COMMANDED. THE AIRCRAFT RETURNED TO THE GATE. MAINTENANCE INSPECTED AND REPLACED THE BRAKE METERING UNIT IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 32-42-03. OPERATION AND LEAK CHECKS WERE COMPLETED.

Part: CONTROL UNIT — FAILED (TE FLAPS)

WHILE PREPARING FOR DEPARTURE, WHEN THE FLAPS WERE SELECTED TO 12 DEGREES, THE FLAP INDICATOR REMAINED AMBER. THE AIRCRAFT RETURNED TO THE GATE. MAINTENANCE INSPECTED AND REPLACED THE FLAP CONTROL UNIT, IN ACCORDANCE WITH DORNIER MAINTENANCE MANUAL 27-50-00. OPERATION CHECKS WERE COMPLETED.

Part: CONNECTOR — DIRTY (LT PROP)

BEFORE TAKEOFF, PROPELLER OVERSPEED TESTED FAILED. AIRCRAFT RETURNED TO THE GATE. MAINTENANCE INSPECTED AND FOUND PROPELLER OVERSPEED GOVERNOR CANNON PLUG DIRTY. CLEANED CANNON PLUG. OPERATIONAL TEST CHECKED GOOD AND AIRCRAFT WAS APPROVED TO RETURN TO SERVICE.

Part: VALVE — FAILED (LT ENGINE)

JUST AFTER LIFT OFF, THE LEFT ENGINE DEICE FAIL CAS MESSAGE CAME ON. RETURNED TO THE FIELD WITHOUT FURTHER INCIDENT. MAINTENANCE REMOVED AND REPLACED THE LEFT ENGINE EJECTOR FLOW CONTROL VALVE. OPERATIONAL CHECKS WERE GOOD AND THE AIRCRAFT WAS APPROVED FOR RETURN TO SERVICE.

Part: ACTUATOR — FAILED (LT TE FLAP)

PASSING THROUGH 13,000 FT, HAD A FLAP ASSYM AND FLAP CONTROL FAIL CAS MESSAGE. RETURNED TO FIELD WITHOUT FURTHER INCIDENT. MAINTENANCE REMOVED AND REPLACED THE LT FLAP ACTUATOR, OPERATIONAL CHECK GOOD.

Part: FLAP CONTROL — FAILED (COCKPIT)

WHILE AT CRUISE FLIGHT, A FLAP ASSYM CAS MESSAGE AND A FLAP FAIL CASS MESSAGE WERE INDICATED. CONSULTED QRH AND VISUALLY ENSURED THAT FLAPS WERE AT ZERO DEGREES, CONTINUED ON TO DAYTON AND LANDED WITHOUT FURTHER INCIDENT. MAINTENANCE REMOVED AND REPLACED THE FLAP CONTROL UNIT, OPERATIONAL CHECKS GOOD.