What was found
THIS WAS A MAINTENANCE OCF TEST FLIGHT. THE AIRCRAFT HAD BEEN IN MX OVERNIGHT FOR A FLAP FAIL CAUTION MESSAGE. AN OCF TEST FLIGHT WAS REQUIRED. DURING CLIMB THE CREW RECEIVED A FLAPS FAIL CAUTION MESSAGE, COMPLIED WITH THE QRH, DECLARED AN EMERGENCY WITH ATC AND RETURNED TO CVG. TRUCKS ROLLED. THE AIRCRAFT LANDED SAFELY AND WENT BACK INTO MAINTENANCE. MX INSPECTED AND FOUND #1 LT FLAP ACTUATOR TRIP INDICATOR TO BE TRIPPED. REMOVED AND REPLACED LH #1 FLAP ACTUATOR. PERFORMED RIGGING AND OPS CHECKS. OPS CHECKS GOOD.