Post-Firing Reserve Inspection and an Overweight Exit
After a main-canopy malfunction, a jumper AAD fired at 750 feet and deployed the reserve. The reserve opened but landed in a tree. The reserve canopy has a 6-inch tear across one cell, one suspension line is broken at the lower attachment, and the free bag has a torn grommet. The AAD cutter has fired. The jumper exit weight is 260 pounds; the reserve canopy placard lists a maximum suspended weight of 254 pounds. The reserve was last packed 60 days ago. The jumper wants you to replace the broken line, patch the tear, and repack the reserve for next weekend. You are a senior rigger with the appropriate ratings and have the canopy manual, which lists repair limits and requires manufacturer repair for tears over 4 inches or any damage to a line attachment.
1. What is the airworthiness disposition of the reserve canopy and free bag? Explain your reasoning.
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The reserve canopy is not airworthy for a rigger-level repair. The manual requires manufacturer repair for tears over 4 inches or any damage to a line attachment; this is a 6-inch tear and a broken line at the lower attachment. A patch and a single line replacement would not be approved and could leave hidden damage. The free bag is also damaged at a grommet, which can cause deployment problems; replace it rather than patch it. Send the canopy to the manufacturer or an approved repair station, and replace the free bag with an approved part. Do not repack for service until the canopy is repaired and inspected.
2. What must be done with the AAD and the packing records before the reserve can return to service?
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The AAD has fired and must be handled per the AAD manufacturer post-fire instructions, including cutter replacement and any required inspection or service. Do not simply reset it and repack. After the canopy and free bag are repaired or replaced, a properly rated rigger must repack the reserve and complete the packing data card and logbook entry. The 60-day-old pack date is irrelevant because the system will be repacked after repair; the new 180-day period starts at the new pack date. Document the AAD work separately.
3. How does the exit weight affect the decision?
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The exit weight is 260 pounds, which exceeds the reserve canopy 254-pound maximum suspended weight. That is an overload condition: it can increase descent speed, opening loads, and the chance of injury, and it is outside the placarded limit. Even after repair, the canopy should not be returned to service for this jumper at that weight. The jumper must reduce exit weight by at least 6 pounds or use a reserve canopy rated for the load. The rigger should not sign off the system as airworthy for that use.