Military Javelin (MJ) Technical Manual, Revision 11.1

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1 Military Javelin (MJ) Technical Manual, Revision E. International Speedway Blvd. Suite 1 DeLand, Florida USA Tel: (+1) Fax: (+1) technicalsupport@cpsworld.com 1-i

2 Release Notes Rev 1; Feb. 18, 2010; Issued by CPS; Entered by ALM --Initial Release. Rev 2; Feb. 18, 2010; Issued by CPS; Entered by ALM --Added revision page. Rev 3; Feb. 22, 2010; Issued by CPS; Entered by ALM --Revised table of contents. Rev 4; Feb. 24, 2010; Issued by CPS; Entered by ALM --Removed JMPI from TOC. Rev 5; Mar. 15, 2010; Issued by CPS; Entered by ALM --Changed cover to MJN. Rev 6; Mar. 15, 2010; Issued by CPS; Entered by ALM --Added Technical Service Bulletins module. Rev 7; Mar. 22, 2010; Issued by CPS; Entered by ALM --Changed TOC to reflect rev changes. Rev 8; Aug. 19, 2010; Issued by CPS; Entered by ALM --Added DBSL and Skyhook publications. Rev 9; Nov. 23, 2010; Issued by CPS; Entered by ALM --Updated table of contents. Rev 10; Sep. 13, 2011; Issued by CPS; Entered by TKD --Updated cover title and TOC. Rev 11; Jul. 31, 2013; Issued by CPS; Entered by LKK --Converted from publication format to book format, re-ordered so flow follows actual packing sequence; --REMOVED How To Use This Manual (was page CPS-TM-PUB-5-R3-3); --ADDED Installing the Skyhook and Cutaway Handle, Packing and Closing the Non-Fluted Reserve Deployment Bag, and Closing the Reserve Container with Skyhook; ; --CHANGED 3-ring release cable lengths from 9½ ± ¼ on RSL side & 7½ ± ¼ on non-rsl side to 6 ± ½ on RSL side & 5½ ± ¼ on non-rsl side per manufacturer specifications. Rev 11.1; Jul. 07, 2014; Issued by CPS; Entered by RJJ --Inserted MS-360 M3/M4 Placard Statement - Minimum Weight in Chapter 4 1-ii

3 Table of Contents Chapter 1: General Information and Nomenclature Parachute Packing and Deployment Log Military Javelin (MJ) Harness/Container Nomenclature... 3 Chapter 2: Reserve Parachute Inspection, Assembly, and Packing Reserve Parachute Inspection and Preparation Attaching the Reserve Parachute to Risers Attaching the Reserve Steering Lines to Toggles Installing the Skyhook and Cutaway Handle Installing the CYPRES AAD with and without Skyhook Flat Pro-Packing the Reserve Over-the-Shoulder Pro-Packing the Reserve Packing and Closing the Fluted and Non-Fluted Reserve Deployment Bag Closing the MJ Reserve Container with and Without Skyhook...76 Chapter 3: Main Parachute Inspection, Assembly, and Packing Attaching the Main Parachute to Risers Attaching the Main Steering Lines to Toggles Attaching the Main Risers to the Harness Flat Packing the Main Parachute for DBSL Flat Packing the Main Parachute Over-the-Shoulder Pro-Packing the Main Parachute Closing the Main Deployment Bag Closing the MJ Main Container for Over-the-Shoulder Ripcord Configuration Closing the MJ Main Container for BOC Hand Deploy Configuration Chapter 4: Appendices Parachute Information, Maintenance, and Repair Technical Service Bulletins iii

4 WARNING AND DISCLAIMER It is beyond the scope of this manual to teach you how to deploy, fly and land this parachute. This manual is only a general guide about this parachute system. It is not a replacement for proper training and instruction. Parachute systems sometimes fail to open properly, even when properly assembled, packed, and operated. There is a risk of equipment damage, serious injury, or death each time this system is used. Each time you use this parachute system you risk bodily injury and death. You can substantially reduce this risk by: (1) Assuring every component of the parachute system has been assembled and packed in strict accordance with the manufacturer s instructions. (2) By obtaining proper instruction in the use of this parachute and the rest of the equipment, and (3) By operating each component of the system in strict compliance with an approved course of instruction and safe parachuting practices. Statement of Compliance The policies contained herein comply with the Federal Aviation Regulations, Part 21. Revision List Complete Parachute Solutions Inc. (CPS) may revise this manual at any time. The only way to be sure this manual is current for your parachute system is to check with CPS at CPS welcomes suggestions of ways to improve this publication. If you feel parts are incomplete or hard to understand, please let us know by writing or ing technicalsupport@cpsworld.com. Disclaimer No Warranty Because of the unavoidable danger associated with the use of this parachute system, the manufacturer makes no warranty, either expressed or implied. It is sold with all faults and without any warranty of fitness for any purpose. The manufacturer also disclaims any liability in tort for damages, direct or consequential, including personal injuries resulting from a defect in design, material, workmanship or manufacturing whether caused by negligence on the part of the manufacturer or otherwise. By using this parachute system, or allowing it to be used by others, the user waives any liability of the manufacturer for personal injuries or other damages arising from such use. COMPLETE PARACHUTE SOLUTIONS, INC EAST INTERNATIONAL SPEEDWAY BLVD. SUITE 1 DELAND, FL USA technicalsupport@cpsworld.com 1-iv

5 General Information and Nomenclature 1320 E. International Speedway Blvd. Suite 1 DeLand, Florida USA Tel: (+1) Fax: (+1) technicalsupport@cpsworld.com 1-1

6 1.1. Parachute Packing and Deployment Log As any conventional ram-air reserve is repeatedly handled and repacked, the fabric permeability will increase. This increased permeability will affect opening, flight and/or landing characteristics. To monitor this important issue, we have incorporated a tracking and inspection program into our reserve canopies. Compliance with this program is mandatory. Each time the reserve is inspected and packed, a single diagonal line / is to be placed in the next open box on the label. In the event of an actual deployment, an X is to be placed in the next available box. The warning label should accurately reflect the repacks and uses on that reserve parachute. In the event a rigger encounters a discrepancy between the packing data card and the warning label, the label should be brought into compliance. The owner of the reserve should be informed that the rigger is simply complying with Performance Designs requirement for the label to accurately reflect the repacks and/or uses on that parachute. After 40 repacks or 25 deployments have been reached, the reserve must have its permeability tested. (In most countries, 40 repacks are usually performed over a 10- to 20-year period.) The testing is performed to ensure that the fabric permeability has not reached a point where the openings and landing performance would be unacceptable. Subsequent to passing this testing, an additional label is affixed and the parachute is then returned into service. The label will contain additional boxes, the specific number being chosen according to the results of the test. Parachute Model and Size Canopy-Specific Weight and Deployment Speed Limitations Parachute Serial # RIGGER: Fill in this area prior to each repack. See instructions above. Figure Sample Parachute Warning Label 1-2

7 1.2. Military Javelin (MJ) Harness/Container Nomenclature Left Main Riser Cover Right Main Riser Cover Reserve Pin Cover Flap Reserve Pilot Chute Cap Staticline Clip Staticline Left Main Side Flap (Flap-3) Main Flex Pin Bottom Main Flap (Flap-1) Main Parachute Ripcord Cable Housing Main Pin Flap Top Main Flap (Flap-2, under Main Pin Flap) Right Main Side Flap (Flap-4) Figure MJ Staticline Configuration, Back View 1-3

8 3-Ring Release Main Base Ring Chest Strap Main Riser Cover Main Parachute Riser Reserve Ripcord Cable Housing Reserve Ripcord Handle Equipment V-Rings, Rear (optional) Waist Band Adapter Leg Strap Equipment Ring, Front Quick Ejector (QE) Snap and Quick-Fit Hip Ring Upper Leg Pad Figure MJ with Skyhook, Left Front View 1-4

9 Main Riser Cover 3-Ring Release Reserve Staticline (RSL) Release Main Parachute Riser Main Base Ring Equipment Ring (Front) Reserve Ripcord Cable Housing Chest Strap Reserve Ripcord Handle Waist Band Adapter Upper Leg Pad Leg Strap B-12 Snap and Quick-Fit Hip Ring Figure MJ without Skyhook, Left Front View 1-5

10 Reserve Staticline Release Tab Main Ripcord Cable Housing Main Ripcord Handle Cutaway Cable Housings Cutaway Handle Equipment Ring, Front Chest Strap Adjustable Main Lift Web Keeper Chest Strap Adapter Equipment V-Ring (optional) Waist Band T-53 Oxygen Bottle Pocket (optional) Quick Ejector Snap Leg Strap V-Ring Figure MJ with Skyhook, Right Front View 1-6

11 Cutaway Cable Housings Main Ripcord Cable Housing Cutaway Handle Main Ripcord Handle Reserve Ripcord Handle Equipment Ring, Front Chest Strap Chest Strap Adapter Adjustable Main Lift Web Keeper Waist Band B-12 Snap Leg Strap V-Ring Figure MJ without Skyhook, Right Front View 1-7

12 Right Main Riser Cover Weapon Tie- Down Loops Main Ripcord Housing Equipment Ring (Front) Side Equipment Ring (Optional) Waist Band Oxygen Pocket Figure MJ, Right Side View 1-8

13 Left Main Riser Cover Reserve Parachute Ripcord Handle Weapon Tie- Down Loops Adjustable Main Lift Web Staticline Clip Pocket Utility Pocket Adjustable Main Lift Web Cover Side Equipment Ring (Optional) Left Lower Leg Pad Figure MJ, Left Side View 1-9

14 This Page Intentionally Left Blank 1-10

15 Chapter 2: Reserve Parachute Inspection, Assembly, and Packing E. International Speedway Blvd. Suite 1 DeLand, Florida USA Tel: (+1) Fax: (+1) technicalsupport@cpsworld.com 2-1

16 2.1. Reserve Parachute Inspection and Preparation OVERVIEW The Performance Designs reserve parachute must be inspected thoroughly before its first pack and before each subsequent repack. This inspection should be performed with even more care and attention when first assembled and after a deployment. A certified rigger or military equivalent must inspect the new Performance Designs reserve and determine its compatibility with your rig. This inspection should be done in a clean, well-lit area with enough room to spread out the reserve parachute VISUAL INSPECTION Top Surface Spread the parachute out on its bottom surface and inspect the top surface starting at the front of the left end cell. Check half of the cell from nose to tail. Then check the other half from tail to nose. Repeat this pattern until each cell s top surface has been inspected. On all fabric portions of the canopy, look for rips, stains, snags, burns, abrasions or failed seams. Bottom Surface Turn the parachute over and spread it out to inspect the bottom surface. Again use the procedure of inspecting half-cells as on the top surface. Look very closely at the line attachments. Even slight damage is cause for rejection in these areas. Line attachments must be completely free of any damage or defects. Check under the ends of the line tabs. Ribs Inspect each rib from leading edge to the trailing edge by looking inside each cell. Also check the cross ports for tears. Stabilizers and Slider Stops Lay the parachute neatly on one side, stacking each loaded rib on top of the others. Verify that the left and right mirror-imaged lines are of the same length. Check that the trim differential between each line group is correct for this reserve. Check the condition of the stabilizers and slider stops on the stabilizer. Suspension Lines Check the full length of each line for damage and wear. Look for fraying at all cascades and where each line attaches to the connector link. Check that all lines are sewn with a bar tack and that the stitching is good. Check the continuity and routing of each line. Slider Ensure the fabric is not torn, the grommets are undamaged with no sharp edges or burrs, and that they are securely attached to the slider. Be sure every suspension line and both steering lines pass through the proper grommet on the slider. Links Visually check the links and their condition. Ensure that the link is not bent or damaged; the barrel is not cracked and operates smoothly. If the link is already attached to the riser, insure it is properly tightened. 2-2

17 PERMEABILITY The permeability of the fabric is very important. As the permeability increases, the parachute will open more slowly and flight performance will deteriorate. The rate of descent will increase and the forward speed will decrease. The ability of the parachute to flare to a soft landing will decrease. To ensure the parachute is safe to use, Performance Designs has established an average permeability limit of 8.0 cfm for the reserve parachute throughout its service life. Fabric permeability does not change while the parachute remains packed; it changes because of use, packing and handling. That s why it is important to maintain a complete history of the parachute. Fabric permeability must be tested if any of the following events occur: The parachute has been submerged in water. 25 jumps have been made on the parachute since it was new or last certified. The parachute has been repacked 40 times since it was new. The parachute has an unknown number of jumps, repacks, or there is reason to believe that jumps or repacks were not properly logged. Flight performance appears to be substandard. There are other reasons to believe the fabric permeability may exceed specifications. Performance Designs is equipped to perform permeability testing. It is recommended that any parachute needing such testing be returned to CPS for facilitation of this process, unless your loft is capable of this testing OPTIONAL PROTECTIVE LINK COVERS Ensure that the protective link covers located on the connector links are the correct size, are positioned correctly, are in good condition and are properly secured with tacking cord TOGGLES The toggle must be installed correctly to the lower control line. The loop fastener on the toggle must mateup properly with the hook fastener on the riser. Performance Designs canopies come with brake settings and toggle tie-on marks set for PIA standard riser/brake dimensions. This standard calls for 4 inches (10.16 cm) from the top of the riser to the top of the brake-setting ring. 2-3

18 FABRIC STRENGTH TESTING Performance Designs recommends that a random sample of 10% of all reserves placed in service within your organization be strength tested once per year. A minimum of 3 per year should be tested if the inventory is less than 30 parachutes. If a failure occurs during one of the tests, the cause of that failure shall be determined. If the cause of fabric failure is due to an isolated event (i.e. acid contamination or a cigarette burn), then the testing may be continued at the 10% level. If the cause of the failure is undetermined, contact the manufacturer for further guidance on further testing and any other required actions. The environment in which the parachute has been used and stored may have a significant effect on the strength of the fabric (i.e., sand, sun, clear water and salt water). Use commercially available 1 inch (2.54 cm) wide fabric testing clamps with rubber-faced jaws and appropriate scale. The scale should be calibrated at least once per year and be accurate within 1.0 lb ( kg). The clamps should be free of any burrs or rough edges that could snag the fabric. A total of three fabric strength tests should be performed; one test on each of the following locations on the parachute: left end cell, top surface right end cell, top surface center top surface near trailing edge The test should never be done where any part of the fabric involved in the test is within 3 inches (7.62 cm) of any seam or the data panel. The test should be done chord-wise. An additional test must be performed on any stained or discolored areas. Attach the locking fabric clamps to the ripstop fabric. The distance between the clamps should be 3 inches (7.62 cm) and the clamps should be aligned so that the ripstop pattern is parallel to the edge of the jaw. Lock the clamps securely to avoid slippage. Pass a short length of cord through the eye of one clamp and secure to the packing table or other object that will allow a 30 lbs (13.61 kg) load without movement. Pass the hook from the spring scale through the other eye and apply a 30 lbs (13.6 kg) load for 3 seconds MAINTENANCE AND REPAIRS Information on maintenance, repairs and associated limitations may be found in the chapter Parachute Information, Maintenance and Repairs. 2-4

19 2.2. Attaching the Reserve Parachute to Risers If link covers are to be installed, first run the covers up the lines far enough to allow attaching the connector link to the riser. Remove all grease and dirt from links, using a solvent that will leave no residue. Trichloroethylene or electrical contact cleaner is recommended. Inspect the links carefully. Check for nicks, burrs and any sign of bending or stress. Check to be sure the barrel will screw down at least 2¾ turns from first engagement with no resistance. Attach the connector links onto the risers and tighten the links finger tight. Perform a thorough line continuity check at this point, making sure that the parachute is rigged correctly. Tighten the connector finger tight with an additional ¼ turn with a 7/16 wrench or crescent wrench. Figure Tighten the Link OPTIONAL: If link covers are to be installed, slide them over the links. You can use a pull-up cord to assist you in doing this. Cut four 12 lengths of waxed nylon super tack cord. Run one strand end between the suspension lines and the other end through the connector link of each riser. Using a surgeons knot, followed by a locking knot, tie the ends together. Snip the long ends off one half inch from the knot. NOTE: Figure shows the two left link covers in the stopped position. Note that access to the link barrel is possible for inspection as shown on the two right link covers (shown for illustration purposes only). Figure Optional Link Covers Installed 2-5

20 Hand tack the risers below the links using one strand of tacking cord and secure with a surgeon s knot, followed by a locking knot. >>RIGGER CHECK<< Figure Hand-Tacked Riser 2-6

21 Attaching the Reserve Steering Lines to Toggles Overview The parachute manufacturer allows the rigger to use either of the two following methods for attaching the finished or unfinished lower steering line to the steering toggle. Method 1: Tied-On Toggle Attachment Unfinished Line: Secure the steering toggle to the unfinished lower steering line by a secured routing and finish knot. Method 2: Lark s Head Toggle Attachment Unfinished Line: Prepare a loop and secure the steering toggle to the lower steering line by making a lark s head knot at the end of the steering line terminal end. Finished Line: Secure the steering toggle to the lower steering line by making a lark s head knot with a premade cat s eye loop at the end of the steering line terminal end. Either method may be used for all canopies: 7-cell, 9-cell, main and/or reserve. 2-7

22 Reserve Steering Lines to Toggles Method 1: Tied-On Toggle Attachment Once the parachute has been correctly attached to the risers and while it is still laid on its side, begin to attach the reserve steering toggles using the following steps for a tied-on toggle: Ensure the steering lines are correctly routed (i.e. they should not wrap around any suspension lines). This is accomplished by starting at the tail of the parachute. Trace the upper steering lines down to the lower steering line. Check that the right hand steering line passes through the right hand rear slider grommet and the left hand steering line passes through the left hand rear slider grommet. Locate the mark on the lower steering line that indicates the correct toggle location. Thread the steering line through the steel guide ring that is located on the back of the rear riser. Now thread the end of the steering line through the steering toggle grommet starting from the Velcro side of the toggle. Adjust the steering line mark (on the steering line) is close to the grommet but has not passed through it. Pass the steering line through the steel guide ring only! DO NOT pass through the locking loop Toggle Mark Figure Thread Steering Line through Steel Ring and Toggle Grommet 2-8

23 While holding the toggle put the mark in place, wrap the cut side of the steering line around the toggle 1½ times Insert the steering line through the grommet again from the backside of the toggle and pull it snug. Ensure that the toggle mark has remained in the correct location. Figure Proper Toggle Mark Position Tie an overhand knot as close to the grommet as possible. Tie a second overhand knot directly below the first. >>RIGGER CHECK<< Figure Second Pass with the Steering Line Figure Overhand Knots 2-9

24 Reserve Steering Lines to Toggles Method 2: Lark s Head Toggle Preparation The factory mark distance from the top of the cat-eye for each model and size can be found in the table in the following section Working towards the tail end, place a mark at each of the following locations: ½ from original mark towards tail end 3½ from original mark towards tail end 6½ from original mark towards tail end. This is the cut mark. Figure Factory Toggle Mark Original Factory Mark Reference Mark 2 Reference Mark 1 Reference Mark 3 Use a different color ink than the factory placed mark to help distinguish between the original and the newly placed marks. Cat-eye Terminal End At the 6½ mark, cut the line at the longest possible angle using scissors. Do not use a hot knife. Figure Line Orientation Figure Tail End Angle Cut 2-10

25 Insert the finger-trapping tool into the line at a distance greater than the amount of line being finger-trapped. The finger-trap tool should emerge at the ½ mark drawn in the previous step. The line between the 3½ mark and the 6½ mark is the portion to be finger trapped Insert the terminal end of the line through the eyelet of the finger-trapping tool. Figure Finger-Trap Tool Insertion Pull the line through until the 3½ mark and the ½ mark are in alignment. Remove the finger-trap tool. NOTE: Ensure that the terminal end remains completely inside the line. Figure Insert the Tail of the Line Figure Proper Alignment 2-11

26 Place a ¾ bartack with 42 stitches at the fingertrap insertion point (1¼ from the beginning of loop) to secure the fingertrap. ¾ 1¼ Double check your measurements against the ruler. Figure Completed Bartack For length specifications see table in next section. >> RIGGER CHECK << Figure Top of the Cat-Eye Figure Finished Loop 2-12

27 Steering Line Length Specifications for Lark s Head Attachment All measurements are in inches and are based on the original factory toggle mark distance from the top of the cat-eye toward the terminal end. Use a different color ink to place reference marks in order to distinguish between the factory mark and the reference marks. The left and right steering lines on one system may vary ± ⅛. Example: Left steering line factory mark is 29. Right steering line factory mark may measure between 28 ⅞ and 29 ⅛. NOTE: Factory mark length equals the finished length. Model Factory Mark Reference Mark 1 Reference Mark 2 Reference Mark 3 OR ¾" ± ½ 26 ¼" ± ½ 29 ¼" ± ½ 32 ¼" ± ½ OR ¾" ± ½ 27 ¼" ± ½ 30 ¼" ± ½ 33 ¼" ± ½ OR ⅝" ± ½ 28 ⅛" ± ½ 31 ⅛" ± ½ 34 ⅛" ± ½ OR " ± ½ 29 ½" ± ½ 32 ½" ± ½ 35 ½" ± ½ OR ± ½ 24 ½ ± ½ 27 ½ ± ½ 30 ½ ± ½ TR ½ ± ½ 25 ± ½ 28 ± ½ 31 ± ½ TR ¾" ± ½ 26 ¼" ± ½ 29 ¼" ± ½ 32 ¼" ± ½ TR ¾" ± ½ 27 ¼" ± ½ 30 ¼" ± ½ 33 ¼" ± ½ TR " ± ½ 28 ½" ± ½ 31 ½" ± ½ 34 ½" ± ½ Figure Steering Line Length Specifications 2-13

28 reserve Steering Lines to Toggles Method 2: Lark s Head Toggle Preparation Route the steering line down through the guide ring located on the riser. NOTE: Prior to hooking up the steering toggles, make sure the steering line passes through the grommet on the slider. Pass the steering line through the steel guide ring only! DO NOT pass through the locking loop Thread a piece of waxed nylon tack cord through the steering line loop. Put both ends of the tack cord through the toggle grommet from the Velcro side. Pull the steering line loop through the grommet using the tack cord as shown. Figure Thread Steering Line through Guide Ring Thread the toggle handle through the finished loop creating a lark s head knot. Do not thread the upper end of the toggle through the loop; this is not a secure method and may detach. Figure Thread Steering Line through Toggle Figure Thread Toggle through Steering Line Loop 2-14

29 Pull the toggle completely through and tighten the knot around the toggle. Repeat this procedure for the other steering line. >>RIGGER CHECK<< Figure Locked Toggle 2-15

30 2.4. Installing the Skyhook and Cutaway Handle Gather the cutaway handle and Skyhook RSL Mate the Skyhook RSL pile Velcro with the harness/container hook Velcro. Correct placement of the RSL will ensure that the loop end is located between the two ends of the cable housing. Figure Cutaway Handle and Skyhook RSL Close the protection flap. Figure Attach Skyhook RSL Figure Close Protection Flap 2-16

31 Insert the long cutaway cable into the innermost cable housing as shown Thread the cutaway cable through the RSL loop. Figure Long Cutaway Cable in Housing Thread cutaway cable through cable housing located under the pin protection flap as shown. Ensure that the RSL is mated to the Velcro so there is no slack when the cutaway cable is routed through the loop. Figure Cutaway Cable through RSL Loop Figure Cutaway Cable through Housing 2-17

32 Insert the short cutaway cable into the outer cable housing as shown Open the pocket as far as possible and place the handle inside the pocket. Ensure that the cables are not twisted and the white label is facing down as shown. Insert the cutaway handle fully into the pocket, ensuring that the handle is pushed as far up to the top of the pocket as possible Figure Short Cutaway Cable in Housing Figure Correct Cutaway Handle Installation 2-18

33 2.5. Installing the CYPRES AAD with and without Skyhook Installing the CYPRES AAD with Skyhook Secure the closing loop by placing a double overhand knot (then tighten against disk). Follow with a single overhand knot, then tighten against the double overhand knot. MJ finished reserve closing loop length is 2¾ ± ¼ Ensure that each knot has been tightened and that the correct loop length has been achieved. Average loop length is 2¾ ± ¼ measured from the inside of the washer to end of the CYPRES loop. Figure CYPRES AAD Closing Loop 2¾ ± ¼ Place the closing loop through the grommet located in the floor plate. Figure Loop Length 2¾ ± ¼ Figure Closing Loop in Anchor Plate 2-19

34 Place the CYPRES control unit and cutter through the hole in the CYPRES pocket flap Route the CYPRES control unit and cutter into the bottom of the Type 3 channel sewn in the pack tray. Figure CYPRES Cable Routing Place the cutter through the opening provided in the channeling. Figure CYPRES Control Unit Routing Figure CYPRES Cutter Routing 2-20

35 Place the cutter in the elastic keeper channel placed at the closing loop. Thread the closing loop through the hole in the cutter Pull the CYPRES control unit cable out of the channel. Figure Final CYPRES Cutter Placement Place the CYPRES control unit in the pocket located underneath Flap-4. Figure Exit the Channel Figure Placing The Control Unit (Bottom View) 2-21

36 Insert the control unit between the plastic window and the elastic layer inside the pocket Fully insert the control unit between the plastic window and the elastic layer inside the pocket. Confirm visibility. Figure Placing the Control Unit (Top View) After installing the cutter and control unit, place the excess CYPRES control box cable around the processing unit. Ensure that the larger cable is on the top. Figure Control Unit Fully Inserted into the Pocket Figure CYPRES Excess Cable Placement 2-22

37 Place the processing unit and excess cable in the elastic pocket sewn to the base of the reserve container. NOTE: After the CYPRES installation, test the unit by turning it on. Refer to the CYPRES operation manual for the correct procedure. Figure Completed CYPRES Installation 2-23

38 Installing the CYPRES AAD without Skyhook Secure the closing loop by placing a double overhand knot (then tighten against disk). Follow with a single overhand knot, then tighten against the double overhand knot. MJ finished reserve closing loop length is 2¾ ± ¼ Ensure that each knot has been tightened and that the correct loop length has been achieved. Average loop length is 2¾ ± ¼ measured from the inside of the washer to end of the CYPRES loop. Figure CYPRES AAD Closing Loop 2¾ ± ¼ Place the closing loop through the grommet located in the floor plate. Figure Loop Length 2¾ ± ¼ Figure Closing Loop in Anchor Plate 2-24

39 Place the CYPRES control unit and cutter through the hole in the CYPRES pocket flap Place the cutter through the Type-3 channel sewn in the pack tray. Figure CYPRES Cable Routing Place the cutter through the opening provided in the channeling. Place the cutter in the elastic keeper channel placed at the closing loop. Thread the closing loop through the hole in the cutter. Figure CYPRES Cutter Routing Figure Final CYPRES Cutter Placement 2-25

40 Place the CYPRES control unit through the Type 3 channel sewn in the pack tray Fully insert the control unit inside the pocket. Confirm visibility. Figure CYPRES Control Unit Route After installing the cutter and control unit, place the excess CYPRES control box cable around the processing unit. Ensure that the larger cable is on the top. Figure Control Unit Fully Inserted into the Pocket Figure CYPRES Excess Cable Placement 2-26

41 Place the processing unit and excess cable in the elastic pocket that is sewn to the base of the reserve container. NOTE: After the CYPRES installation, test the unit by turning it on. Refer to the CY- PRES operation manual for the correct procedure. Figure Completed CYPRES Installation 2-27

42 Flat Pro-Packing the Reserve PARACHUTE RIGGER PACKING TOOL CHECKLIST This checklist, or a checklist approved by your command, is to be used with each auxiliary parachute inspection and repack cycle. An inventory of the packing tools must be done before the work is to begin and after the work has been completed. Multiple tools of the same type must be counted and recorded. If zero used, mark 0 in the blank provided next to that tool. Some of the tools listed below are optional and may be used to perform the rigger s duties. Some tools may damage the parachute system if used incorrectly. If left in the completed packed parachute, some tools will prevent the parachute from opening properly. This will cause injury or death to the jumper. If you are unfamiliar with any tool refer to Poynter s Parachute Manual or U.S. DOT FAA Parachute Rigger Handbook, FAA-H Check After Completion Pre-inspection Post-Inspection Packing Paddle (wood) each packing Paddle (wood) each Packing Paddle (metal) each packing Paddle (metal) each Shot Bags each Shot Bags each Pull-Up Cords each pull-up Cords each Locking Pull-Up Cord each locking Pull-Up Cord each Leverage Device each leverage Device each Molar Strap each Molar Strap each Velcro Line Protectors each velcro Line Protectors each Temporary Locking Pin each temporary Locking Pin each Temporary Tacking each temporary Tacking each Tensioning Device each tensioning Device each Pull Check Tool each pull Check Tool each Packing Hook each packing Hook each Needle each needle each Nipper each nipper each Scissors each Scissors each Bodkin each Bodkin each Seam Ripper each Seam Ripper each Closing Plate each Closing Plate each Power Tool each power Tool each Para Tool (pliers) each para Tool (pliers) each Wrench each wrench each NOTE: Follow your unit s SOP RIGGER CHECKS, which may be at different points in the packing process than the listed CPS-recommended RIGGER CHECKS. 2-28

43 Line Continuity Check After attaching the reserve parachute connector links and steering toggles to the risers, begin the line continuity check. Place the harness/container with the harness facing up, away from the packing surface. Lay the parachute away from the harness/ container. Place the slider at the connector links. Ensure that all four risers have no twists and are laying flat on the floor. Arrange the reserve parachute by gathering the leading edge (nose) together and lift off the ground. Starting with the end cell, ensure that the outside end cell line runs straight through the slider grommet and connects at the outside of the connector link. Ensure that there are no other lines twisted around that line. Check the inside line of the end cell for the same type of continuity. Performing the same procedure, work towards the center cell by checking each cell and line for continuity without interference. Once reaching the center cell, check the opposite end cell outside line and continue the same procedure to the center cell. After the leading edge of the reserve parachute has had a continuity check, arrange the reserve parachute by gathering the trailing edge (tail) together and lift off the ground. NOTE: Follow your unit s SOP line continuity check which may differ from this CPSrecommended line continuity check. Figure A-Line Continuity Check 2-29

44 Now turn the harness/container over in the direction that will undo the 180-degree turn in the lines and lay it on the ground with the harness down, facing the packing surface. At this point the lines and rear risers must not have any twists in them. Return to the reserve parachute and gather all upper steering lines. Ensure that the slider grommets are touching the rear connector links and that there are no twists in the risers. Trace the upper steering lines to the steering line cascade. Continue tracing the line through the slider grommet then through the riser guide ring and finally to the steering toggle. Ensure that the steering line s path is straight and not wrapped around any other suspension lines. Remove all twists from the control line. Perform the same procedure on the opposite steering line. Check the D-line group. Grasp the upper steering lines in one hand and grasp the stabilizer panel where the end cell outside line connects. Drop the steering lines. Beginning with the outside line, visually trace the line through the slider grommet to the outside of the connector link. Now check the inside line on the end cell and ensure that it is the next line on the connector link. Continue this procedure until you have reached the center cell lines. Repeat this process on the opposite side of the parachute until you have reached the center cell. >>RIGGER CHECK<< NOTE: If any line on the reserve parachute is routed incorrectly or obstructed between the line attachment point and the connector link, you must disconnect the affected connector link and reroute each line with correct continuity. Figure Steering Line Continuity Check 2-30

45 SETTING THE BRAKES Pull the steering line brake setting cat-eye through the guide ring. Pass the brake locking loop through the steering line cateye loop. Insert toggle tip through the locking Figure Locking Loop through Cat-Eye Gather the excess brake line, S- fold and stow the excess brake line around the toggle tip. Figure Toggle Tip Inserted Figure Excess Brake Line S-Folded and Stowed 2-31

46 Secure the excess brake line with the Velcro cover. >>RIGGER CHECK<< Figure Excess Brake Line Secured 2-32

47 Flaking and Folding the Reserve Parachute Place the slider up against the connector links. Separate the front line groups from the rear line groups (rear line group includes steering lines) In left hand grab the right and left rear line groups and in the right hand grab the right and left front line group. Step in between the separated line groups and walk towards the parachute working the line groups apart. While spreading the line groups apart, shake the parachute side to side to settle the fabric. FRONT LINE GROUPS Figure REAR LINE GROUPS Proper Line Separation STEERING LINES In a single motion, swing the parachute forward and lay it on the floor. Figure Parachute Orientation TRAILING EDGE (TAIL) LEADING EDGE (NOSE) Figure Lay Parachute on Packing Surface 2-33

48 Flake the parachute until all T-seams at the top skin are straight from leading edge to the trailing edge. T-seams are easily identified by the two visible rows of stitching that run from the leading edge to the trailing edge. While flaking, put some tension on the suspension lines to straighten them as you work Continue straightening the T- seams working toward the tail section. T-SEAM Figure Flaking the Parachute Flake the nose. Ensure that the reinforcement tapes are aligned. Figure Tail Section Straightened Figure Flaking the Leading Edge 2-34

49 Fold the three bottom cells under the parachute. Fold the three top cells on top of the parachute. Spread the center cell. Place half under the parachute and half on top Grasp the parachute fabric at the A- and B-line group and the fabric between the A- and B-line group. While holding equal tension on each line group, bring A- line group in a direct line with the harness/ container. Move canopy fabric as needed to ensure a straight line from the A-line group to the harness container. Stack the B-line group on top of the A-line group. Figure Leading Edge Treatment Pull the fabric of the three cells to the left to separate the two parachute sides, or to the right side if you orientate the nose to the right. NOTE: Use the center cell seam as a guide. This is typical in stacking all line groups. Figure Stack A-Lines on Top of B-Lines Figure Cells Separated 2-35

50 While keeping tension on the A- and B-line groups, grasp the fabric directly above the C-line group, and place the C-line group on top of the B-line group. After separating the cells to the outside of center. At this time A-, B-, and C-line groups should be on top of each other. Clear the stabilizer after each fold Figure shows rigger s view of a seven-cell parachute, with three cells placed to the right and three cells placed to the left. The center cell is dividing each side. Figure Stack C-Lines on Top of B-Lines Keeping tension on the C-line group, grasp the fabric directly above the D-line group and place the D-line group on top of the C-line group. Apply tension evenly by reaching underneath entire canopy to tighten lines. Pull tension at each fold. Figure Cells Separated Left and Right Figure D-Lines on Top of C-Lines 2-36

51 Figure shows rigger s view of three cells placed to the left and three cells to the right. The center cell is dividing each side. Shot bags may be used to keep the fabric in place. Ensure left and right line groups are directly on top of each other. Remove and count the shot bags when finished Gently clear fabric away from the center. This will begin to create the air channel. Figure Shot Bags Holding Cells in Place While holding tension on the D-line group, gently bring the fabric between the D and C-line groups toward the outside. Begin running the hand at the line attachment point working toward the end on the stabilizer panel. Figure Right and Left Line Groups Separated Figure Fabric Cleared Between C and D-Lines 2-37

52 While holding tension on the D- and C-line groups, gently bring the fabric between the C- and B-line groups toward the outside. Begin running the hand at the line attachment point working toward the end on the stabilizer panel While holding tension on the C- and B-line groups, sweep the fabric between the B- and A-line groups toward the outside. Begin running the hand at the B-line attachment point working toward the A-line attachment point. Figure Fabric Cleared between B and C-Lines Clear each stabilizer to ensure that they are unobstructed. Repeat the same process of moving material away from the air channel and the fabric between line groups and clearing the stabilizers on the other side of the parachute. Figure Fabric Cleared Between A and B-Lines Figure Clear Stabilizers 2-38

53 Once each side has been cleared, grasp the entire right line group and parachute fabric at the top and apply tension to straighten the lines. Repeat this process with the left side of the parachute Once both sides have been cleared, move the tail section away from the center of the pack job. Grasp the fabric fold between the C- and D-line groups, place the fold onto the C- and D-line fabric fold on the other side of the parachute. Figure Tension Applied to Line Groups Remove the large wrinkles from the A-B fabric fold by smoothing the fabric by hand or packing paddle. NOTE: Always work the fabric away from the lines. Figure C-D Fabric Temporarily Placed on Top Figure A-B Fabric Fold Neatened 2-39

54 Place a reduction fold along the A-B fabric fabric. Place a long fold along the B-C Figure A-B Fabric Long-Folded Grasp the fabric fold between the C- and D-line groups that was temporarily moved and place it back on top of the B-C fabric fold. Remove the large wrinkles from the C-D fabric fold by smoothing the fabric by hand. Figure B-C Fabric Long Folded Figure C-D Fabric Fold Neatened 2-40

55 Pull the stabilizer out and lay it on top of the C-D fabric fold. Clear the stabilizer panel that runs from the outside D-line to the parachute trailing edge Flake the tail. Figure Stabilizer Panel Cleared Ensure all seams are over the air channel and all steering lines tight Locate the manufacturer s warning label. Figure Tail Flaked Figure Tail Shown Flaked All to One Side 2-41

56 Split and flip half the tail torward the opposite side of the parachute Spread the center cell out evenly to cover the flaked tail. Ensure that the manufacturer s data block is centered in the middle and all lines are tight. Lines should be on the edge of the air channel. Figure Split and Fold Over Half the Flaked Tail Grasping the slider in the center of the fabric, carefully walk the slider to the base of the stacked canopy. Figure Center Cell Dressed Over Flaked Tail Figure Slider Grommets Against Slider Stops 2-42

57 Quarter the slider by flaking the material between the slider grommets into the dressed stabilizers. >>RIGGER CHECK<< Ensure that ALL the slider grommets are snug against ALL the slider stops sewn to the stabilizer panels. Place hand (or paddle) under the slider grommets. This will help to make an even fold. Figure Slider Quartered S-fold the dressed parachute by making the first S-fold approximately 6-8. With either hand, grasp the stabilizers and slider. Place the opposite hand on the parachute approximately 15 up from the lower edge. Fold the stabilizers and slider toward the top of the parachute. In the same motion S-fold the base of the slider back toward the harness/container system. After the first S-fold, reset the slider grommets snug against the slider stops. Figure Prepare First S-Fold Figure S-Fold Finished 2-43

58 Replace the center cell of the tail back to its original position and tuck the parachute fabric back in between the nose and A-B line groups fabric The width of the cocooned parachute should be about the same width as the deployment bag. Figure Parachute Fabric Tucked in Place Figure Properly Cocooned Parachute 2-44

59 Over-the-Shoulder Pro-Packing the Reserve PARACHUTE RIGGER PACKING TOOL CHECKLIST This checklist, or a checklist approved by your command, is to be used with each auxiliary parachute inspection and repack cycle. An inventory of the packing tools must be done before the work is to begin and after the work has been completed. Multiple tools of the same type must be counted and recorded. If zero used, mark 0 in the blank provided next to that tool. Some of the tools listed below are optional and may be used to perform the rigger s duties. Some tools may damage the parachute system if used incorrectly. If left in the completed packed parachute, some tools will prevent the parachute from opening properly. This will cause injury or death to the jumper. If you are unfamiliar with any tool refer to Poynter s Parachute Manual or U.S. DOT FAA Parachute Rigger Handbook, FAA-H Check After Completion Pre-inspection Post-Inspection Packing Paddle (wood) each packing Paddle (wood) each Packing Paddle (metal) each packing Paddle (metal) each Shot Bags each Shot Bags each Pull-Up Cords each pull-up Cords each Locking Pull-Up Cord each locking Pull-Up Cord each Leverage Device each leverage Device each Molar Strap each Molar Strap each Velcro Line Protectors each velcro Line Protectors each Temporary Locking Pin each temporary Locking Pin each Temporary Tacking each temporary Tacking each Tensioning Device each tensioning Device each Pull Check Tool each pull Check Tool each Packing Hook each packing Hook each Needle each needle each Nipper each nipper each Scissors each Scissors each Bodkin each Bodkin each Seam Ripper each Seam Ripper each Closing Plate each Closing Plate each Power Tool each power Tool each Para Tool (pliers) each para Tool (pliers) each Wrench each wrench each NOTE: Follow your unit s SOP RIGGER CHECKS, which may be at different points in the packing process than the listed CPS-recommended RIGGER CHECKS. 2-45

60 Line Continuity Check After attaching the reserve parachute connector links and steering toggles to the risers, begin the line continuity check. Place the harness/container with the harness facing away from the packing surface. Lay the parachute away from the harness/ container. Place the slider at the connector links. Ensure that all risers have no twists and are laying flat on the floor. Arrange the reserve parachute by gathering the leading edge (nose) together and lift off the ground. Starting with the end cell, ensure that the outside end cell line runs straight through the slider grommet and connects at the outside of the connector link. Ensure that there are no other lines twisted around that line. Check the inside line of the end cell for the same type of continuity. Performing the same procedure, work towards the center cell by checking each cell and line for continuity without interference. Once reaching the center cell, check the opposite end cell outside line and continue the same procedure to the center cell. After the leading edge of the reserve parachute has had a continuity check, arrange the reserve parachute by gathering the trailing edge (tail) together and lift off the ground. NOTE: Follow your unit s SOP line continuity check which may differ from this CPSrecommended line continuity check. Figure A-Line Continuity Check 2-46

61 Now turn the harness/container over in the direction that will undo the 180- degree turn in the lines and lay it on the ground with the harness facing the packing surface. At this point the lines and rear risers must not have any twists in them. Return to the reserve parachute and gather all upper steering lines. Ensure that the slider grommets are touching the rear connector links and that there are no twists in the risers. Trace the upper steering lines to the steering line cascade. Continue tracing the line through the slider grommet then through the riser guide ring and finally to the steering toggle. Ensure that the steering line s path is straight and not wrapped around any other suspension lines. Remove all twists from the control line. Perform the same procedure on the opposite steering line. Check the D-line group. Grasp the upper steering lines in one hand and grasp the stabilizer panel where the end cell outside line connects. Drop the steering lines. Beginning with the outside line, visually trace the line through the slider grommet to the outside of the connector link. Now check the inside line on the end cell and ensure that it is the next line on the connector link. Continue this procedure until you have reached the center cell lines. Repeat this process on the opposite side of the parachute until you have reached the center cell. >>RIGGER CHECK<< NOTE: If any line on the reserve parachute is routed incorrectly or obstructed between the line attachment point and the connector link, you must disconnect the affected connector link and reroute each line with correct continuity. Figure Steering Line Continuity Check 2-47

62 SETTING THE BRAKES Pull the steering line brake setting cat-eye through the guide ring. Pass the brake locking loop through the steering line cateye loop. Insert toggle tip through the locking Figure Locking Loop through Cat-Eye Gather the excess brake line, S- fold and stow the excess brake line around the toggle tip. Figure Toggle Tip Inserted Figure Excess Brake Line S-Folded and Stowed 2-48

63 Secure the excess brake line with the Velcro cover. >>RIGGER CHECK<< Figure Excess Brake Line Secured 2-49

64 Flaking and Folding the Reserve Parachute Facing the reserve parachute, with your fingers separate the front and rear suspension lines. With the thumbs separate the steering lines as shown Keeping the suspension line groups separated, walk towards the parachute pushing the slider as you go. Separate the right and left line groups and shake the parachute side to side to settle the fabric. Figure Separate the Suspension Lines Figure Separate the Right and Left Line Groups 2-50

65 Bring all suspension line groups together and place in one hand then place all line groups to rest on the shoulder (either side). Starting with the parachute end cell nearest the body, pull out the leading edge cells one at a time to clear and organize the nose. Figure Clear and Organize the Nose 2-51

66 Place the organized nose between the knees to keep the nose in control Starting with either the right or left side, locate and separate the A and B-line groups. Place your arm between the line groups down into the parachute and push the parachute fabric to the outside. Repeat this process between the B and C- line groups then the C and D-line groups. Repeat this process on the opposite side of the parachute between each line group. Quarter the slider. Figure Place the Canopy Nose between the Knees Figure Push the Fabric to the Outside 2-52

67 Here is an example showing the line groups unobstructed by the parachute fabric. Notice that the fabric between each line group is organized to the outside of the line groups. A B C D Place all line groups in one hand and place the other mid way down the parachute to support the fabric. Carefully lay the parachute on the packing surface while maintaining control. Apply light tension to the suspension lines. Figure Unobstructed Line Groups Figure Lay the Parachute on the Packing Surface 2-53

68 Once the parachute is on the packing surface, neaten the fabric to decrease pack volume by using the hand to sweep the fabric to the outside between each line group on both sides Carefully roll the parachute fabric over to expose the nose. Straighten and organize three cells each on both sides of the parachute as shown. Figure Neaten the Fabric Return the fabric between the A and B-line groups back to the original position. Smooth the fabric to decrease wrinkles and remove trapped air. Ensure that the slider remains quartered while smoothing the fabric. Figure Expose the Nose Figure Smooth the Fabric 2-54

69 Place a reduction fold between the A- and B-line groups as shown. Smooth the fabric to decrease wrinkles. Repeat this same process with the fabric between the B- and C-line groups and between the C- and D-line groups. Repeat this same process on the other side of the parachute Locate the parachute stabilizer panel between the outside D-line and the outside line on the trailing edge (tail). Grasp the outside line on the tail section and place it so that the line is stacked on the major line groups. Figure Long Fold the Fabric Flake one side of the tail. Figure Clear the C-D Stabilizers Ensure that the upper steering lines are placed in the middle during the flaking so that they all are stacked on the major line groups. Repeat this process on the other side of the tail section. When finished the warning label must be centered on top of the completed tail section. Figure Quarter Fold Each Cell 2-55

70 Between the right and left line groups, pull the slider reinforcing tape from between the line groups clearing the fabric from any obstruction. Now grasp the fabric in the center of the slider and pull up towards the stabilizers to ensure that the slider grommets are tight up against the slider stops sewn to the stabilizer panels. Wrap the center cell of the tail section around the fabric between the A-B, B-C, C-D line groups and tail as shown. Do not wrap the tail around the nose section Fold the three leading edge cells over towards the parachute to where the reinforcement tapes are touching the tail section. Figure Wrap the Center Cell Now fold the nose under the parachute leaving the reinforcement tapes in the same place. The nose reinforcement tapes will lay on the packing surface when finished. Figure Fold the Leading Edge Cells Figure Fold the Nose Under 2-56

71 Ensure that all line groups are stacked on top of each other and that ALL slider grommets are snug against ALL the slider stops sewn to the stabilizer panels. >>RIGGER CHECK<< S-fold the dressed parachute by making the first S-fold approximately 6-8. With the right hand grasp the stabilizers and slider. Place the left hand on the parachute approximately 15 up from the lower edge. Fold the stabilizers and slider toward the top of the parachute. In the same motion S-fold the base of the slider back toward the harness/container system. Figure Ensure Grommets Are Snug against Stops Ensure that ALL the slider grommets are snug against ALL the slider stops. Figure Begin the First S-Fold Figure Finish the S-Fold 2-57

72 Replace the center cell on the tail back to its original position and tuck the parachute fabric back in between the nose and A-B-line groups fabric. Neaten the cocoon from the tail up to the top of the canopy. Figure Tuck the Trailing Edge in Place 2-58

73 2.8. Packing and Closing the Fluted and Non-Fluted Reserve Deployment Bag Packing and Closing the Non-Fluted Reserve Deployment Bag Position the deployment bag so that the safety stow loops are visible and the suspension line pouch is towards the packing surface (floor). SAFETY STOW LOOPS Each set of safety stow loops is one continuous, free-floating bungee that runs through a channel The top of the bag is shown folded back and contains the four safety stow loops. Figure Safety Stow Loops Each of the two side flaps contains two grommets. The closing flap is the last flap to be closed. It has two sets of grommets. side Flap side Flap closing Flap Prepare the deployment bag by mating Velcro line protectors onto the Velcro hook strips sewn at the line pouch opening on the back of the bag. To prevent line damage, cover the entire hook portion of the Velcro strip with the pile tabs. NOTE: Velcro line protectors shown are equipped with yellow flags to help ensure removal following line stowage. Figure Deployment Bag Flaps Figure Installed Velcro Line Protectors 2-59

74 Place the deployment bag on or near the cocooned parachute. Ensure that the width of the folded parachute is the same width as the widest portion of the bag ± 1 inch Gently lift the base of the parachute with one hand, being careful not to disturb the folds or lines. With the other hand, slide the deployment bag underneath the parachute. Figure Parachute Cocooned to Width of Bag With the deployment bag placed under the parachute, make an S-fold in the parachute. Figure Deployment Bag under the Parachute Figure S-Folded Parachute 2-60

75 While kneeling on the S-fold of the parachute, lift the top section and place it in your lap. Inspect the nose arrangement. The nose cells are easily identified by white reinforcement tape. Spread the center cell apart, placing half to the right and half to the left. For a 7-cell parachute, ensure three nose cells point to the right and three nose cells point to the left. For a 9-cell parachute, ensure four nose cells point to the right and four point to the left Place the top of the parachute back down on the packing surface. Locate the T-seam in the middle of the center cell and follow it to the nose section. Separate the left and the right sides and keep the center cell in the center. Figure Pictured) Nose Cells Spread Evenly (7-Cell Parachute Form the two ears by dressing them into a long and narrow roll. Roll the top of the center cell under, but keep the leading edge of the nose exposed. Figure T-Seam on Properly Separated Parachute Figure Parachute Rolled, Creating Two Ears 2-61

76 Fold one ear under itself to reduce the length to the depth of the bag Lift the top of the deployment bag to open it and place the folded ear into the upper corner of the bag. Work the fabric into the bag by pulling the top of the bag over the parachute while pushing the parachute into the corner of the bag. Fold the other ear in half and place it into the deployment bag. Make both folds even in length to ensure symmetrical displacement of bulk in the deployment bag. Figure Ear Folded Under Grasp the side flap and push the S-folded parachute into the bag, forcing the fabric into the upper corners. Do this on each side of the bag. Ensure that the corners are even. Distributing the parachute to the sides of the bag as much as possible will create a better space for the pilot chute. Figure Folded Ear Inserted into Bag Figure Evenly Packed Deployment Bag 2-62

77 Thread one pull-up cord through each safety stow. Route a ~3-inch bight of the deployment bag bridle through each of the two top safety stows. This bight is a packing aid and will be removed before finishing the pack job. Route the bottom pull-up cords through the side flap s bottom grommets, ensuring that the pull-up cords exit the grommets to the outside of the bag Route the bottom pull-up cords from the side flaps through the corresponding grommets on the closing flap. Ensure that the pull-up cords exit the grommets to the outside of the bag. Figure Bridle Staging and Pull-Up Cord Routing Route the pull-up cords from the top safety stow loop through the top grommets on the side flaps. Ensure that the pull-up cords exit the grommets to the outside of the bag. Figure Bottom Pull-Up Cord Routing Figure Top Pull-Up Cord Routing 2-63

78 Route the pull-up cords from the side flaps through the corresponding grommets on the closing flap. Pull the pull-up cords tight to close all flaps. NOTE: Ensure that no canopy material is trapped in the grommets and that the grommets are aligned Grasp the pull-up cord from the top grommet, and pull it through the grommet until there is enough safety stow loop to allow for a bight of suspension lines. Open the loop and insert a bight of lines 3½ ± ½, measured from the safety stow loop to the outside edge of the bight. Figure Bag Being Closed by Pull-Up Cords 3½ ± ½ Grasp the pull-up cord from the other top grommet, and pull it until there is enough safety stow loop to allow for a bight of suspension lines. Open the loop and insert a bight of lines 3½ ± ½. Slowly remove the deployment bag bridle bights and pull-up cords from the top safety stow loops. Figure First Line Bight 3½ ± ½ Figure Second Line Bight 2-64

79 Grasp the pull-up cord from the opposite grommet, and pull it until there is enough safety stow loop to allow for a bight of suspension lines. Open the loop and insert a bight of lines 3½ ± ½. NOTE: Although the rear safety stow loops are not locked, they are easily retrievable by slowly pulling the pull-up cords. 3½ ± ½ Continue by pulling the final pullup cord through the last set of grommets until there is enough safety stow loop to allow for a bight of suspension lines. Open the loop and insert a bight of lines 3½ ± ½. Slowly remove both pull-up cords. Figure Third Line Bight 3½ ± ½ Ensure that the upper and lower steering line cascades are placed between two locking stows. WARNING: Do not place the steering line cascades within any stow bight. Figure Fourth and Final Line Bight Figure Steering Line Cascades Proper Placement 2-65

80 To prevent line damage, ensure the entire hook portion of the Velcro strip is covered with the protective pile tabs. Open the line pouch on the back of the deployment bag and place a bight of lines into the opposite corner from the last locking stow Place a bight of lines in the opposite side of the pouch. Make each line stow the same width as the inside of the pouch. Figure First Suspension Line Bight Stowed Continue stowing the remaining lines until there are of line between the pouch and connector links. Ensure that the lines exit from the center of the deployment bag. Once the suspension lines are stowed, remove the Velcro line protection strips. Mate the hook and pile at the line pouch. Figure Opposite Suspension Line Bight Stowed Figure Lines with Remaining Unstowed 2-66

81 PACKING AND CLOSING THE FLUTED RESERVE DEPLOYMENT BAG Place the deployment bag on or near the cocooned parachute. Ensure that the width of the folded parachute is the same width as the widest portion of the bag ± Gently lift the base of the parachute with one hand, being careful not to disturb the folds or lines, and with the other hand slide the deployment bag underneath the parachute. Figure Cocoon Width = Deployment Bag Width With the deployment bag placed under the parachute, make an S-fold in the parachute. Figure Slide Deployment Bag under the Canopy Figure S-Fold 2-67

82 While kneeling on the reserve parachute, lift the top and place it in your lap. Inspect the nose arrangement. The nose cells are easily identified by the white reinforcement tapes. Ensure three nose cells point to the right and three nose cells point to the left. Spread the center cell apart placing half to the right and half to the left Pull the top edge of the center nose cell up several inches to better expose the entire center cell as shown. Figure Spread Center Cell Place the top of the parachute back down on the packing surface. Locate the T-seam in the middle of the center cell and follow it to the nose section. Separate the left and the right sides and keep the center cell in the center. Figure Expose the Center Cell REINFORCEMEnt TAPE Figure Split the Parachute Top into Two Sections 2-68

83 Form the two sections by dressing them into a long and narrow roll Roll the top of the center cell under as shown but keep the nose leading edge exposed. Figure Form the Two Sections Fold one ear under itself to reduce the length to the depth of the bag. Figure Roll Top of Center Cell Under Figure Fold One Ear 2-69

84 Lift the top of the deployment bag to open it and place the right- or left-folded ear into the upper corner of the bag. Work the fabric into the top by pushing the reserve parachute up into the corner while holding tension on the bag Make both ear folds even in length to ensure proper displacement of bulk in the deployment bag. After placing the second ear into the other side of the bag, grasp the side flap and push the S-folded parachute into the bag forcing the fabric into the upper corners. Do this on each side of the bag. Ensure that the corners are even. Figure First Ear into Bag Route a pull-up cord through each safety stow loop as shown on Flap-1 Terminology: Flap-1 Safety Stows with Pull-up Cords Upper Stow: Closest to Bridle Lower Stow: Next to edge of bag Figure Deployment Bag Displacement Check Flap-1 Flap-4 Grommets Outer Grommets: Next to the edge of bag Inner Grommets: Interior of bag Flap-2 Flap-4 Flap-3 Figure Loop Pull-Up Cords through Each Safety Stow 2-70

85 Using the deployment bag bridle, place a bight of bridle into each safety stow loop Thread the lower pull-up cords through the loop on side Flaps-2 and -3, continuing through the inner grommets on Flap-4, routing the safety stows with them. Figure Bridle Bights in Safety Stow Loops Flap 1 Flap 3 Flap 2 Flap Pull tension on the lower pull-up cords to symmetrically force the canopy further into the reserve bag. Once safety stows have cleared inner grommets, place a bight of bridle into each safety stow loop. Figure Grommets Lower Stows through Side Flaps & Inner Figure Pull Tension on Both Lower Pull-up Cords 2-71

86 Thread the upper safety stow pull-up cords from Flap-1 through the outer grommets on Flap-4. NOTE: Ensure that no canopy material is trapped in the grommets. Flap 2 Flap 1 Flap 4 Flap Grasp the left pull-up cord coming from the outer grommet on Flap-4 and pull it through the Flap-4 outer grommet until there is enough safety stow loop to allow for a bight of suspension lines. Open the loop and insert a bight of lines 3½ ± ½ measured from the safety stow loop to the outside edge of the bight. Figure mets Upper Safety Stows through Outer Grom- 3½ ± ½ Slowly remove the pull-up cord from the safety stow loop Pull the other safety stow pull-up cord through the Flap-4 outer grommet until there is enough safety stow loop to allow for a bight of suspension lines. Open the loop and insert a bight of lines 3½ ± ½ measured from the safety stow loop to the outside edge of the bight. Slowly remove the pull-up cord from the safety stow loop. Figure Insert the First Stow Bight 3½ ± ½ Figure Insert the Second Stow Bight 2-72

87 Pull the lower safety stow pullup cord coming from the inner grommets on the opposite side until there is enough safety stow loop to allow for a bight of suspension lines. Open the loop and insert a bight of lines 3½ ± ½ measured from the safety stow loop to the outside edge of the bight. 3½ ± ½ Continue by pulling the final safety stow pull-up cord through the last inner grommet until there is enough safety stow loop to allow for a bight of suspension lines. Open the loop and insert a bight of lines 3½ ± ½ measured from the safety stow loop to the outside edge of the bight. Slowly remove the safety stow pull-up cord. WARNING: Do not place the steering line cascades within any stow bight. >> RIGGER CHECK<< Open the line pouch on the back of the deployment bag. Using a packing hook, place a bight of lines into the line stow flute opposite and furthest from the last locking stow. Rotate lines as you stow them for the first and second stows. Figure Figure Insert the Third Stow Bight Insert the Fourth Stow Bight Figure Begin Stowing the Suspension Lines 2-73

88 Place a bight of lines into the line stow flute on the opposite side. Make each line stow the same width as the inside of the pouch Place another bight of lines on the opposite side of the pouch, and cross over to stow bights three and four. Figure Insert the Second Bight into the Flute Continue stowing the remaining lines until there is of line between the pouch and connector links. Ensure the lines exit the center of the deployment bag. Figure Insert Third and Fourth Stow Bights Figure Final Stows Completed 2-74

89 Once the suspension lines are stowed, mate the hook and pile securely to close the line pouch With the bag completely closed, confirm there is of line between the pouch and connector links, and the lines exit the center of the deployment bag. Figure Close the Line Pouch Figure Stow Lines with Remaining 2-75

90 2.9. Closing the MJ Reserve Container with and Without Skyhook Closing the MJ Reserve Container with Skyhook Prior to placing the reserve parachute into the reserve container set the CYPRES loop length at 2¾ ± ¼ from the disc. The loop at this length will protrude from the floor plate 2½ ± ¼. Thread a pull-up cord through the reserve container closing loop. Thread the pull-up cord ends through the hole in the CYPRES cutter as shown. Ensure that the reserve closing loop passes through the cutter hole. NOTE: Recommended minimum pull-up cord length is Lift the deployment bag and temporarily place it on the main parachute pack tray. Arrange the reserve parachute risers in the reserve pack tray. Ensure that the risers lay flat without twist in the pack tray. Ensure that the risers lay flat along the shoulder line and into the tray. Do not allow any slack in the risers after they are set. Figure Reserve Container Pack Tray Place the deployment bag on the top portion of the reserve pack tray. Straighten the suspension lines between the bag and risers. Thread the closing loop and pull-up cord through the grommet of the reserve deployment bag. Figure Place Reserve Risers Figure Deployment Bag on Container 2-76

91 Place the reserve parachute into the reserve pack tray. Work the corners of the bag into the bottom corners of the container Ensure that the red Skyhook lanyard and 1,000 lb. Spectra closing pin lanyard are attached to the reserve staticline (RSL) using a lark s head knot. Fold the red Skyhook lanyard 3½ from the lark s head knot. Place the fold in the red pocket on Flap-1. Figure Bag Corners into Container Fold the reserve deployment bag bridle up to the green loop/skyhook. (Skyhook is located on other side of bridle behind the green loop). Place two 7 S-folds of bridle on each side of the deployment bag grommet. Figure Insert Red Skyhook Lanyard Figure S-Fold Bridle 2-77

92 Place the pull-up cord through the grommet on Flap-1. Pull the closing loop to the surface. Using a temporary pin, pin the closing loop above Flap Pinch the green loop located on the bridle and insert it into the Type III pocket on Flap-1. Figure Pin Closing Loop above Flap Flip the bridle over to expose the Skyhook. Place the red lanyard OVER the bridle to the left. Place the red lanyard loop over the Skyhook and between the Lexan covers. Figure Green Loop in Flap-1 Pocket Figure Red Lanyard Loop over Skyhook 2-78

93 Secure the red lanyard to the Skyhook by using a safety tie. Use one turn of seal thread (4-6 lb. tensile strength maximum) through the holes in both top and bottom Lexan covers. Secure the safety tie with a surgeon s knot finished with a locking knot. Clip ½ from knot. WARNING: Failure to secure the red lanyard to the Skyhook with safety tie may cause the Skyhook to be inoperable. >>RIGGER CHECK<< Close Flaps-2 and -3 and temporarily pin the closing loop above Flap-3. Ensure that the reserve bridle is routed out the top of the container. Figure Lanyard Secured to Skyhook S-fold the remaining bridle material and place it on Flap-2. Place the bagged high speed pilot chute on Flap-3. Figure Flaps-2 and -3 Closed Figure S-Folded Pilot Chute on Flap

94 When threading the main parachute long cutaway cable through the cable housing, ensure that the cable passes through the loop at the end of the Collins lanyard. WARNING: The Collins lanyard loop must only have two lanyards (the locking pin lanyard and the red Skyhook lanyard) attached by a lark s head knot. Only the long cutaway cable shall pass through the loop itself Run a bodkin through the grommet located on the top of the reserve pilot chute. Figure Collins Lanyard Loop Pass the end of the bodkin through one of the openings in the base of the reserve pilot chute. Place both ends of the pull-up cord through the slot at the end of the bodkin. A waxed cord may be used to assist in threading the bodkin as shown. Figure Bodkin through Reserve Pilot Chute Figure Bodkin Threaded with Pull-Up Cord 2-80

95 Pull the pull-up cord through the reserve pilot chute. Ensure that the S-folded bridle remains on one side of the closing loop and the bagged high speed pilot chute on the other Center the reserve pilot chute base over the grommet on Flap-3. While pulling the pull-up cord, compress the pilot chute spring until the top is flush with the container. Ensure no fabric is trapped in between the spring coils. >>RIGGER CHECK<< Figure Pull-Up Cord through Reserve Pilot Chute Pull the closing loop to the surface, remove the temporary pin from above Flap-3 and pin the loop above the top of the reserve pilot chute. Figure Compress Pilot Chute Figure Pilot Chute Pinned 2-81

96 Tuck the pilot chute fabric evenly underneath the pilot chute cap top and sides only. NOTE: Use care not to tear or damage the pilot chute fabric by using sharp tools. Use a wooden packing paddle only Divide the remaining pilot chute evenly to the right and to the left. Thread the pull-up cord through the grommet on Flap-4. Pull the closing loop to the surface, remove the temporary pin from above pilot chute cap and pin the loop above the Flap-4 grommet. Figure Pilot Chute Fabric Tucked under Cap Distribute the excess pilot chute material evenly and tuck under Flap-4. A wooden packing paddle may be used. Figure Temporary Pin Flap-4 Closed Figure Excess Pilot Chute Folded under Flap

97 Thread the pull-up cord through the grommet on Flap-5. Pull the closing loop to the surface, remove the temporary pin from above Flap-4 and pin the loop above the grommet on Flap-5. Place the tip of Flap-5 into the pocket on Flap Insert the reserve ripcord cable into the cable housing. Figure Pin Loop above Flap-5 Grommet Insert the metal handle all the way into the pocket. Ensure that the cable is pushed all the way into the housing against the cable stops. Figure Reserve Ripcord Cable in Housing Figure Reserve Handle in Pocket 2-83

98 Insert the closing pin through the Marine eye located at the terminal end of the reserve ripcord cable. The Marine eye is bevel cut; place the closing pin through the eye from the beveled side Remove the temporary pin and pin the closing loop above Flap-5 with the reserve closing pin. Ensure that the point of the closing pin is under the Type III binding tape. Carefully remove the pull-up cord. Figure Closing Pin and Marine Eye Mated Insert the ripcord pull check tool on the ripcord pin as shown. Ensure that the point of the closing pin is under the Type III binding tape. >>RIGGER CHECK<< Figure Closing Pin through Closing Loop Figure Ripcord Pin Check Tool Installed 2-84

99 Using a pull force gauge or a calibrated fish scale, apply a straight steady force on the rip cord handle until initial movement of the ripcord pin is observed. Pull slowly. Minimum Pull Force: 12 lbs. Maximum Pull Force: 27 lbs Remove the pull check tool. Ensure that the point of the closing pin is under the Type III binding tape. Place a packing paddle into the reserve tuck tab pocket. Figure Steady Pull Force Applied Using a packing paddle insert the tuck tabs under Flaps-2 and -3. Figure Paddle in Reserve Tuck Tab Pocket Figure Tuck Reserve Tuck Tabs 2-85

100 Place the reserve closing pin protection flap over Flap-5. Tuck the side tuck flaps under the sides of Flap-5. Tuck the end tab into the pocket on Flap-4. WARNING: COUNT ALL TOOLS AND EQUIPMENT. FAILURE TO ACCOUNT FOR ALL TOOLS MAY RESULT IN A TOOL BEING LEFT IN THE PARACHUTE WHICH MAY LEAD TO AN EQUIPMENT MALFUNCTION RESULT- ING IN INJURY OR DEATH TO THE PARACHUTIST. Figure Pin Protection Flap Closed 2-86

101 Closing the MJ Reserve Container without Skyhook Prior to placing the reserve parachute into the reserve container, the reserve closing loop shall be 2¾ ± ¼ un-stretched, (prior to install) which can result in a loop length of 2 ¾ -3 ¼ after closing the reserve container. This will allow the loop to stretch to the appropriate length for all atmospheric/humidity conditions. If using a pre-stretched loop, the loop shall not exceed 3¼ ± 1/8. Confirm length and tolerances with system technical drawings prior to installation. NOTE: It is recommended that a new CYPRES loop be installed prior to every reserve repack. NOTE: The Cypres loop length is a guide. Many variables can affect ideal loop length, including, but not limited to: rigger experience, canopy pack volume, canopy bulk distribution within the reserve deployment bag, placement of reserve deployment bag in container, humidity, use of leverage devices, etc. Figure Reserve Closing Loop Installed Lift and rotate the deployment bag and temporarily place it on the main parachute pack tray. Arrange the reserve parachute risers in the reserve pack tray. Ensuring that the risers lay flat without twisting, fan out the risers so that the rear risers are outboard. Thread the closing loop end through the hole in the CYPRES cutter. Thread a pull-up cord through the reserve container closing loop. Do not allow any slack in the risers after they are set. >>RIGGER CHECK<< Figure Place Reserve Risers in Pack Tray 2-87

102 Without disturbing the position of the risers, rotate the reserve deployment bag into the reserve container. Cleanly organize the suspension lines between the reserve deployment bag and reserve risers Work the corners of the reserve deployment bag into the bottom corners of the reserve container. Figure Place Deployment Bag in Container Thread the pull-up cord through the grommet on Flap-1. Pull the closing loop to the surface, place a temporary pin in the closing loop. TIP: In order to maintain the shape of the freebag, it may be necessary to place a flat hand under the flap while tensioning the pull-up cord. This would hold true for Flap-2 also. Figure Work Lower Corners of Bag into Container 1 Figure Close Flap

103 Thread the pull-up cord through the grommet on Flap-2. Pull the closing loop to the surface, remove the temporary pin and insert it into the closing loop above Flap Move some of the bulk of the high-speed pilot chute away from the reserve pilot chute as shown in the figure. Only move enough so the reserve pilot chute will have a flatter base upon which to sit. Figure Close Flap S-fold the bridle using six (6) folds approximately 8 each. Figure Move Bulk of High-Speed Pilot Chute Figure S-Fold the Bridle 2-89

104 Place the high-speed pilot chute onto the left side of the container, forming a V with the bridle on the right, and high-speed pilot chute on the left (rigger s preference) Ensure that the high-speed pilot chute does not interfere with the closing loop or temporary pin. Figure Position High-Speed Pilot Chute Lay the base of the pilot chute next to the grommet on Flap-2. Run a bodkin through the grommet located on the top of the reserve pilot chute. Ensure the bodkin does not pass through any of the spring coils. Then pass the end of the bodkin through one of the openings in the base of the reserve pilot chute. Place both ends of the pull-up cord through the slot at the end of the bodkin. Pull the pull-up cord through the reserve pilot chute. Figure Ensure Pull-Up Cord and Pin are Clear Figure Thread Pull-Up Cord into Bodkin 2-90

105 Center the reserve pilot chute base over the grommet on Flap-2. While pulling the pull-up cord, compress the pilot chute spring until the top is flush with the container. Ensure no fabric is trapped in between the coils of the spring Pull the closing loop to the surface, remove the temporary pin and pin the loop above the top of the reserve pilot chute. Figure Compress Pilot Chute Tuck the top portion of the pilot chute fabric evenly under the pilot chute cap. Figure Pin Pilot Chute Figure Tuck Fabric under Cap 2-91

106 Continue folding the pilot chute fabric evenly under both sides of the pilot chute cap. NOTE: Use care not to tear or damage the pilot chute fabric by using sharp tools. Use a packing paddle with smooth clean edges Smooth the remaining pilot chute fabric as shown. NOTE: Use care not to tear or damage the pilot chute fabric by using sharp tools. Use a packing paddle with smooth clean edges. Figure Continue Folding Fabric under Cap Draw the fabric around the pilot chute by forming an X with the left and right sides as shown. DO NOT OVER STRESS THE FABRIC. NOTE: Use care not to tear or damage the pilot chute fabric by using sharp tools. Use a packing paddle with smooth clean edges. Figure Smooth Fabric under Cap Figure Form X with Remaining Fabric 2-92

107 Fold the remaining pilot chute fabric toward the pilot chute cap as shown Thread the pull-up cord through the grommet on Flap-3. Figure Fold Remaining Fabric Pull the closing loop to the surface, remove the temporary pin and pin the loop above the grommet on Flap-3. Ensure the excess pilot chute material remains tucked under Flap Ensure that the reserve cable is routed the ripcord through the RSL ring and then through the guide ring. Figure Tuck Excess PC Fabric Under Flap-3 Ripcord Channel RSL Ring Guide Ring Figure Confirm RSL Routing 2-93

108 Thread the pull-up cord through the grommet on Flap-4. Pull the closing loop to the surface, remove the temporary pin and pin the loop above the grommet on Flap-4 using the reserve ripcord terminal pin. Place the tip of Flap-4 into the pocket on Flap Ensuring that the point of the closing pin is under the Type III binding tape, position the ripcord pin. Figure Insert Terminal Pin Place a packing paddle into the tuck tab pocket on Flap-1. Figure Point of Ripcord Pin under Binding Tape Figure Paddle in Reserve Tuck Tab Pocket 2-94

109 Using a packing paddle insert the tuck tab between the reserve riser and the reserve bag. Repeat the process on Flap Place the reserve closing pin protection flap over Flap-5. Figure Tuck Reserve Tuck Tabs Tuck the side tuck flaps under the sides of Flap-5. Tuck the end tab into the pocket on Flap-4. WARNING: COUNT ALL TOOLS AND EQUIPMENT. FAILURE TO ACCOUNT FOR ALL TOOLS MAY RESULT IN A TOOL BEING LEFT IN THE PARACHUTE WHICH MAY LEAD TO AN EQUIPMENT MALFUNCTION RESULTING IN INJURY OR DEATH TO THE PARACHUTIST. Fill out reserve log record book. >>RIGGER CHECK<< Figure Pin Protection Flap Closed 2-95

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111 Chapter 3: Main Parachute Inspection, Assembly, and Packing 1320 E. International Speedway Blvd. Suite 1 DeLand, Florida USA Tel: (+1) Fax: (+1) technicalsupport@cpsworld.com 3-1

112 3.1. Attaching the Main Parachute to Risers If link covers are to be installed, first run the covers up the lines far enough to allow attaching the connector link to the riser. Remove all grease and dirt from links, using a solvent that will leave no residue. Trichloroethylene or electrical contact cleaner is recommended. Inspect the links carefully. Check for nicks, burrs and any sign of bending or stress. Check to be sure the barrel will screw down at least 2-3/4 turns from first engagement with no resistance. Attach the connector links onto the risers and tighten the links finger tight. If link covers are to be installed, slide them over the links and onto the lines. You can use a pull-up cord to assist you in doing this. Perform a thorough line continuity check at this point, making sure that the parachute is rigged correctly. Tighten the connector finger tight with an additional ¼ turn with a 7/16 wrench or crescent wrench. Figure Tighten the Link OPTIONAL: If link covers are to be installed, cut four 12-inch lengths of waxed nylon super tack cord. Run one strand end between the suspension lines and the other end through the connector link of each riser. Using a surgeons knot, followed by a locking knot, tie the ends together. Snip the long ends off one half inch from the knot. NOTE: Figure shows the two left link covers in the stopped position. Note that access to the link barrel is possible for inspection as shown on the two right link covers (shown for illustration purposes only). Figure Optional Link Covers Installed 3-2

113 Hand tack the risers below the links using one strand of tacking cord and secure with a surgeon s knot, followed by a locking knot. >>RIGGER CHECK<< Figure Hand-Tacked Riser 3-3

114 Attaching the Main Steering Lines to Toggles Overview The parachute manufacturer allows the rigger to use either of the two following methods for attaching the finished or unfinished lower steering line to the steering toggle. Method 1: Tied-On Toggle Attachment Unfinished Line: Secure the steering toggle to the unfinished lower steering line by a secured routing and finish knot. Method 2: Lark s Head Toggle Attachment Unfinished Line: Prepare a loop and secure the steering toggle to the lower steering line by making a lark s head knot at the end of the steering line terminal end. Finished Line: Secure the steering toggle to the lower steering line by making a lark s head knot with a premade cat s eye loop at the end of the steering line terminal end. 3-4

115 Main Steering Lines to Toggles Method 1: Tied-On Toggle Attachment Once the parachute has been correctly attached to the risers and while it is still laid on its side, begin to attach the main steering toggles using the following steps for a tied-on toggle: Ensure the steering lines are correctly routed (i.e. they should not wrap around any suspension lines). This is accomplished by starting at the tail of the parachute. Trace the upper steering lines down to the lower steering line. Check that the right hand steering line passes through the right hand rear slider grommet and the left hand steering line passes through the left hand rear slider grommet. Locate the mark on the lower steering line that indicates the correct toggle location. Thread the steering line through the steel guide ring that is located on the back of the rear riser. Now thread the end of the steering line through the steering toggle grommet starting from the Velcro side of the toggle. Adjust the steering line mark (on the steering line) is close to the grommet but has not passed through it. Pass the steering line through the steel guide ring only! DO NOT pass through the locking loop Toggle Mark Figure Thread Steering Line through Steel Ring and Toggle Grommet 3-5

116 While holding the toggle put the mark in place, wrap the cut side of the steering line around the toggle 1½ times Insert the steering line through the grommet again from the backside of the toggle and pull it snug. Ensure that the toggle mark has remained in the correct location. Figure Proper Toggle Mark Position Tie an overhand knot as close to the grommet as possible. Tie a second overhand knot directly below the first. >>RIGGER CHECK<< Figure Second Pass with the Steering Line Figure Overhand Knots 3-6

117 main Steering Lines to Toggles Method 2: Lark s Head Toggle Preparation The factory mark distance from the top of the cat-eye for each model and size can be found in the following table. NOTE: If steering line is finished, skip to following section, Method 2: Installing the Standard Toggle Using the Lark s Head Method or Method 2: Installing the HAHO Toggle Using the Lark s Head Method Working towards the tail end, place a mark at each of the following locations: ½ from original mark towards tail end 3½ from original mark towards tail end (4½ for HAHO toggles) 6½ from original mark towards tail end (7½ for HAHO) This is the cut mark. NOTE: HAHO toggles are larger and require larger loops. Note measurement changes from standard procedure. Use a different color ink than the factory placed mark to help distinguish between the original and the newly placed marks. Figure Factory Toggle Mark Original Factory Mark Reference Mark 2 Reference Mark 1 Reference Mark 3 Cat-eye Terminal End At the 6½ mark (7½ for HAHO toggles), cut the line at the longest possible angle using scissors. Do not use a hot knife. Figure Line Orientation Figure Tail End Angle Cut 3-7

118 Insert the finger-trapping tool into the line at a distance greater than the amount of line being finger-trapped. The finger-trap tool should emerge at the ½ mark drawn in the previous step. The line between the 3½ mark and the 6½ mark (4½ mark and the 7½ for HAHO toggles) is the portion to be finger trapped Insert the terminal end of the line through the eyelet of the finger-trapping tool. Figure Finger-Trap Tool Insertion Pull the line through until the 3½ mark (4½ for HAHO toggles) and the ½ mark are in alignment. Remove the finger-trap tool. NOTE: Ensure that the terminal end remains completely inside the line. Figure Insert the Tail of the Line Figure Proper Alignment 3-8

119 Place a ¾ bartack with 42 stitches at the fingertrap insertion point (1¼ from the beginning of loop) to secure the fingertrap. ¾ 1¼ Double check your measurements against the ruler. Figure Completed Bartack Finished Loop For length specifications see table in next section. >>RIGGER CHECK<< Figure Top of the Cat-Eye Cat-eye Figure Finished Loop 3-9

120 Steering Line Length Specifications for Lark s Head Attachment All measurements are in inches and are based on the original factory toggle mark distance from the top of the cat-eye toward the terminal end. Use a different color ink to place reference marks in order to distinguish between the factory mark and the reference marks. The left and right steering lines on one system may vary ± ⅛. Example: Left steering line factory mark is 29. Right steering line factory mark may measure between 28 ⅞ and 29 ⅛. NOTE: Factory mark length equals the finished length. Model Factory Mark Reference Mark 1 Reference Mark 2 Reference Mark 3 CR ½ ± ½ 26 ± ½ 29 ± ½ 32 ± ½ MS ½ ± ½ 25 ± ½ 28 ± ½ 31 ± ½ MS ⅛ ± ½ 23 ⅝ ± ½ 26 ⅝ ± ½ 29 ⅝ ± ½ MS ⅞ ± ½ 25 ⅜ ± ½ 28 ⅜ ± ½ 31 ⅜ ± ½ MS-300 M4 24 ⅜ ± ½ 24 ⅞ ± ½ 27 ⅞ ± ½ 30 ⅞ ± ½ MS ⅛ ± ½ 22 ⅝ ± ½ 25 ⅝ ± ½ 28 ⅝ ± ½ MS ± ½ 23 ½ ± ½ 26 ½ ± ½ 29 ½ ± ½ MS ⅜ ± ½ 24 ⅞ ± ½ 27 ⅞ ± ½ 30 ⅞ ± ½ Figure Steering Line Length Specifications 3-10

121 Main Steering Lines to Toggles Method 2: Lark s Head Toggle Preparation Route the steering line down through the guide ring located on the riser. NOTE: Prior to hooking up the steering toggles, make sure the steering line passes through the grommet on the slider. Pass the steering line through the steel guide ring only! DO NOT pass through the locking loop Thread a piece of waxed nylon tack cord through the steering line loop. Put both ends of the tack cord through the toggle grommet from the Velcro side. Pull the steering line loop through the grommet using the tack cord as shown. Figure Thread Steering Line through Guide Ring Thread the toggle handle through the finished loop creating a lark s head knot. Do not thread the upper end of the toggle through the loop; this is not a secure method and may detach. Figure Thread Steering Line through Toggle Figure Thread Toggle through Steering Line Loop 3-11

122 Pull the toggle completely through and tighten the knot around the toggle. Repeat this procedure for the other steering line. >>RIGGER CHECK<< Figure Locked Toggle 3-12

123 Attaching the Main Risers to the Harness The 3-Ring Release The 3-Ring Release System was invented by the Relative Workshop in It was the first practical release that allowed parachutists to jettison their main canopies in one motion by simply pulling a single handle. Not only is the 3-Ring easier to operate than previous parachute release systems, it is also more reliable. Failures of a properly built and assembled 3-Ring system are virtually unknown. Once the main is jettisoned, the only things left on the harness are two smooth rings that cannot snag a deploying reserve. Some other popular release systems can and have interfered with the deploying reserve. Knowing how the 3-Ring release works will help you assemble and inspect it properly. Begin by peeling the release handle from the Velcro on the harness. Peeling, rather than pulling, makes it easier to separate the handle from the webbing. Look behind the risers near the harness and observe the movement of the cable as you pull the handle. When the cable clears the white loop, the release is disengaged. Now slowly pull one of the risers off the harness. As you pull, you ll notice that the white loop gets pulled through the grommet by the action of the smallest ring. Each ring forms a lever with a ten-to-one mechanical advantage as it passes through the other. A force of 1,000 lbs. on the large harness ring exerts a force of only ten pounds on the white loop. (Opening shock usually totals about 1,000 lbs., or 500 lbs. on each riser). Because of the mechanical advantage provided by the 3-Ring design, only a force of approximately a pound on the top ring keeps the release together. That s why it s important to keep foreign matter like bits of grass and sticks out of the 3-Ring assembly. A small stick in the white loop could prevent a riser from releasing. It is also important to understand one of the properties of the nylon components of the system. When nylon stays in the same position for a long time, it begins to conform to that position, or take a set. If the 3-Ring release system stays assembled for too long, the nylon can become so stiff that the low drag from a malfunction (such as a streamer or bag lock) won t pull the riser off the ring. Before assembling the 3-Ring release, make sure the risers aren t twisted or reversed. 3-13

124 REQUIRED PERIODIC MAINTENANCE FOR THE 3-RING RELEASE SYSTEM The Booth 3-Ring Release System has been in use for many years with excellent results. Although the system is as durable as the rest of the harness/container assembly, it requires periodic maintenance and inspection to ensure proper operation. Generally it is NOT recommended that the risers be attached to the harness when new and then forgotten. Like all parachute gear, the 3-Ring Release should be carefully inspected and operated on a regular basis. This is especially important if the rig has not been used for 6 months or more, such as during the winter. Immediate inspection is required if it has been subjected to some abuse such as a drag across the runway, a water landing or exposure to a lot of dust or sand. Yearly or as needed, operate the 3-Ring Release System on the ground. Extract the cable completely from the housings and disconnect the risers. Systems that have been in long-term storage only need to be serviced prior to putting into operational mode. While the system is disassembled, closely inspect it for wear. Check the white locking loops (the ones that pass over the smallest ring and through the grommet) to be sure they are not frayed or have taken a hard set. Check the Velcro on the breakaway handle and main lift web to be sure it is clean and adequately holds the handle. Debris in the hook Velcro can be cleaned out with a fine-toothed comb. Check the cable ends for a smooth finish. The ends are finished at the factory to have a smooth, tapered surface. This prevents the cable from hanging up in the loop. Check the cable ends and consult a rigger or the manufacturer if a burr or hook is present. Check the stitching, including that which holds the large rings to the harness. Pull downward on the housings. They shouldn t move downwards more than ½. Take each riser and vigorously twist and flex the webbing near where it passes through each ring. The idea is to remove any set or deformation of the webbing. Do the same thing to the white loop. Check the housings for dents or other obstructions. Use the cable to do this. Clean and lubricate the release cable with a silicone spray or light oil such as a 3-in-1 brand. Put a few drops on a paper towel and firmly wipe the cable a few times. A thin invisible film should remain too much will attract grit and dirt, or the oil could become tacky in cold weather. Too little oil will require more force to extract the cable during a breakaway. Inspect the fittings at the end of each housing. If one of these fittings were to come off the housing, a riser might release prematurely. If any wear is found, consult a rigger or the manufacturer before using. Reassemble the system. Double check it. Make sure the risers aren t reversed. It s important to maintain the system even more frequently in humid, muddy or freezing conditions. If the container system becomes immersed in mud or muddy water, clean the 3-Ring Release System with a mild solution of soap and water. Any rusted components must be replaced. 3-14

125 Rigging the 3-Ring Release System 3-Ring Release Cable Lengths: After the cables have been installed in the housings of your harness/container there should be 7 of excess cable on the RSL side and 6 of excess cable on the non-rsl side. These measurements can vary slightly due to slight housing variations. A tolerance of ± ¼ (6.5mm) is acceptable when installed. Pass the ring on the end of the riser through the large ring from above. Fold it back toward the front riser Thread the smallest ring through the middle ring in the same way, ensuring it doesn t pass through the larger ring. Figure Insert Second Ring Bring the locking loop over the small ring only and then down through the riser grommet so it passes through the back of the riser. Figure Insert Third Ring Figure Insert Locking Loop through the Riser 3-15

126 Continue threading the locking loop through the grommet on the end of the cable housing. The flat side of the cable housing grommet should be against the riser. Thread the cable through the locking loop, ensure the locking loop isn t twisted. Do not put a sharp bend in the cable, as this may put a permanent kink in it After locking the loop, ensure all cable slack has been pulled from the cable housing. Insert the free end of the cable in the channel on the back of the riser. Repeat the above steps with the other riser. Figure Release Cable through Locking Loop Attach the reserve staticline (RSL) shackle to the ring located on the side of the right riser and secure tab with the snap. >>RIGGER CHECK<< Figure Cable into Retention Channel Figure Properly Rigged 3-Ring Release 3-16

127 3.4. Flat Packing the Main Parachute for DBSL Installing The Slider Reefing Line System Place the four bridle connector links through the grommet at the top of the inner bag. Pull the bridle through the grommet until the bag stop hits the grommet. Attach the bridle end to the pilot chute using a lark s head knot Place the four bridle connector links through the grommet located on top of the main parachute. Lift the grommet. Push the red lines into the grommet and shake the grommet area to work the connector links through the grommet located at the bottom of the parachute. Figure Pilot Chute Attached to Bridle Once one of the links has come through you may use it to pull the remaining links through. Figure Connector Links through Top Grommet Figure Lines Pulled Through 3-17

128 With the harness/container facing the packing surface, spread the right and left line groups apart. Place the bridle and connector links near the slider. Ensure there are no twists in the red lines Install the links onto the slider loops. Links should be finger tight. Ensure that all lower bridle links are installed as illustrated with the short end of the link through the slider loop. Figure Bridle and Connector Links near Slider Figure Bridle Reefing Line Attached to Slider 3-18

129 With the harness/container backpad facing the packing surface, spread the right and left line groups apart. Ensure that the bridle runs from the slider to the grommet on the bottom of the main parachute without interference from any suspension line. >>RIGGER CHECK<< Figure Reefing Line Routing Check 3-19

130 FOLDING AND FLAKING THE MS MAIN PARACHUTE FOR DBSL In one hand gather all the packing tabs located on the parachute s top surface. Begin with the tabs located near the trailing edge. Keep them separate from the tabs located on the leading edge. Once you have nine tabs each from the trailing and leading edge, put some tension on the lines, spread the tabs and lay the parachute on the packing surface. NOTE: Pilot chute and reefing bridle are not shown in following figures Make a thorough inspection of all components of the main parachute: pilot chute, reefing bridle, deployment bags, main parachute, lines, slider, and links. Complete a suspension line continuity check of the outside 4-line and brake lines. Figure Nine Packing Tabs Straighten the top seams. Figure Inspection and Continuity Check Flake the leading edge by clearing the nose cells. Figure Nose Cells Cleared 3-20

131 A. Fold the nose even with line group B. Fold line group A onto line group Figure Nose Folded Fold line group D on top of line group C. Figure Line Group A onto Line Group B Figure Line Group D over Line Group C 3-21

132 Pull the slider reefing line through the grommet located on the top surface of the parachute as shown. This will pull the slider up the lines towards the slider stops. Smooth the fabric out and keep tension on the line groups that have been rolled or stacked Continue to pull the slider into the parachute, between the stabilizers against the slider stops. Ensure the slider is between the red attachment lines as shown. Figure Slider against Slider Stops Note that the slider is positioned against the slider stops, between the stabilizers. Figure Slider into Parachute, between Red Lines Figure Slider against Slider Stops 3-22

133 tension. Grasp the C-D lines, maintaining Place the C-D line group on top of A-B line group. Keep tension on the C-D line group with one hand. Grasp the tail line group with the other hand and with a sweeping motion, place it on top of the C-D line group. Figure Grasp C-D Lines Setting the Main Deployment Brakes Pull the steering line brake setting cat-eye through the guide ring. Pass the brake locking loop through the steering line cateye. Figure C-D Lines on A-B Lines Figure Cat-Eye through Guide Ring 3-23

134 Insert the toggle tip through the locking loop. Insert the toggle tip into the upper keeper, ensuring that the control line above the cateye is inboard of the riser as shown Lock the lower steering toggle down by putting the lower toggle tuck tab in the lower keeper on the back of the riser. Ensure that the loop of the control line below the cat-eye is outboard of the riser as shown. Figure Tip through Loop Thread the folded end of the steering line from bottom to top through the elastic loops located on the back of the riser. Figure Toggle Locked Figure Completed Toggle 3-24

135 Flake the tail section by folding each cell into quarters by beginning with the end cell. Fold each half cell in half to resemble an S- fold of the entire tail section on each side. Ensure that the upper steering lines are placed in the middle during the flaking so that all are stacked on the major line groups. Repeat this process on the other side of the tail section Repeat this process on the other side of the tail section. When finished, the warning label must be on top of the completed tail section. Ensure that the stabilizers are cleared, especially the B-C and C-D stabilizers located on the nose side. Figure Flake the Tail Pull the parachute trailing edge down so that it is flush with the slider grommets. Wrap the tail section around the parachute to cocoon the flaked parachute. >>RIGGER CHECK<< Figure Warning Label on Top of Tail Figure Trailing Edge Flush with Slider Grommets 3-25

136 Place one hand under the slider and one hand on top the parachute approximately from the trailing edge of the parachute. Make the first fold by bringing the trailing edge on top of the parachute. Ensure that the corners on the slider grommets are pointing towards the harness/ container. NOTE: You must be able to see the Parachute Packing/Deployment Log placard Using the forearms and knees press the air out of the main parachute. Figure First S-Fold While keeping your knees on the first S-fold, bring the parachute up to your chest and place your hand at the same width as the bottom fold. Make the second S-fold by making a fold on top of the first fold. Figure Press Air Out Figure Second S-Fold 3-26

137 Complete the second S-fold by placing the fold on top of the first fold Closing the Main Deployment Bag for DBSL Expose the top parachute surface grommet so that it can be matched up with the inner staticline bag grommet when placed into the inner staticline bag. Figure Completed S-Fold Place the S-folded main parachute into the inner staticline bag. Figure Match Parachute and Inner Bag Grommet At the locking stow loop attachments, place natural colored tandem Tube Stoes on locking stows one and two. NOTE: Locking stow attachment points three through twelve use 2 ⅜ standard retainer bands. Flap-2 Flap-1 Figure Place the Main Parachute in the Bag 3-27

138 Ensure that the two grommets line up and that no fabric is trapped between the grommets. Lightly pull any slack out of the bridle that may be trapped between the grommets. >> RIGGER CHECK << Rigger s view, facing the deployment bag and away from the harness, place Flap-1 over the bag. Place the Tube Stoe through the left grommet on Flap-1. Figure Flap-1 Left Grommet Ensure Grommets Are Clear of Any Fabric Flap Place Flap-2 over the bag. Figure Insert First Tube Stoe Place the same Tube Stoe through the left grommet on Flap-2. Pull the bridle and place a 2 ± ½ bridle bight into the Tube Stoe. NOTE: The 2 bridle bight shall be typical for all bridle bights when closing the inner staticline bag. Flap-2 Left Grommet Flap-1 Flap-2 Figure Secure First Bridle Bight 3-28

139 Fold Flap-2 back to get access to the adjacent Tube Stoe. Grasp the Tube Stoe and place it through the adjacent grommet on Flap-1. Flap-2 Flap Return Flap-2 back in position then place the Tube Stoe through the grommet on Flap-2. Place a bridle bight in the Tube Stoe. Figure Pull Tube Stoe through Flap-1 Grommet Flap-1 Flap bag. Locate the retaining band at mid Figure Pull Tube Stoe through Flap -2 Grommet 2 Place the retainer band through the grommet on Flap-1. NOTE: The remaining stows shall be made using 2 ⅜ retainer bands. NOTE: Each bridle bight shall have two wraps with the retainer band. Flap-2 Flap-1 Figure met Place Retainer Band through Flap-1 Grom- 3-29

140 Place the same retainer band through the grommet on Flap-2 and place a bridle bight in the retainer band. NOTE: Each bridle bight shall have two wraps with the retainer band. Flap-2 Flap At the top of the bag, place the retainer band through the grommet on Flap-1. Figure Place the Third Bridle Stow Flap-2 Flap Take the same retainer band and place it through the grommet on Flap-2. Place a bridle bight in the retainer band. NOTE: Each bridle bight shall have two wraps with the retainer band. Figure Prepare Fourth Bridle Stow Flap-2 Flap-1 Figure Secure Fourth Bridle Stow 3-30

141 quence. Complete the locking stow se- Stow 2 Stow 1 Stow 3 Stow 6 Stow 4 Stow Use one bridle fold for stows 7 and 8, and then use two bridle folds for the remaining stows. Set the bag upright and continue stowing the bridle. Figure Completed Locking Stows Bridle Stop NOTE: Each bridle bight shall have two wraps with the retainer band. NOTE: Ensure that the bridle stop is located between stows as shown. >> RIGGER CHECK << Stow Preparing outer bag: Attach the staticline to the outer staticline bag with a lark s head knot. Install 2 ⅝ tandem retainer bands on all band attachment loops. Then place one strand of 8/7 cotton ticket* long through the tab located on top of the pilot chute as shown. * Cord Specifications 8/7 COTTON 1LB KS ODS T/IVB VT-276H Manufacturer: Eddington Thread Manufacturing Figure ment Bag Figure Properly Stowed Bridle on Inner Deploy- Cotton Ticket through Pilot Chute Tab 3-31

142 Place the pilot chute into the outer bag. Route both ends of the 8/7 cotton ticket through the grommet of the outer staticline bag. Pull both ends of the 8/7 cotton ticket through the grommet Wrap the cotton ticket around the staticline attachment webbing as shown. Figure Cotton Ticket through Grommet Tie the cotton ticket to the outer staticline bag with a surgeon s knot, followed by a locking knot, creating a 3 loop. Figure Cotton Ticket around Staticline Webbing Figure Pilot Chute Tied to Staticline Bag 3-32

143 The resulting loop should be approximately three finger widths in length as shown Trim the break cord approximately 1 from the knot. Figure View of Loop inside of Outer Bag Lay the outer staticline bag on the packing surface. Arrange the pilot chute over the bag. Long fold the pilot chute twice. Ensure that there is of bridle left unstowed between the pilot chute base and the final bridle stow. Figure Trim Break Cord 1 from Knot Figure Long Fold Pilot Chute Twice 3-33

144 Short fold the pilot chute so that it is the same width as the outer bag Short fold the pilot chute and place in the outer staticline bag. Pull the outer staticline bag up while pushing the pilot chute down into the bag. >>RIGGER CHECK<< Figure Short Fold Pilot Chute Once Roll the inner staticline bag containing the main parachute forward. Place the corners of the inner staticline bag onto the outer staticline bag. Push the inner bag into the outer bag until it is completely inside the other bag. Figure Place the Pilot Chute into the Outer Bag Figure Place the Inner Bag into the Outer Bag 3-34

145 Starting with either right or left center locking stow retainer bands, draw the flap and bag mouth together. Place the retainer band through the white Type III nylon cord loop Open the retainer band and insert a bight of lines 2 ½ ± ½ measured from the retainer band to the outside edge of the bight. Figure Start with Either Center Locking Band 2½ ± ½ Repeat the stow procedure on the other center locking stow retainer band. Figure Insert First Bight of Lines Figure Repeat on Other Side 3-35

146 Make the two locking stows. Ensure that they are made using the same procedure as the first two locking stows. Stow the remaining lines by placing the retainer band through the white Type III nylon cord loop, then by placing a line bight in the retainer band. NOTE: Make the last line stow so there is approximately of suspension lines between the last stow and the connector links Closing the Main Container for DBSL Place the main parachute below the main container. Place the main risers along the shoulder line and tuck them into the space between the container flaps and riser covers. Ensure that the risers lay flat along the shoulder line and into the pack tray. Ensure that the risers do not have any twist in them. Do not allow any slack in the risers after they are set Place a pull-up cord through the main closing loop. Place the main parachute in the main container pack tray. Tuck the bottom corners of the bag into the container. Pull both line groups on the right and left risers out of the container near the connector links. Make a 2 line stow bight on the right line group and place it in the retainer band attached to the top of the staticline bag. Use two wraps with the retainer band. Do the same process on the left line group. Press all four corners of the bag into the pack tray. >> RIGGER CHECK << Figure Figure Figure Stow the Remaining Lines Arrange the Risers Set the Staticline Bag 3-36

147 Ensure that the static line is placed to the right side. Thread the pull up cord through the closing loop on the Flap-1. Pull the closing loop through the grommet on until the loop surfaces. Flap-1 You may pin the loop with the staticline cable pin, temporary locking pin or continue holding the pull up cord and loop with the knee Thread the pull up cord through the grommet on Flap-2 and pull the closing loop through the grommet until it surfaces. Figure Close Flap-1 If used, pull the staticline cable pin cable from the closing loop and place it back in the loop above Flap-2. Flap-2 Flap Thread the pull up cord through the grommet on Flap-3 and pull the closing loop through the grommet until it surfaces. Figure Close Flap-2 If used, pull the staticline cable pin from the closing loop above Flap-2 and place it back in the loop above Flap-3. Flap-2 Flap-3 Figure Close Flap

148 Thread the pull-up cord through the grommet on Flap-4 and pull the closing loop through the grommet until it surfaces. If used, pull the staticline cable pin from the closing loop and place it back in the loop above Flap-4. Slowly pull the pull-up cord out of the closing loop pulling away from the tip of the cable pin. Route the staticline to the right. Tuck the main pin protection flap under Flap-2. Flap-3 Flap Stow the staticline beginning with the lower right retainer band by placing a 3 bight using 2 wraps with the retainer band. Figure Close Flap-4 Stow 1 Stow Continue with the same process back and forth until there is enough staticline left to stow the staticline clip in the clip pocket. NOTE: Each staticline stow must be held in place with two wraps of a 2-3/8 retainer band. Rotate the flexpin and place in the ripcord channel. Figure Begin to Stow the Staticline >> RIGGER CHECK << Figure Completed Staticline Stows 3-38

149 pocket. Stow the staticline clip in the clip Figure Completed DBSL Configuration 3-39

150 Flat Packing the Main Parachute PARACHUTE RIGGER PACKING TOOL CHECKLIST This checklist, or a checklist approved by your command, is to be used with each auxiliary parachute inspection and repack cycle. An inventory of the packing tools must be done before the work is to begin and after the work has been completed. Multiple tools of the same type must be counted and recorded. If zero used, mark 0 in the blank provided next to that tool. Some of the tools listed below are optional and may be used to perform the rigger s duties. Some tools may damage the parachute system if used incorrectly. If left in the completed packed parachute, some tools will prevent the parachute from opening properly. This will cause injury or death to the jumper. If you are unfamiliar with any tool refer to Poynter s Parachute Manual or U.S. DOT FAA Parachute Rigger Handbook, FAA-H Check After Completion Pre-inspection Post-Inspection Packing Paddle (wood) each packing Paddle (wood) each Packing Paddle (metal) each packing Paddle (metal) each Shot Bags each Shot Bags each Pull-Up Cords each pull-up Cords each Locking Pull-Up Cord each locking Pull-Up Cord each Leverage Device each leverage Device each Molar Strap each Molar Strap each Velcro Line Protectors each velcro Line Protectors each Temporary Locking Pin each temporary Locking Pin each Temporary Tacking each temporary Tacking each Tensioning Device each tensioning Device each Pull Check Tool each pull Check Tool each Packing Hook each packing Hook each Needle each needle each Nipper each nipper each Scissors each Scissors each Bodkin each Bodkin each Seam Ripper each Seam Ripper each Closing Plate each Closing Plate each Power Tool each power Tool each Para Tool (pliers) each para Tool (pliers) each Wrench each wrench each NOTE: Follow your unit s SOP RIGGER CHECKS, which may be at different points in the packing process than the listed CPS-recommended RIGGER CHECKS. 3-40

151 Preparing the Main Deployment Bag for Freefall Configuration Start by installing 2 x ⅜ retainer bands on all stow loops. Install the main parachute deployment bag by turning it inside out. Locate the loop sewn to the inside top. Place the loop through the bag attachment ring located on the center cell of the main parachute. Now place the entire bag through the loop sewn to the bag to produce a lark s head knot Attach the pilot chute bridle by placing it through the channel in the loop sewn to the top outside of the main parachute deployment bag. Run one end of the bridle through the loop on the opposite end making a lark s head knot. NOTE: Yellow bridle shown for illustration purposes only. >>RIGGER CHECK<< Figure Parachute Attached to Deployment Bag Figure Pilot Chute Attached to Deployment Bag 3-41

152 cord Installing the Main Rip- Insert the main ripcord into the cable housing and check the cable for freedom of movement Secure the main ripcord handle in the ripcord pocket. Ensure that the handle is fully inserted into the pocket. Figure Check Cable Movement Figure Main Ripcord Handle Inserted 3-42

153 Flaking and Folding the Main Parachute In one hand gather all the packing tabs located on the parachute top surface. Begin with the tabs located near the trailing edge. Keep them separate from the tabs located on the leading edge. Once you have nine tabs each from the trailing and leading edge, put some tension on the lines, spread the tabs and lay the parachute on the packing surface Complete a suspension line continuity check of the outside four lines and brake lines. Figure Front and Rear Packing Tabs Straighten the top seams. Flake the leading edge by clearing all nine nose cells. Figure Inspection and Continuity Check Figure Clear the Nose Cells 3-43

154 A. Fold the nose even with line group B. Fold line group A onto line group Figure Nose Folded Fold line group D on top of line group C. Figure Line Group A onto Line Group B Figure Line Group D over Line Group C 3-44

155 Pull the slider up the lines towards the slider stops. Smooth the fabric out and keep tension on the line groups that have been rolled or stacked Continue to pull the slider into the parachute, between the stabilizers against the slider stops. Figure Slider towards Slider Stops Note that the slider is positioned against the slider stops, between the stabilizers. Figure Slider into Parachute Figure Slider against Slider Stops 3-45

156 tension. Grasp the C-D lines, maintaining Place the C-D line group on top of A-B line group. Keep tension on the C-D line group with one hand. Grasp the tail line group with the other hand and with a sweeping motion, place it on top of the C-D line group. Figure Grasp C-D Lines Setting the Main Deployment Brakes Pull the steering line brake setting cat-eye through the guide ring. Pass the brake locking loop through the steering line cateye. Figure C-D Lines on A-B Lines Figure Cat-Eye through Guide Ring 3-46

157 Insert the toggle tip through the locking loop. Insert the toggle tip into the upper keeper, ensuring that the control line above the cateye is inboard of the riser as shown Lock the lower steering toggle down by putting the lower toggle tuck tab in the lower keeper on the back of the riser. Ensure that the loop of the control line below the cat-eye is outboard of the riser as shown. Figure Tip through Loop Thread the folded end of the steering line from bottom to top through the elastic loops located on the back of the riser. Figure Toggle Locked Figure Completed Toggle 3-47

158 Ensure that all the stabilizers are cleared, especially the B-C and C-D stabilizers. Flake the tail section by folding each cell into quarters by beginning with the end cell. Fold each half cell in half to resemble an S- fold of the entire tail section on each side. Ensure that the upper steering lines are placed in the middle during the flaking so that all are stacked on the major line groups Repeat this process on the other side of the tail section. When finished, the warning label must be on top of the completed tail section. Figure Flake the Tail Section Pull the parachute trailing edge down so that it is flush with the slider grommets. Wrap the tail section around the parachute to cocoon the flaked parachute. >>RIGGER CHECK<< Figure Warning Label on Top of Tail Figure Trailing Edge Flush with Slider Grommets 3-48

159 Place one hand under the slider and one hand on top the parachute approximately from the trailing edge of the parachute. Make the first fold by bringing the trailing edge on top of the parachute. Ensure that the corners on the slider grommets are pointing towards the harness/ container. NOTE: You must be able to see the Parachute Warning Label Make the second S-fold to prepare the canopy for insertion into the main deployment bag. Figure First S-Fold Figure Complete the S-Folds 3-49

160 Over-the-Shoulder Pro-Packing the Main Parachute PARACHUTE RIGGER PACKING TOOL CHECKLIST This checklist, or a checklist approved by your command, is to be used with each auxiliary parachute inspection and repack cycle. An inventory of the packing tools must be done before the work is to begin and after the work has been completed. Multiple tools of the same type must be counted and recorded. If zero used, mark 0 in the blank provided next to that tool. Some of the tools listed below are optional and may be used to perform the rigger s duties. Some tools may damage the parachute system if used incorrectly. If left in the completed packed parachute, some tools will prevent the parachute from opening properly. This will cause injury or death to the jumper. If you are unfamiliar with any tool refer to Poynter s Parachute Manual or U.S. DOT FAA Parachute Rigger Handbook, FAA-H Check After Completion Pre-inspection Post-Inspection Packing Paddle (wood) each packing Paddle (wood) each Packing Paddle (metal) each packing Paddle (metal) each Shot Bags each Shot Bags each Pull-Up Cords each pull-up Cords each Locking Pull-Up Cord each locking Pull-Up Cord each Leverage Device each leverage Device each Molar Strap each Molar Strap each Velcro Line Protectors each velcro Line Protectors each Temporary Locking Pin each temporary Locking Pin each Temporary Tacking each temporary Tacking each Tensioning Device each tensioning Device each Pull Check Tool each pull Check Tool each Packing Hook each packing Hook each Needle each needle each Nipper each nipper each Scissors each Scissors each Bodkin each Bodkin each Seam Ripper each Seam Ripper each Closing Plate each Closing Plate each Power Tool each power Tool each Para Tool (pliers) each para Tool (pliers) each Wrench each wrench each NOTE: Follow your unit s SOP RIGGER CHECKS, which may be at different points in the packing process than the listed CPS-recommended RIGGER CHECKS. 3-50

161 cord Installing the Main Rip- Insert the main ripcord into the cable housing and check the cable for freedom of movement Secure the main ripcord handle in the ripcord pocket. Ensure that the handle is fully inserted into the pocket. Figure Check Cable Movement Line Continuity Check Figure Main Ripcord Handle Inserted Complete a suspension line continuity check of the outside four lines and brake lines. Figure Inspection and Continuity Check 3-51

162 Setting the Main Deployment Brakes Pull the steering line brake setting cat-eye through the guide ring. Pass the brake locking loop through the steering line cateye Insert the toggle tip through the locking loop. Insert the toggle tip into the upper keeper, ensuring that the control line above the cateye is inboard of the riser as shown. Figure Cat-Eye through Guide Ring Lock the lower steering toggle down by putting the lower toggle tuck tab in the lower keeper on the back of the riser. Ensure that the loop of the control line below the cat-eye is outboard of the riser as shown. Figure Tip through Loop Figure Toggle Locked 3-52

163 Thread the folded end of the steering line from bottom to top through the elastic loops located on the back of the riser. >>RIGGER CHECK<< Flaking and Folding the Main Parachute Facing the main parachute, use your fingers to separate the front and rear suspension lines. Separate the steering lines with your thumbs as shown. Figure Completed Toggle Keeping the suspension line groups separated, walk towards the parachute, pushing the slider as you go. Figure Separate the Suspension Lines Figure Right Line Groups in Right Hand, Left Line Groups in Left Hand 3-53

164 Separate the right and left line groups and shake the parachute side to side to organize the fabric. When a collapsible slider is used, be sure to release the locks and extend the slider to its full shape and size With the left and right sides of the parachute/slider even, bring all suspension line groups together. Figure Settle the Fabric Place all lines over one shoulder (or on a suspended packing hook). Figure Bring Suspension Lines Together Figure Place Lines Over Shoulder 3-54

165 Starting with the parachute end cell nearest the body, pull out the leading edge cells one at a time to clear and organize the nose Continue pulling all leading edge cells from both sides until the nose is all to one side. Figure Clear Each Nose Cell Figure Clear and Organize the Nose 3-55

166 Place the organized nose between the knees to keep the nose under control Starting with either the right or left side, locate and separate the A and B-line groups. Place your arm between the line groups down into the parachute and push the parachute fabric to the outside. Repeat this process between the B and C- line groups then the C and D-line groups. Repeat this process on the opposite side of the parachute between each line group. Figure Place Parachute Nose Between Knees Figure Push the Fabric to the Outside 3-56

167 Looking down into the parachute, the lines should be toward the inside and each cell neatly flattened toward the outside Once the line groups are all unobstructed, clear the stabilizers. Figure Overhead View Figure Clear the Stabilizers 3-57

168 Quarter the slider by pushing the fabric into the center of the pack job and pulling the fabric outward between all four line groups, left and right and then front and rear. Follow the stabilizers on each side all the way through to the tail section. Create a lapel fold and flake the tail section. >>RIGGER CHECK<< Reach down and pick up the tail at the center point of the trailing edge. NOTE: The warning label is located on the center cell. Figure Quarter the Slider Figure Pick Up the Tail 3-58

169 Center the warning label on the line groups and wrap the trailing edge around the line groups. Figure Wrap the Tail around the Line Groups 3-59

170 Dress the tail by bringing both sides of the tail around the canopy, pulling light tension to smooth out the fabric. Figure Dress the Tail 3-60

171 Wrap the tail away from your body as shown. Three (3) to four (4) turns is sufficient Slide your hand under the canopy and gently swing it away from your body and lay the canopy down on the packing surface. Figure Wrap the Tail Figure Place Parachute on Packing Surface 3-61

172 Kneel on the warning label to maintain tension on the lines and wrapped tail. Wrap the canopy sides under the main portion of the pack job so the cocooned parachute is the same width as the main deployment bag Make the first S-fold approximately 6-8 in length. Figure Cocoon the Parachute Make the second S-fold to prepare the canopy for insertion into the main deployment bag. The remaining fabric from the top of the canopy can be rolled under. Ensure the bag attachment point is centered and exposed as shown. Figure Begin the S-Fold Figure Complete the S-Folds 3-62

173 3.7. Closing the Main Deployment Bag Prepare the deployment bag by inspecting the retainer bands. Replace any unserviceable retainer bands. Carefully place the deployment bag flap under the folded parachute. Begin placing the parachute into the main deployment bag (flap down) by placing one end of the parachute in the bag Finish with the opposite side. Work the parachute into the corners of the bag. Place a hand between the S-folds to push fabric down into corners. Figure Insert Left Half of Parachute into Main Bag The main deployment bag is now ready to close. Figure Insert Right Half of Parachute into Main Bag Figure Ready for Locking Stows 3-63

174 Begin closing the bag by inserting one of the center stow bands (left or right - rigger s choice) into the corresponding grommet on the flap. Insert a bight of lines 3½ ± ½ measured from the retainer band to the outside edge of the bight. NOTE: All locking stows are singlewrapped. 3½ ± ½ Place the second locking stow at the innermost retainer band on the opposite side. Insert a bight of lines 3½ ± ½ measured from the retainer band to the outside edge of the bight. NOTE: All locking stows are singlewrapped. Figure First Locking Stow Place the third locking stow at the outermost retainer band on the same side as the first stow. Insert a bight of lines 3½ ± ½ measured from the retainer band to the outside edge of the bight. Now place the fourth stow using the same procedure. NOTE: All locking stows are singlewrapped. Figure Second Locking Stow Figure Third and Fourth Locking Stows 3-64

175 Stow the remaining lines as shown until there is of suspension line remaining. >>RIGGER CHECK<< Figure Stow Remaining Suspension Lines 3-65

176 3.8. Closing the MJ Main Container for Over-the-Shoulder Ripcord Configuration Main Closing Loop in Base of Main Pack Tray Once all suspension lines are properly stowed, lift the main parachute by the bridle then lay the bag down just below the main container. Take any twist out of the risers and place them flat along side of the reserve container. NOTE: Place the main risers ON TOP of the sub Flap-which lays on top of the reserve risers. Ensure that there is no slack in the risers between the 3-Ring riser attachment and the parachute connector links as shown Before placing the main parachute in the main pack tray, place a pull-up cord in the main closing loop. Ensure the main closing loop does not exceed 6½ in length. Figure Deployment Bag Below Main Container Main Closing Loop Retainer Reserve Container Main Deployment Bag Lift the main parachute deployment bag up and place it into the pack tray with the lines facing down in the tray. The bridle attachment must be on top facing up. Figure Main Closing Loop Anchor Figure Place Deployment Bag into Pack Tray 3-66

177 Place the kicker sub flap connected to flap-1, over the main deployment bag. S-fold the entire main parachute bridle to a width of 8 ± 1. Place it on top of the sub flap Place the base of the spring-loaded pilot chute on top of the folded bridle and deployment bag. Begin compressing the spring from the bottom of the pilot chute placing fabric in between each coil. Work your way up to the pilot chute cap until the spring is completely compressed. Hold the compressed pilot chute down with one knee, and then thread the pull-up cord through the grommet on the Flap-1. Continue holding the pilot chute cap down and pull the closing loop through the grommet until the loop surfaces. You may temporarily pin the loop with the ripcord pin or continue holding the pull-up cord and loop with the knee Thread the pull-up cord through the grommet on Flap-2 and pull the closing loop through the grommet until the closing loop surfaces. If used, pull the ripcord pin from the closing loop and insert it above Flap-2. Figure Figure S-Fold Main Parachute Bridle Pilot Chute Base on Top of Bridle Figure Close Flap

178 Thread the pull-up cord through the grommet on Flap-3 and pull the closing loop through the grommet until it surfaces Thread the pull-up cord through the grommet on Flap-4 and pull the closing loop through the grommet until it surfaces. Using the ripcord pin, pin the closing loop above Flap-4. To avoid damage to the locking loop, move the pull-up cord to the side and under the ripcord pin prior to removal. Slowly pull the pull-up cord out of the closing loop. Tuck the main pin flap in under Flap-2. Figure Close Flap Close riser flaps. Figure Close Flap-4 and Pin MJ parachute system pack job completed. Count your tools. >>RIGGER CHECK<< Figure Completed Pack Job 3-68

179 Closing the MJ Container: Main Closing Loop in Flap-1 Once all suspension lines are properly stowed, lift the main deployment bag with one hand controlling the last line stow, and lay the bag down on top of the reserve. Place the risers in the riser stowage channel with the rear risers against the reserve container. Stagger riser ends to reduce bulk. Ensure there is no slack in the risers between the 3-Ring riser attachment and the parachute connector links as shown Before placing the main parachute in the main pack tray, place a pull-up cord in the main closing loop. Ensure the main closing loop does not exceed 1½ in length. Figure Deployment Bag on Reserve Container Lift the main parachute deployment bag up and place it into the pack tray with the lines facing down in the tray. The bridle attachment must be on top facing up. Figure Main Closing Loop Anchor Figure Deployment Bag into Pack Tray 3-69

180 Place the kicker-sub flap connected to Flap-1 over the main deployment bag. S-fold the entire main pilot chute bridle to a width of 8 ± 1. Place it on top of the sub-flap. kicker sub-flap Place the base of the spring-loaded pilot chute on top of the folded bridle and deployment bag. Begin compressing the spring from the bottom of the pilot chute placing fabric in between each coil. Work your way up to the pilot chute cap until the spring is completely compressed. >>RIGGER CHECK<< 1 Figure S-Fold Main Parachute Bridle Hold the compressed pilot chute down with one knee, and then thread the pull-up cord through the grommet on the Flap-2. Figure Pilot Chute Base on Top of Bridle Continue holding the pilot chute cap down and pull the closing loop through the grommet until the loop surfaces. You may temporarily pin the loop with the ripcord pin or continue holding the pull-up cord and loop with the knee Figure Close Flap

181 Thread the pull-up cord through the grommet on Flap-3 and pull the closing loop through the grommet until it surfaces Thread the pull-up cord through the grommet on Flap-4 and pull the closing loop through the grommet until it surfaces. Using the ripcord pin, secure the closing loop above Flap-4. To avoid damage to the closing loop, move the pull-up cord to the side and under the ripcord pin prior to removal. Slowly pull the pull-up cord out of the closing loop. Figure Close Flap Flap-2. Tuck the main pin flap in under Figure Close Flap-4 and Pin Fill out main log record book. >>RIGGER CHECK<< Figure MJ parachute system pack job completed 3-71

182 3.9. Closing the MJ Main Container for BOC Hand Deploy Configuration Place the main parachute risers along side of the reserve container. Place the deployment bag into the main pack tray. Place a pull-up cord in the closing loop located in the grommet on Flap-1. Place the pilot chute bridle to the right top portion of the main container. Place the Flap-1 sub-flap on the bag and pull the pull-up cord toward Flap Thread the pull-up cord through the grommet on Flap-2. Ensure that the pilot chute bridle is placed to the right side and the top end of the main container as shown. Pull the closing loop through the grommet on Flap-2. To temporarily hold the closing loop in place put a knee on the loop to hold it in place or pin the closing loop with the curved locking pin located on the pilot chute bridle Thread the pull-up cord through the grommet on Flap-3. Pull the closing loop through the grommet on Flap-3. To temporarily hold the closing loop in place put a knee on the loop to hold it in place or pin the closing loop with the curved locking pin located on the pilot chute bridle. Figure Figure Close Flap-1 Close Flap-2 Figure Close Flap

183 Thread the pull-up cord through the grommet on Flap-4. Pull the closing loop through the grommet on Flap-4. Pin the closing loop with the curved locking pin located on the pilot chute bridle. Slowly remove the pull-up cord by pulling one end in the same direction that the pin is pointing Place and tuck the bridle that is above the pin between Flaps-2 and -4. Tuck the bridle under the bridle protection flap sewn to the right of Flap-1. Figure Close Flap Ensure that the bridle is tucked under the bridle protection flap from the closing pin to the point where the bridle protection flap meets the container back pad. Figure Tuck Bridle Protection under Flap Figure Ensure Bridle Is Secure 3-73

184 Place the pilot chute with the mesh facing away from the packing surface and near the main container. Fold the pilot chute in thirds as shown S-fold the remaining bridle the same width as the fabric fold. Leave of bridle between the mouth of the elastic bottom of container (BOC) pocket and the S-fold. This will allow enough length in bridle to allow pilot chute insertion into the BOC pocket. Figure Fold Pilot Chute in Thirds Fold half the pilot chute over toward the container. This will expose the pilot chute handle as shown. Figure S-Fold Remaining Bridle Figure Half-Fold Pilot Chute Toward Container 3-74

185 Fold half of the folded pilot chute into thirds again Fold the other half of the folded pilot chute into thirds. Figure Fold First Half of Folded Pilot Chute Fold the folded pilot chute twice. Figure Fold Remaining Half in Thirds Figure Fold Pilot Chute Twice 3-75

186 Place the folded pilot chute and remaining bridle into the elastic BOC pocket Ensure that the pilot chute handle is correctly positioned. WARNING: DO NOT place the pilot chute handle in the elastic BOC pocket. Figure Stow Pilot Chute in BOC Figure Ensure Handle Is Clear 3-76

187 Chapter 4: Appendices 4-1

188 Parachute Information, Maintenance, and Repair 365-Day Repack Cycle 1300 E. International Speedway Blvd DeLand, FL USA Tel: Fax: DATE: Tuesday, November 21, 2006 TO: RE: CPS 365-Day Parachute Repack Cycle (Main and Reserve) Performance Designs, Inc. recognizes many factors may affect opening times of a packed, stored main parachute. Some of these factors are beyond the control of Performance Designs, Inc. Currently, too many of these variables exist to accurately quantify a maximum timeframe for which a main parachute may remain packed until use. Therefore, Performance Designs, Inc. recommends the end user pay very close attention to the following list of items. These items should be considered while the main parachute remains packed and stored. Factors that can affect the main parachute opening time include, but are not limited to:! The chemical reaction that occurs between rubber (rubber bands) and brass (deployment bag grommets). If left in contact with each other, a reaction between the rubber bands and brass grommets causes deterioration of the rubber. This can severely change the opening characteristics by creating a line dump scenario.! Excessive temperature. High temperatures, while increasing the elasticity of rubber, also decrease its strength.! Rubber degradation due to extended shelf life or storage conditions. If rubber is stored in excessive heat or for long periods without use, it can degrade and/or become brittle (dry rot).! Zero-porosity fabric has the potential to maintain its packed, brick-like shape over time. A remote possibility exists for the layers of packed fabric to take a set in its stored position after being compressed for some length of time. The longer the layers of fabric are compressed, the more potential for the fabric to take a set. CN NOV REV 0 4-2

189 1300 E. International Speedway Blvd DeLand, FL USA Tel: Fax: PD recommends the following in order to minimize some of these factors:! Ensure the use of non-brass (i.e. stainless steel) grommets on the D-bag to prevent the brass-rubber reaction.! Performance Designs, Inc. recommends the following storage conditions for the canopies: temperatures ranging between 60 F and 75 F and humidity ranging from 30% to 60%. For long-term storage and storage outside those ranges, we recommend representative samples be tested and/or inspected to ensure no harmful conditions have occurred during storage.! Replace all rubber bands when packing if there is a chance the parachute will be stored for an extended period of time. Use rubber bands with a recent manufacture date. Also make sure to exercise the rubber bands by stretching them. If a packed parachute has been dormant for a year, the rubber band may have become brittle and the user runs the risk of premature breakage. As long as the aforementioned conditions and factors are controlled and adherence to the guidelines is exhibited, Performance Designs, Inc. has no objections to the use of a 365-day repack cycle. If you have any further questions or comments, please do not hesitate to contact Performance Designs, Inc. Sincerely, Bill Coe Performance Designs, Inc. President CN NOV REV 0 4-3

190 4-4

191 MS-360 M3/M4 Placard Statement Minimum Weight Note: The MS-360 M3 & M4 warning labels contain the following statement: ** Minimum weight must be increased in degraded wind/ weather conditions. Consult technical manual. Ref:P01 Minimum Weight Considerations The minimum placarded weight applies to the canopy s use in stable wind and weather conditions. As winds and turbulence increase, the minimum safe weight needs to be increased progressively. The goal is to maintain a forward speed and descent rate that will help to increase flight stability throughout the control range of the canopy. Gusty wind conditions and turbulence are more problematic for the jumper when a canopy is lightly loaded. Jumping in these conditions should be avoided when they are known to exist. Defining rigid categories for each jumper s weight and skill level under various wind/weather conditions is not possible or practical. However, these general statements may provide additional guidance: Lightly loaded canopies will have a slower forward speed and descent rate and may not have sufficient penetration even in light winds. Turbulence will have a greater influence on the canopy. Light turbulence and wind gusts, which may allow canopies with higher wing loadings to fly through easily, may be sufficient to stall or collapse a lightly loaded canopy. Increasing suspended weight by attaching ancillary equipment to a light-weight jumper may be appropriate until the conditions become unsafe for jumping regardless of the weight and resultant wing-loading of the canopy. These concepts hold true for all canopies and many types of aircraft, however there comes a time when safe flight is not possible due to turbulence, excessive wind and other degrading weather conditions. ********* End of Statement 6/17/

192 CLEANING THE PARACHUTE ASSEMBLY Washing a parachute is not recommended unless deemed absolutely necessary. Washing a parachute can weaken and/or increase the permeability of the fabric. Washing can also cause shrinkage in the nylon fabric, tapes and the cotton/nomex components (i.e., bridle attachment area). Do not dry clean parachutes. Parachute components may be spot cleaned or cleaned as a unit and care must be taken that the cleaning process does not do more damage than the original soiling. This chapter also covers identification and removal of some types of contamination. Items such as acid, salt water and petroleum products are covered. HAND WASHING (IF ABSOLUTELY NECESSARY) 1. A mild soap or soap solution and a water softener may be used. 2. Immerse the parachute into clean, fresh water contained in a smooth vessel, such as a bathtub. 3. Do NOT wring the parachute fabric. Damage to fabric permeability will result. 4. Gently move items by hand until all air pockets are removed. Agitate as little as possible or damage to fabric permeability will result. 5. Empty the vessel of dirty water and refill with fresh warm, clear water. 6. Rinse the parachute several times in warm, fresh water until rinse water is clear. DRYING A PARACHUTE The procedure for drying a parachute is as critical as the procedure for washing it. Asymmetric shrinkage may occur if the parachute is dried unevenly. 1. Remove pilot chute assembly and/or drogue/slider control line. 2. Hang parachute full-length or the seams may experience uneven shrinkage creating a built-in turn. 3. Hang reserve parachute assembly by all four connector links for the same time. ACID CONTAMINATION Nylon that has been contaminated by acid may have irregular shaped spots of gray or dead white color. The acid-contaminated fabric may also become powdery when scraped lightly. Parachute components suspected of acid contamination may be tested with blue litmus paper. Dampen the suspect area with distilled water. Then lay the litmus paper on the area in question. If the paper turns pink, acid is present. Be careful not to touch the litmus paper. Touching the paper can cause an erroneous response. If an area tests positive for acid and the affected area is known to be localized, that area should be neutralized with a solution of distilled water and ammonia. Household ammonia will work. Ammonia will not damage nylon or hardware. The damaged area should be removed and the resulting hole should be patched. If the extent of contamination cannot be determined or if it affects large portions of the parachute, the parachute should be first destroyed then disposed of. 4-6

193 REMOVAL OF SALT WATER CONTAMINATION Crystals of dry salt and the presence of pale brown, circular stains are often evidence of salt-water exposure. If the parachute is allowed to dry after salt-water immersion without being rinsed in fresh water, salt crystals will form, causing damage to the fabric and suspension lines. Parachutes exposed to salt water should be rinsed out several times in warm, fresh water in a smooth tub. Use of a water softener is recommended. Hang assembly in drying tower in accordance with the section above entitled Drying a Parachute. The maximum complete salt-water immersion limits for the parachute are listed below. The parachute assembly should be cleaned within 8 hours of immersion. Remove from service any parachute assembly or sub-assembly for any of the following conditions: 1. Immersion in salt water for more than 6 hours if the parachute contains cadmium-plated parts. 2. Immersion in salt water for more than 24 hours if the parachute contains stainless steel parts (i.e., slider stops). 3. Immersion in salt water and cannot be cleaned for 36 hours. REMOVAL OF PERSPIRATION Perspiration causes damage to the parachute much like salt water does. Small amounts are not significant and may be ignored. For larger areas heavily contaminated, clean the parachute in accordance with the Removal of Salt Water Contamination section above. REMOVAL OF FRESH WATER Dry parachute assembly in accordance with the section above entitled Drying a Parachute. REMOVAL OF MILDEW 1. Wash affected area with mild soap and water solution. 2. Rinse affected area thoroughly with fresh, clear water. 3. Hang assembly in drying tower in accordance with the section above entitled Drying a Parachute. REMOVAL OF FIREFIGHTING AGENTS Parachute fabric and webbing exposed to light water, protein foam, PKP and any combination of such shall be thoroughly washed within 30 hours of exposure. Hang assembly in drying tower in accordance with the section above entitled Drying a Parachute. Metallic parts or components so exposed shall be disassembled as far as practical, washed, dried and examined. Metallic components treated in this manner may be returned to service if undamaged. Remove from service any parachute assembly or sub-assembly for any of the following conditions: 1. Contamination by soda-acid firefighting agent. Hardware items may be returned to service after cleaning. 2. Contamination by firefighting agents such as light water, protein foam, PKP or any combination of such, if not decontaminated within 30 hours. Hardware items may be returned to service after cleaning. 4-7

194 REMOVAL OF PETROLEUM PRODUCTS Hydrocarbons usually do not harm nylon. Petroleum products such as oil or grease have a greenish or brownish appearance. Wash the affected area by repeated applications of mild soap and water solution. Each application shall be followed by a rinse in clean, fresh water. 1. Continue washing and rinsing affected area until clean. 2. Hang assembly in drying tower in accordance with the section above entitled Drying a Parachute. REMOVAL OF BLOODSTAINS 1. Soak the stained area in cold water. 2. Hand wash affected area with mild soap and water solution. 3. Rinse affected area thoroughly with fresh clean water. 4. Hang assembly in drying tower in accordance with the section above entitled Drying a Parachute. REMOVAL OF SOIL 1. Hang the parachute and shake to remove most of the dirt and sand. 2. Brush lightly with a soft-bristled brush. 3. If the assembly is extremely contaminated, perform the following: a. Wash only the soiled areas in warm water with a mild soap. b. Rinse affected area thoroughly with fresh clean water. 4. Hang assembly in drying tower in accordance with the section above entitled Drying a Parachute. 4-8

195 REPAIR LIMITATIONS OVERVIEW This section contains some limitations to adhere to when performing parachute repairs. REPAIR QUALIFICATIONS Minor Repairs - a senior rigger or country s equivalent may perform minor repairs. Major Repairs - a master rigger or country s equivalent may perform major repairs. Factory Repairs - these repairs may only be performed at the Performance Designs factory. These include all repairs that are not specifically listed as minor or major repairs. PATCHES Holes or snags smaller than the size of one ripstop box (1/8, 3.2mm) may remain unrepaired as long as no more than one hole exists within any 10 (25.4cm) circle. A maximum of three such holes or snags per cell are allowed. Ripstop tape is not authorized for use on Performance Designs reserve parachutes. If the damage is enough to warrant a repair, a sewn repair must be performed. Darning is not a means of repairing Performance Designs parachutes. Any hole or tear up to 1 (25.4 cm) in length may be repaired by a senior rigger as long as the closest area of the completed repair is at least 1 from the nearest seam and at least 5 from the nearest tape or line attachment. These are minor repairs. MATERIALS Reserves may only be repaired using certified materials. All replacement materials must come from the Performance Designs factory. Under-strength thread and fabric is frequently found in the field. The only way to be sure materials meet Performance Designs standards is to obtain them directly from Performance Designs. 4-9

196 BASIC PATCH PROCEDURE OVERVIEW The Raghanti Basic Patch is recognized as the preferred patching method throughout the industry. The patching method does not require pins nor does it require a measuring square. The Raghanti Basic Patch can be made in almost any size as long as it falls within the limitations for patches (listed in Limitations section below). LIMITATIONS A senior rigger (or country s equivalent) is qualified to repair any damage up to 1 (25.4 cm) in length or width as long as the closest area of the completed repair will be: at least 1 (2.54 cm) from the nearest seam, and at least 5 (12.7 cm) from the nearest tape or line attachment. Small snags and holes smaller than 1/8 square (one ripstop box) located further than 10 (25.4 cm) from the closest line attachment may remain unrepaired as long as there is no more than one in any 10 (25.4 cm) diameter circle. A maximum of three such snags per cell are allowed. Ripstop tape is not authorized for use on Performance Designs reserve parachutes. If the damage is enough to warrant a repair, a sewn repair must be performed. EXAMPLE OF A 6 SQUARE PATCH Equipment and supplies needed: Marking pencil Single needle sewing machine with white E thread Square pieces of fabric of the same type and color as the parachute area that is to be repaired The following example shows two different color fabrics for clarity. Ruler Hemostat Scissors Nippers 4-10

197 Inspect the entire parachute for damage. Mark the boundaries of the damage. Allow 2 for repair from each boundary. A 6 patch will cover approximately two square inches of damage for this example.a seven inch square piece of fabric will be needed to make a 6 patch, using ½ seam allowance. Always place the patch on the inside of the parachute Measure half the patch size or 3 out to the left of the center of damage following one ripstop line in the fabric. Make a center line mark and a intersecting left border mark as shown. Measure half the patch size or 3 up to the left border ripstop line from the center line mark the top border and left border as shown. Count down ten ripstop boxes from the top border and make a mark. This is the start mark Count 14 ripstop boxes down from any corner of the seven 28 square piece and make a start mark. Figure Figure Locate and Mark Damaged Area Determine Patch Layout Figure Mark the Repair Starting Point 4-11

198 Make a 4-block fold in the patch, place the two start marks on top of each other using the hemostat to hold the 4-block seam allowance in place and sink the needle. Always sew in a counter clockwise direction around patches so the bulk of the parachute does not have to go through the bed of the machine. Beginning at the start mark, sew the first side to the mid point or the patch Count up four blocks from the bottom edge of the patch and use the hemostat to form a corner. Line up the ripstop boxes and load each piece with the same pressure. Then, sew to the corner maintaining 1/16 edge distance. Figure Establish the Start Point Repeat this step until you have sewn the first two corners down. At this point, check the last corner to ensure it will fall in the top and left border marks made when the measurement step was done. Then sew the last two corners down. It is important to pull the fabric the same speed the machine goes while sewing and to set the hook in the stitch loop before lifting the foot to turn a corner. Always make a 4-6 oversew past the start point. Figure Sewing the First Seam Figure First Two Corners Sewn Down 4-12

199 If the fabric was loaded correctly, the patch will be square and lay flat without any bubble Using the scissors, cut the damage out out of the parachute, making your initial cut to within seven ripstop boxes in from the stitching that holds the patch on. Be very careful not to cut the patch material. Figure First Side Complete Place your hand through the cut just made and remove the remaining damage seven stop blocks in from the stitching. Using your hand to protect the back side will prevent damaging the patch. Figure Begin Removing Damaged Material Figure Complete Removal of Damaged Material 4-13

200 Make a diagonal cut in each corner to within three ripstop boxes from the corner stitching Place the work under the sewing machine foot and, using the hemostat, grab one ripstop in the from the cut edge. Place the parachute fabric behind the fold back of the patch forming a French fell seam. Do this in two places and seat the one space box fold back against the patch stitch row with the tip of the hemostat. Sink the needle and repeat this step until the second side of the patch is sewn. Finish with a 4-6 oversew. NOTE: Begin sewing the side opposite of the original start point and sew around the parachute patch repeating this process on each side Ensure that each corner is fully seated and square. Use the side of the presser foot as a guide for stitching. Inspect the work thoroughly. Figure Figure Cut the Corners Preparing the French Seam Figure Completed Patch 4-14

201 LINE REPLACEMENT OVERVIEW Damaged suspension lines shall not be repaired. A Master Rigger or equivalent should replace the lines. Also, lines shall be replaced in pairs to minimize any asymmetrical line trim issues that may result from a single line replacement. Any line, tape or webbing damage is classified as a major repair and therefore can only be performed by a Master Rigger or his equivalent. REQUIRED EQUIPMENT AND MATERIALS 1. Replacement lines from manufacturer 2. V-T-295 size E nylon thread of the same color as used on the rest of the lines 3. Bar tack or zig-zag machine 4. Scissors 5. Seam ripper 6. Finger trapping needle COMPLETE STEERING LINE REPLACEMENT PROCEDURE 1. Remove the damaged steering line. 2. Starting with the outboard side, attach the new line to the parachute using the same knot as used on the other lines. 3. Bartack the fingertrap. Ensure the bartack originates at the fingertrap entry and extends toward the live side of the fingertrap. 4. Repeat steps 1 through 3 to attach all upper steering lines to the parachute. 5. Thread the lower steering line through the slider and steering line guide ring on the riser and tie to the steering toggle or loop. 6. Apply even tension and adjust all knots. Recheck all measurements. 7. Inspect the work thoroughly. Double check line lengths. 8. Perform a line continuity check. LOWER STEERING LINE (LST) REPLACEMENT 1. Remove the damaged lower steering line. 2. Place the new lower steering line through the lower loops of the upper steering lines. 3. Fingertrap the line back into itself, ensuring the marks on the line match up. 4. Bartack the fingertrap ensuring it originates at the fingertrap entry and extends toward the live side of the fingertrap. 5. Attach bottom end of the lower steering line to the rapide link in the same location as the damaged lower line. 6. Perform a continuity check. 4-15

202 SUSPENSION LINE REPLACEMENT The line being replaced will either be an A-B line or a C-D line. These lines come from the factory as follows: The A portion of the A-B line and the C portion of the C-D line will have a prefabricated loop for parachute attachment. (see picture) The B portion of the A-B line and the D portion of the C-D line come straight line (without a loop) and cut at an angle for finger trapping. PROCEDURE 1. Remove the damaged line. 2. Attach either the A- or the C-line (depending on which line is being replaced) to the parachute using a lark s head knot. 3. Attach either the B- or the D-line (depending on which line is being replaced) to the parachute by wrapping the line around the parachute attachment loop to resemble a lark s head knot. 4. Verify the finger-trap match marks are aligned. This ensures the line is at its proper length. 5. Fingertrap the line back into itself, ensuring the marks on the line match up. 6. Bartack the fingertrap. Ensuring it originates at the fingertrap entry and extends toward the live side of the fingertrap. 7. Perform a line continuity check. 8. Repeat steps 1 through 7 for the line opposite the damaged line to ensure symmetry and trim. 4-16

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