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Product Name: Big Boss HLL
Part #: 30800
Instruction Manual
Do not throw away these instructions!
Read and understand these instructions before using equipment!
Introduction 1
Applicable Safety Standards
Worker Classifications
Product Specific Applications
Limitations
Components and Specifications
Installation and Use
Maintenance, Cleaning, and Storage
Inspection
Inspection Log
Safety Information
Labels
1
2
2
3 - 4
4
5 - 7
8
8
8
9
10
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Introduction
Thank you for purchasing a Guardian Fall Protection Big Boss HLL. This manual must be read and understood in
its entirety, and used as part of an employee training program as required by OSHA or any applicable state
agency.
This and any other included instructions must be made available to the user of the equipment. The user must
understand how to safely and effectively use the Big Boss HLL, and all fall safety equipment used in
combination with the Big Boss HLL.
User Information
Date of First Use:
Serial #:
Trainer:
User:
Applicable Safety Standards
When used according to instruction specifications, this product meets or exceeds all applicable OSHA 1926
Subpart M and OSHA 1910 standards for fall protection. Additionally, all applicable components meet or
exceed ANSI Z359 standards for fall protection. Applicable standards and regulations depend on the type of
work being done, and also might include state-specific regulations. Consult regulatory agencies for more
information on personal fall arrest systems and associated components.
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Worker Classifications
CAUTION
!
Qualified Person: A person with an accredited degree or certification, and with extensive experience or
sufficient professional standing, who is considered proficient in planning and reviewing the conformity of fall
protection and rescue systems.
Competent Person: A highly trained and experienced person who is ASSIGNED BY THE EMPLOYER to be
responsible for all elements of a fall safety program, including, but not limited to, its regulation, management,
and application. A person who is proficient in identifying existing and predictable fall hazards, and who has
the authority to stop work in order to eliminate hazards.
Authorized Person: A person who is assigned by their employer to work around or be subject to potential or
existing fall hazards.
It is the responsibility of a Qualified or Competent person to supervise the job site and ensure all
applicable safety regulations are complied with.
Understand the following definitions of those who
work near or who may be exposed to fall hazards.
Product Specific Applications
WARNING
!
Personal Fall Arrest: Big Boss HLL may be used to support a MAXIMUM 4 personal fall arrest
systems (PFAS) for use in Fall Arrest applications. Structure must withstand loads applied in the
directions permitted by the system of at least 5,000 lbs. Maximum free fall is 6‘, or up to 12’ if
used in combination with equipment explicitly certified for such use. Applicable D-ring: Dorsal.
Use of equipment in unintended applications may result in serious
injury or death. Maximum 1 attachment per connection point.
Restraint: Big Boss HLL may be used in Restraint applications by a MAXIMUM 4 users. Restraint
systems prevent workers from reaching the leading edge of a fall hazard. Always account for fully
deployed length of lanyard/SRL. Structure must withstand loads applied in the directions
permitted by the system of at least 1,000 lbs. No free fall is permitted. Restraint systems may
only be used on surfaces with slopes up to 4/12 (vertical/horizontal). Applicable D-rings: Dorsal,
Chest, Side, Shoulder.
For all applications: worker weight capacity range
(including all clothing, tools, and equipment) is 130-310 lbs.
NEVER for simultaneous use in Fall Arrest and Restraint.
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Limitations
Fall Clearance: There must be sufficient clearance below the anchorage connector to arrest a fall before the
user strikes the ground or an obstruction. When calculating fall clearance, account for a MINIMUM 2’ safety
factor, deceleration distance, user height, length of lanyard/SRL, harness stretch, lifeline deflection, and all
other applicable factors.
Diagram shown is an example fall clearance calculation ONLY.
Swing Falls: Prior to installation or use, make considerations for eliminating or minimizing all swing fall
hazards. Swing falls occur when the anchor is not directly above the location where a fall occurs. Always work
as close to in line with the anchor point as possible. Swing falls significantly increase the likelihood of serious
injury or death in the event of a fall.
TOTAL FALL CLEARANCE = DEFLECTION + FREE FALL + DECELERATION + STRETCH + Safety MARGIN + Swing Fall
Anchor Point
DEFLECTION
SPAN =
Big Boss HLL
Work Surface
Work Surface
Lifeline Deection (See Below)
Free Fall Distance
Deceleration Distance
Harness Stretch (1.5’)
Safety Margin (2’)
Swing Fall (If Applicable)
10’
What’s the length of your HLL span?
20’
30’
40’
50’ 70’
60’
Anchor Point
80’
82’
DEFLECTION =
8.4’
9.4’
10.4’
11.4’
12.4’
13.4’
14.4’
15.4’
15.6’
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Compatibility: When making connections with Big Boss HLL, eliminate all possibility of roll-out. Roll-out
occurs when interference between a hook and the attachment point causes the hook gate to unintentionally
open and release. All connections must be selected and deemed compatible with Big Boss HLL by a
Competent Person. All connector gates must be self-closing and self-locking, and withstand minimum loads of
3,600 lbs. See the following for examples of compatible/incompatible connections:
Connector
closed and
locked to
D-ring. OK.
Two connectors
to same
D-ring. NO.
Incompatible
or irregular
application,
which may
increase risk
of roll-out. NO.
Two or more
snap hooks or
carabiners
connected to
each other. NO.
Components and Specifications
Materials: Polyester, powder-coated aluminum, and galvanized steel.
Includes:
- (1) Carrying Bag
- (1) Drum and Tensioner Housing
- (1) 82’, 16 mm, Double
- (2) Carabiners
- (2) O-rings
-Braided Polyester Rope
Connector
to integral
lanyard.
NO.
Connector
directly to
webbing.
NO.
Connector
directly to
horizontal
lifeline. NO.
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Installation and Use
Prior to use, plan your system:
1. Ensure all PFAS equipment is selected and deemed compatible by a Competent Person.
2. Eliminate or minimize all risk of swing fall.
3. Determine desired location for HLL; ensure location is free of debris, rot, cracking, and hazardous materials.
4. Installation, set-up, and use of HLL system must be done under the supervision of a Qualified Person.
Installation:
1. Ensure rope is properly threaded in tensioner by adhering to steps # 2 - 4.
2. Unscrew knob on tensioner housing and open housing plate to reveal rope threading diagram as shown.
3. Thread rope such that the anchor (live) end and terminated (dead) end exit tensioner as indicated. Rope
must sit in the groove of the drum. Close tensioner plate and tighten knob until snug.
Anchor (live) end
Terminated (dead) end
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4. Install compatible anchorage connector at first HLL span termination point. Then, connect anchor (live) end
of Big Boss HLL to anchorage connector with a carabiner. Repeat at second HLL span termination point by
connecting Big Boss HLL tensioner to second compatible anchorage connector.
5. Pull initial rope slack through tensioner by hand. This step is only to remove excess rope slack, not to
achieve proper tension.
6. Compress and hold tensioner handle and rotate handle until correct tension is reached. Apply force to
handle in turning direction only, as shown by arrow on handle.
7. To confirm proper tension, locate midpoint of HLL span. At this point, rope sag must match data specified in
graph and table on pg. 7. Never exceed specified sag. Sag less than specified is acceptable, but be sure to
never over-tension rope. Always use sag method to ensure system is set correctly. Rope will slip to prevent
over-tensioning, however it is not necessary to tension to this point. Never extend handle in any way to
increase leverage.
Compress
tensioner
handle
Rotate handle
as shown
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Anchor Point Anchor Point
9
8
7
6
5
4
3
2
Midpoint Span Sag (Inches)
1
EXCESS SAG - DO NOT USE
Midpoint
Sag
Span Length
HLL Tension Guide
OK FOR USE
0
10 20 30 40 50 60 70 80
HLL Span Length (Feet)
Span Length Required Sag at Midpoint
10’
20’
30’
40’
50’
60’
70’
82’ 7.7”
1.0”
1.3”
1.7”
2.3”
3.1”
4.1”
5.5”
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Maintenance, Cleaning, and Storage
If Big Boss HLL fails inspection in any way, immediately remove it from service, and contact Guardian to
inquire about its return or repair.
Cleaning after use is important for maintaining the safety and longevity of Big Boss HLL. Remove all dirt,
corrosives, and contaminants from Big Boss HLL before and after each use. If Big Boss HLL cannot be cleaned
with plain water, use mild soap and water, then rinse and wipe dry. NEVER clean Big Boss HLL with corrosive
substances.
When not in use, store equipment where it will not be affected by heat, light, excessive moisture, chemicals,
or other degrading elements.
Inspection
Prior to EACH use, inspect Big Boss HLL for deficiencies, including, but not limited to, corrosion, deformation,
pits, burrs, rough surfaces, sharp edges, cracking, rust, paint buildup, excessive heating, alteration, and
missing or illegible labels. IMMEDIATELY remove Big Boss HLL from service if defects or damage are found, or if
exposed to forces of fall arrest.
Ensure that applicable work area is free of all damage, including, but not limited to, debris, rot, rust, decay,
cracking, and hazardous materials. Ensure that selected work area will support the application-specific
minimum loads set forth in this instruction manual. Work area MUST be stable.
At least every 12 months, a Competent Person other than the user must inspect Big Boss HLL. Competent
Person inspections MUST be recorded in inspection log in instruction manual and on equipment
inspection grid label. The Competent Person must sign their initials in the box corresponding to the
month and year the inspection took place.
During inspection, consider all applications and hazards Big Boss HLL have been subjected to.
Inspection Log
Date of First Use: __________________.
Product lifetime is indefinite as long as it passes pre-use and Competent Person inspections. User must
inspect prior to EACH use. Competent Person other than user must complete formal inspection at least
every 12 months. Competent Person to inspect and initial.
This inspection log must be specific to one Big Boss HLL. Separate inspection logs must be used for each
Big Boss HLL. All inspection records must be made visible and available to all users at all times.
If equipment fails inspection IMMEDIATELY REMOVE FROM SERVICE.
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Safety Information
Failure to understand and comply with safety regulations may result in
WARNING
!
Do not alter equipment. Do not misuse equipment.
Workplace conditions, including, but not limited to, flame, corrosive chemicals, electrical shock, sharp objects,
machinery, abrasive substances, weather conditions, and uneven surfaces, must be assessed by a Competent
Person before fall protection equipment is selected.
The analysis of the workplace must anticipate where workers will be performing their duties, the routes they
will take to reach their work, and the potential and existing fall hazards they may be exposed to. Fall
protection equipment must be chosen by a Competent Person. Selections must account for all potential
hazardous workplace conditions. All fall protection equipment should be purchased new and in an unused
condition.
Fall protection systems must be selected and installed under the supervision of a Competent Person, and used
in a compliant manner. Fall protection systems must be designed in a manner compliant with all federal, state,
and safety regulations. Forces applied to anchors must be calculated by a Competent Person.
Unless explicitly stated otherwise, the maximum allowable free fall distance for lanyards must not exceed 6’.
No free fall allowed for non-LE SRLs. Class A SRLs must arrest falls within 24”; Class B SRLs must arrest falls
within 54”.
Harnesses and connectors selected must be compliant with manufacturer’s instructions, and must be of
compatible size and configuration. Snap hooks, carabiners, and other connectors must be selected and applied
in a compatible fashion. All risk of disengagement must be eliminated. All snap hooks and carabiners must be
self-locking and self-closing, and must never be connected to each other.
A pre-planned rescue procedure in the case of a fall is required. The rescue plan must be project-specific. The
rescue plan must allow for employees to rescue themselves, or provide an alternative means for their prompt
rescue. Store rescue equipment in an easily accessible and clearly marked area.
Training of Authorized Persons to correctly erect, disassemble, inspect, maintain, store, and use equipment
must be provided by a Competent Person. Training must include the ability to recognize fall hazards, minimize
the likelihood of fall hazards, and the correct use of personal fall arrest systems.
NEVER use fall protection equipment of any kind to hang, lift, support, or hoist tools or equipment, unless
explicitly certified for such use.
Equipment subjected to forces of fall arrest must immediately be removed from use.
Age, fitness, and health conditions can seriously affect the worker should a fall occur. Consult a doctor if there
is any reason to doubt a user’s ability to withstand and safely absorb fall arrest forces or perform set-up of
equipment. Pregnant women and minors must not use this equipment.
Physical harm may still occur even if fall safety equipment functions correctly. Sustained post-fall suspension
may result in serious injury or death. Use trauma relief straps to reduce the effects of suspension trauma.
serious injury or death. Regulations included herein are not all-inclusive,
are for reference only, and are not intended to replace a Competent
Person’s judgment or knowledge of federal or state standards.
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Labels
6305 S 231st Street, Kent, WA 98032
SERIAL NUMBER 17-0000000
DATE OF MANUFACTURE 01/2017
MAX USERS 4
MODEL TYPE RVT2
PRODUCT TYPE HLL125-GDY
MAX USER WEIGHT 310 lbs
US Patent Pending
1-800-466-6385
PPELAB-319 ISS. 90780(Rev. B)
OSHA 1926 Subpart M
OSHA 1910
EN 795 1996 CLASS C
Anchorages should be sufficiently
strong enough to
withstand a force of
5000lbs
MANUFACTURED IN THE UK
10 85116 (Rev. J)
Distributed by Engineered Fall Protection | Sales@EngineeredFallProtection.com | (314) 492-4422 | www.EngineeredFallProtection.com
Guardian Fall Protection 6305 S. 231st St., Kent, WA 98032
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