Miller MP20, MP30 Maintance Manual

MILLER® FALCON SERIES SELF-RETRACTING LIFELINES

OPERATION AND MAINTENANCE MANUAL

WARNING:

ALL PERSONS USING THIS EQUIPMENT MUST READ AND UNDERSTAND ALL INSTRUCTIONS.
FAILURE TO DO SO MAY RESULT IN SERIOUS INJURY OR DEATH.

FALCON RETRACTABLE LIFELINES

The Miller
by personnel in applications where fall protection in combination with unrestricted worker mobility is
needed.

Proper use of fall arrest systems can save lives and reduce the potential of serious injuries from a
fall. The user must be aware that forces experienced during the arrest of a fall or prolonged
suspension may cause bodily injury. Consult a physician if there is any question about the user’s
ability to use this product. Pregnant women and minors must not use this product.

®

Falcon Series Retractable Lifelines are self-contained retractable lifelines designed to be used

Falcon Series Models MP20 & MP30

Carabiner

Fasteners

Stainless Steel Swivel

Front Label
Back Label w/Identification Insert (back)

Housing

Ferrules

Cable

Self-Locking Snaphook

1

Carabiner

Fasteners

Carry Handle
(Never use for attachment.)

Falcon Series Models MP50 & MP65

Stainless Steel Swivel

Front Label
Back Label w/Identification Insert (back)

Housing

Ferrules

Self-Locking Snaphook

Cable

I. REQUIREMENTS

A. WARNINGS AND LIMITATIONS
Proper precautions should always be taken to remove any obstructions, debris and other material
from the work area that could cause injuries or interfere with the operation of the unit. Caution
should also be taken to insure that all equipment will be clear of all other recognized hazards and
that proper precautions have been taken to address all safety issues in the work area.

Note: Users should be familiar with pertinent regulations governing this equipment. All individuals who use this
product must be correctly instructed on how to use the system, and must read and understand the following
instructions before using the unit.

• For use by one person only. The design working load is 310 pounds (140.6 kg) — DO NOT
EXCEED THIS WEIGHT.

• Only trained personnel should use this device.

• Do not use the unit if the lifeline doesn’t retract.

• Do not use the unit if the lifeline brakes do not engage. Refer to inspection procedures for more
details.

• Do not use the unit if any part of the system appears to be damaged.

• Never use the Carry Handle (MP50 & 65) as an attachment point.

• Do not use the unit if it has been subject to fall arresting forces. Return the unit to Miller Fall
Protection or an authorized service center.

• Do not use the unit if the load impact indicator has been activated.

2

• Do not attempt to service this device; if it does not operate satisfactorily or requires repairs,
return the unit to Miller Fall Protection or an authorized service center for repairs.

• Do not lubricate this device.

• The lifeline must be kept clean.

• The equipment should be installed overhead and used in such a manner as to reduce the
potential for a pendulum fall.

• Allow adequate fall clearance below the work surface when using this device.

• Never work above the device.

• Never use the device as a restraint or positioning device.

• Never allow the lifeline to become slack or to pass under or entwine around the user’s arms,
legs, or any other obstacle or person.

• Do not allow cable, rope or webbing lifelines to come in contact with anything that will damage
the lifeline including but not limited to sharp, abrasive, rough or high temperature surfaces,
welding, heat sources, electrical hazards, or moving machinery.

• Use in highly corrosive or caustic environment dictates a more frequent inspection and
servicing program to ensure the integrity of the unit is maintained. Contact Miller Fall Protection
in cases of doubt.

• Employers must provide for prompt rescue in the event of a fall.

• Do not allow lifeline in any application to bend or be subjected to fall arresting forces over
structural members or edges.

• Failure to follow instructions could cause serious injury or death.

• Note: All Miller Falcon models can be coupled with a 928LS Shock-Absorber for users that

weigh between 311 and 400 lbs. (141 and 181 kg.) The 928LS must be mounted between the back
D-ring of the user’s harness and the snaphook of the Falcon.

B. SYSTEM COMPATIBILITY

Miller retractable lifelines are designed for use with
Miller approved components. Substitution or
replacement with non-approved components will
endanger the compatibility within the system and
may affect the reliability and safety of the total
system. It is recommended that the user wear a
Miller full-body harness to distribute the fall
arresting forces over the body and to keep an
unconscious or injured worker in an upright
position.

II. INSTALLATION

LOCKING

CARABINER

TYPICAL INSTALLATION

ANCHORAGE

ANCHORAGE
CONNECTOR

The Falcon series retractable lifelines must be
mounted to an overhead anchor by the attachment
swivel using a locking carabiner or another Miller
Fall Protection approved mounting device. The
anchorage fixtures must be capable of supporting
a 5,000 lb. (22kN) tensile load or meet OSHA

1926.502 requirements for a safety factor of two.
Review all warnings and instructions when
selecting a mounting location.

The Falcon series retractable lifelines must be
inspected and tested satisfactorily before each use
as described in section III. Operation & Inspection.
Before the user is subject to a fall hazard, connect
the snap hook of the unit onto the back D-ring of
the user’s harness.

MP20 (6.2m)

OR

MP30 (10m)

SHOWN

3

III. OPERATION & INSPECTION

A. GENERAL INSPECTION

•Before use, inspect device for loose fasteners, bent, cracked, distorted, worn, malfunctioning, or
damaged parts.

B. GENERAL OPERATION
WARNING: The following operation checkpoints and inspections must be done prior to each use:

1. Anchorage Connection: Make sure the carabiner is properly seated and in the locked position

between the attachment swivel on the unit and the anchor point or make certain the unit is properly
installed in the Miller mounting device. The anchorage connector and anchorage point must be capable
of supporting 5,000 Ibs. (22kN) or meet OSHA 1926.502 requirements for a safety factor of two.

2. Lifeline Retraction: With the device in the mounted position, test the lifeline retraction and tension by
pulling out several feet of the lifeline and allow it to retract back into the unit. Always maintain a light
tension on the lifeline as it retracts. The lifeline should pull out freely and retract all the way back into the
unit.
a. If the lifeline does not pull out smoothly or sticks when retracting, pull all of the lifeline out of the
housing and allow it to retract slowly under tension.
b. The lifeline should be checked regularly for signs of damage. Inspect for cuts, burns, corrosion, kinks,
frays, or worn areas.
c. Do not pull the lifeline out of the housing or let it retract while the unit is laying flat. Always inspect and
operate the unit in a mounted position.

3. Braking Mechanism: The braking mechanism can be tested by graspi ng the lifeline above the load
indicator and applying a sharp steady pull downward which will engage the brakes. There should be no
slippage of the lifeline while the brakes
are engaged. Once tension is released,
the brakes will disengage and the unit will
return to the retractable mode.

4. Snap Hook: Check the snap hook to
be sure that it operates freely, locks, and
the swivel operates smoothly. Inspect the
snap hook for any signs of damage to the
keepers and any bent, cracked, or
distorted components.

5. Snap Hook Load Indicator: A load
indicator is located in the swivel of the
snap hook. The swivel eye will elongate
and expose a red area when subjected to
fall arresting forces as shown.

UNITS THAT DO NOT PASS THIS
INSPECTION OR HAVE BEEN
SUBJECTED TO FALL ARRESTING
FORCES MUST BE REMOVED FROM
SERVICE.

SNAP HOOK ACTIVATION INSPECTION

BEFORE

AFTER- RED WILL

APPEAR HERE WHEN
SUBJECTED TO FALL
ARREST FORCES

4

IV.TRAINING

It is the responsibility of the user to assure that they read, understand, and follow all instructions and are
trained in the care and use of this device. Training should be repeated periodically and any time there is
a change of components within the system. Training must be conducted without exposing the trainee to a
fall hazard.

V. MAINTENANCE

A. SERVICING

Servicing must only be carried out by a Miller Fall Protection approved service technician trained in the
repair and service of Miller Fall Protection Falcon Series fall arrest lifeline systems/devices. A record log
of all servicing and inspection dates for this device must be maintained by the company safety officer.

This device must be returned to Miller Fall Protection or an approved service center whenever
subjected to fall arresting forces for physical inspection and recertification. Only original Miller

replacement parts are approved for use in this device. Contact your Miller distributor or call Miller Fall
Protection’s Customer Service Department at 1-800-873-5242 for a return goods authorization number.
(The Following Note Applies Only To CSA Approved Products) Note: CSA Z259.2.2 Requires Type
2 and Type 3 devices to be returned to the manufacturer or an approved service agent no more than 2
years after the date of manufacture for inspection and maintenance and annually thereafter.

B. CLEANING

Periodically clean the exterior of the device and wipe the lifeline using a damp cloth and mild detergent.
Towel dry.

C. STORAGE

Store in a clean, dry location when not in use. The lifeline should be fully retracted into the unit when not
in use.

FRONT I.D.LABEL (FIG. A)

FALCON SELF–RETRACTING LIFELINE
WARNING: FAILURE TO OBSERVE INSTRUCTIONS

MAY RESULT IN SERIOUS OR FATAL INJURY
COMPLIANCE:

OSHA 1926.502, OSHA 1910.66, ANSI A10.14,
CSA Z259.2.2-98 (TYPE 2), ANSI Z359.1

MAX ARRESTING FORCE 900 LBS. (4 kN)
MAX ARREST DISTANCE 3' - 6" (1.06 m)
MAX CAPACITY 310 LBS. (140.6 kg)

LOAD-INDICATING SNAPHOOK WARNING:

REMOVE FROM SERVICE IF RED APPEARS

FIG. A

5

BACK WARNING LABEL (FIG. B)

FIG. B

INSTALLATION

• SEE INSTRUCTIONS FOR MOUTING
PROCEDURE.

• ANCHORAGE AND MOUNTING HARDWARE
MUST BE CAPABLE OF SUPPORTING A 5,000
LB. (22kN) STATIC LOAD OR MEET OSHA

1926.502 REQUIREMENTS FOR A SAFETY
FACTOR OF TWO.

• INSPECT BEFORE USE FOR ANY SIGNS OF
DAMAGE, WEAR OR MALFUNCTIONING
COMPONENTS.

• DEVICE MUST BE TAKEN OUT OF SERVICE FOR
INSPECTION AND RECERTIFICATION AFTER
ARRESTING A FALL OR LOAD INDICATOR HAS
BEEN ACTIVATED.

BEFORE USING

• CHECK LIFELINE RETRACTION BY PULLING
OUT A MINIMUM OF 4 FT. (1.2M.) OF LIFELINE
AND ALLOW IT TO RETRACT UNDER LIGHT
TENSION.

• CHECK BRAKING ACTION BY GRASPING LIFELINE ABOVE LOAD INDICATOR AND APPLYING
A SHARP PULL TO THE LIFLINE. THE BRAKES MUST ENGAGE.

• RELEASE THE TENSION AND ALLOW LIFLINE TO RETRACT SLOWLY INTO THE UNIT. THE
LIFLINE SHOULD RETRACT COMPLETELY.

• ALLOW ADEQUATE FALL CLEARANCE BELOW THE WORK SURFACE WHEN USING THIS
DEVICE.

WARNING: MANUFACTURER’S INSTRUCTIONS SUPPLIED WITH THIS PRODUCT AT THE TIME
OF SHIPMENT MUST BE FOLLOWED: FAILURE TO DO SO MAY RESULT IN SERIOUS INJURY OR
DEATH. ONLY FOR USE BY ONE PERSON AS A PERSONAL FALL ARRESTER. DEVICE MUST
BE TAKEN OUT OF SERVICE FOR INSPECTION AND RECERTIFICATION

**THIS SELF-RETRACTING LIFLINE SHOULD BE INSPECTED BY THE USER PRIOR TO EACH USE
ACCORDING TO MANUFACTURER’S INSTRUCTIONS.**

IDENTIFICATION LABEL (FIG. C)

MODEL/LENGTH

MP20G/20FT (6.2m) · 3/16” (4.8mm) GALVANIZED STEEL CABLE
MP20SS/20FT (6.2m) · 3/16” (4.8mm) STAINLESS STEEL CABLE
MP30G/30FT (10m) · 3/16” (4.8mm) GALVANIZED STEEL CABLE
MP30SS/30FT (10m) · 3/16” (4.8mm) STAINLESS STEEL CABLE
MP50G/50FT (15m) · 3/16” (4.8mm) GALVANIZED STEEL CABLE
MP50SS/50FT (15m) · 3/16” (4.8mm) STAINLESS STEEL CABLE
MP65G/65FT (20m) · 3/16” (4.8mm) GALVANIZED STEEL CABLE

DATE OF MANUFACTURE
DATE DE FABRICIATION

XX/XX

SERIAL NO/NO. DE SERIE

FIG. C

MODEL/LENGTH

MODELE/LONGUEUR

MPXXX/XXFT

LB554 REV. A

MP65SS/65FT (20m) · 3/16” (4.8mm) STAINLESS STEEL CABLE
DATE OF MANUFACTURE: MM\YY
SERIAL NO.: XXXXX

6

MILLER FALCON - MP SERIES SELF-RETRACTING LIFELINES MODEL SPECS

Model LifeLine Material Length Weight (lbs.) A (inches) B (inches) C (inches)

MP20G

MP20SS

MP30G

MP30SS

MP50G

MP50SS

MP65G

MP65SS

3/16” (4.8mm)

galvanized cable

3/16” (4.8mm)

stainless steel cable

3/16” (4.8mm)

galvanized cable

3/16” (4.8mm)

stainless steel cable

3/16” (4.8mm)

galvanized cable

3/16” (4.8mm)

stainless steel cable

3/16” (4.8mm)

galvanized cable

3/16” (4.8mm)

stainless steel cable

A

B C

20’ (6.2m) 8.9 (4.0kg) 12.1 (30.8cm) 8.4 (21.3cm) 4.0 (10.2cm)
20’ (6.2m) 8.9 (4.0kg) 12.1 (30.8cm) 8.4 (21.3cm) 4.0 (10.2cm)

30’ (10m) 10.8 (4.9kg) 12.1 (30.8cm) 8.4 (21.3cm) 4.0 (10.2cm)
30’ (10m) 10.8 (4.9kg) 12.1 (30.8cm) 8.4 (21.3cm) 4.0 (10.2cm)
50’ (15m) 14.8 (6.7kg) 15.5 (39.4cm) 9.8 (24.8cm) 4.0 (10.2cm)
50’ (15m) 14.8 (6.7kg) 15.5 (39.4cm) 9.8 (24.8cm) 4.0 (10.2cm)
65’ (20m) 17.2 (7.8kg) 15.5 (39.4cm) 9.8 (24.8cm) 4.0 (10.2cm)
65’ (20m) 17.2 (7.8kg) 15.5 (39.4cm) 9.8 (24.8cm) 4.0 (10.2cm)

7

MATERIAL SPECIFICATIONS
Housing: High Impact Nylon

Fasteners: Stainless Steel
Top Swivel: Stainless Steel
Ferrules: Aluminum or Copper
Cable: Galvanized or Stainless Steel
Snaphook: Drop Forged Steel
Brake Pawls: Bronze
Drum: Aluminum
Frame Plates: Aluminum or Stainless Steel
Power Spring: Stainless Steel
Mainshaft: Stainless Steel

TECHNICAL SPECIFICATIONS
Max Working Load: 310 lbs -140.62 kg

Ultimate Strength: 3600 lbs. -16.01kN
Lifeline Tension: 3 to 4 lbs. -13.3/17.8 N
Free Fall Distance: 24” Max. - 609.6 mm
Deceleration Distance: 42” Max – 1.06m
Arresting Force: 900 lbs. (approx.) – 4kN
Strength Test: 300 lbs. 4’ free fall

(1.33 kN @ 1.22m free fall)

I227
REV. B
MFP9720108

Sperian Protection
43 Garden Boulevard
Dingley VIC 3172
1300 139 166

FAX: [phone]

www.millerfallprotection.com.au

8

p

W

Miller Falcon 16ft and 20ft SRL MILLER FALL PROTECTION

Model: MP16P/16FT or MP20P/20FT

New Product Information/Instruction Manual Insert:

We would like to thank you for your purchase of Miller Fall Protection equipment. Please
carefully read this supplemental Instruction and specification sheet. It contains special
instructions, inspections and maintenance procedures that are unique to the Falcon 16ft/20ft
product line, and should be referenced in addition to the Miller Falcon instruction booklet also
included with this product. Should you have any questions about your Miller Fall Protection

roduct, please contact the Miller Technical Service at 1300 139 166

Load Indicator
Activation Inspection

In addition to the standard inspection
procedures, the load indicator should be
inspected prior to each use to ensure the unit
has not seen fall arresting forces.

Before

After Fall Arrest

arning Labels

SP345 REVA

Miller Falcon 16ft and 20ft SRL MILLER FALL PROTECTION

Model: MP16P/16FT or MP20P/20FT

Description

Miller Falcon 16ft (4.9m) and 20ft. (6.1m) web lifelines
with stainless steel swivel, aluminum snaphook and
carabiner.

Nearly indestructible, high impact-resistant
thermoplastic housing withstands the harsh rigors of
the toughest applications. Pound for pound the
strongest, most durable line of self-retracting lifelines
on the market.

Materials

Housing: High-strength thermoplastic

Hub: Aluminum and high-strength
Braking

Mechanism: High-strength steel, yellow zinc

Lifeline: Core: Technora® (aramid fiber)

Snaphook: Aluminum
Carabiner: Aluminum

polypropylene

composite

chromate plating

Outer cover: Chemically-treated
polyester for increased abrasion
resistance

Technical

Maximum
Working Load: 400lbs (181kg)

Working Length
Capacity: 16ft (4.9m) or 20ft (6.1m)

Maximum
Arresting Force: <900lbs/f (4kN) for up to 310lbs.

<1800lbs/f (8kN) for up to 400lbs.

(140kg) Working Load

(181kg) Working Load

Certification

Meets all applicable OSHA, ANSI, CSA and CE
requirements.

www.millerfallprotection.com.au

WARNING!

TO ASSURE THE ACCURACY OF THE DATA. IT DOES NOT PROVIDE IMPORTANT PRODUCT WARNINGS AND INSTRUCTIONS. MILLER FALL PROTECTION RECOMMENDS

ALL USERS OF FALL PROTECTION EQUIPMENT UNDERGO THOROUGH TRAINING, AND THAT ALL WARNINGS AND INSTRUCTIONS PROVIDED WITH THE PRODUCTS BE

THIS DOCUMENT PROVIDES AN OVERVIEW OF FALL PROTECTION PRODUCTS AVAILABLE FROM MILLER FALL PROTECTION AND CARE HAS BEEN TAKEN

THOROUGHLY READ AND UNDERSTOOD PRIOR TO EACH USE. FAILURE TO READ AND FOLLOW ALL PRODUCT WARNINGS AND INSTRUCTIONS COULD RESULT IN

MODEL NUMBER *L - LENGTH WEIGHT WEIGHT
WITHOUT CARABINER WITH CARABINER

MP16P/16FT 16’ (4.9m) 2.90lbs.(1.31kg) 3.32lbs (1.50kg)

MP20P/20FT 20’ (6.1m) 2.98lbs.(1.35kg) 3.40lbs (1.54kg)

SERIOUS INJURY OR DEATH.