Honeywell Miller Full-Body Harnesses and Body Belts User Manual

Introduction

This user instruction manual covers all Miller and Miller Titan full-body harnesses, as well as body belts (excluding Linemen’s Belts). Thank you for your purchase of Honeywell Miller fall protection equipment manufactured by Honeywell Industrial Safety.

WARNING: All persons using this equipment must read, understand, and follow all instructions. Failure to do so may result in serious injury or death. Do not use this equipment unless properly trained.

1.0 Purpose

Honeywell Industrial Safety offers a wide array of full-body harnesses for every application. While full-body harnesses may be used for positioning, travel restraint, and rescue, they are the only acceptable form of body wear for fall arrest. Harness designs offer superior safety and functionality with features developed to meet key user needs, such as comfort, fit, ease-of-use, style, durability, compliance, flexibility, and convenience.

WARNING: Always use a full-body harness for fall arrest. Body belts may be used for positioning and travel restraint only.

2.0 General Fall Protection Requirements

2.1. General Requirements

• Users must retain the manufacturer’s instructions and make them readily available.
• Users must reference applicable OSHA, ANSI, or CSA standards.
• Proper training is essential for safe use.
• Full-body harnesses meeting OSHA, ANSI/ASSP, and CSA standards are intended for use with personal fall arrest systems that limit maximum arrest forces to 1800 pounds (8kN) or less.
• Remove obstructions from the work area and ensure the potential fall path is clear.
• Allow adequate fall clearance below the work surface.
• A competent person must ensure system compatibility.
• All equipment must be inspected before each use and by a competent person at least annually. Discard any damaged or deteriorated equipment.

WARNING: Any equipment subject to a fall must be removed from service. The user shall have a rescue plan and the means to implement it.

Equipment must not be altered. Repairs must be performed only by the manufacturer or authorized entities. Never use fall protection equipment for purposes other than those for which it was designed. Consider environmental hazards when selecting equipment. Do not expose equipment to chemicals, heat, flames, or other conditions that may cause harm. Protect synthetic materials from slag, hot sparks, open flames, or other heat sources. Avoid contact with sharp, abrasive, rough, or high-temperature surfaces, electrical hazards, or moving machinery.

WARNING: Never remove product labels, which include important warnings and information.

2.2. Warnings and Limitations Capacity

The allowable capacity of Miller and Miller Titan harnesses varies among the requirements of ANSI, CSA, and OSHA. Users must refer to the harness identification label to verify compliance with specific standards.

*Includes body weight, clothing, and tools.

**CSA Z259.10 does not specify a capacity range; the manufacturer may establish maximum capacity based on testing.

***Honeywell rates harnesses to a maximum of 420 lb (190.5 kg). Users and employers must determine compliance with ANSI standards limiting capacity to 130-310 lb (59-140 kg).

Note: For OSHA 1926.502(d)(16), employers must modify criteria and protocols for users with a combined weight between 310 lb (140.6 kg) and 420 lb (190.5 kg) to ensure compliance.

2.3. System Compatibility

Miller full-body harnesses and body belts are designed for use with Honeywell-approved components only. Substitution with non-approved components may affect safe function and system compatibility.

WARNING: Always refer to regulations and standards regarding personal fall arrest system component requirements and the instructions provided with each component.

Limits of Use

Fall arrest connecting devices shall be attached to the dorsal attachment element (back D-ring) unless the application allows for an alternate attachment.

Anchorage Requirements

Anchorages must support 5,000 lb (22.2 kN) per worker or meet OSHA 1926.502 requirements (safety factor of two). ANSI anchorage requirements:

• Fall arrest systems: Anchorages must withstand a static load of 5,000 lb (22.2 kN) for non-certified or two times the maximum arresting force for certified anchorages.
• Positioning systems: Anchorages must withstand a static load of 3,000 lb (13.3 kN) for non-certified or two times the foreseeable force for certified anchorages.
• Travel restraint: Anchorages must withstand a static load of 1,000 lb (4.5 kN) for non-certified or two times the foreseeable force for certified anchorages.
• When multiple systems are attached to an anchorage, multiply strengths by the number of systems.

3.0 Wearing a Full-Body Harness

Correct fit is essential. Users must be trained to select the size and maintain the fit. Ensure buckles are connected and aligned, leg and shoulder straps are snug, chest straps are in the mid-chest area, and leg straps are positioned to avoid contact with genitalia during a fall. Maintain a proper fit throughout the work shift.

3.1. Donning a Harness

1. Hold harness by back D-ring. Shake to allow straps to fall in place.
2. Release and unbuckle chest, waist, and/or leg straps if connected.
3. Slip straps over shoulders so D-ring is located in the middle of the back between shoulder blades.
4. Pull leg strap between legs and connect to the corresponding end. Repeat with the second leg strap. Tighten leg straps snugly without obstructing blood circulation. Connect waist strap/belt if present.
5. Connect chest strap and position in the mid-chest area, 6” (152mm) to 8” (203mm) below the trachea but not below the sternum. Tighten to keep shoulder straps taut.
6. Tighten shoulder straps until snug.
7. Readjust harness fit as needed for snugness and full range of movement. Secure excess strap in elastic loop keepers.
8. Verify correct harness fit: All buckles connected, webbing not twisted and snug, back D-ring centered, chest strap positioned correctly.

Helpful Hint: Hang the harness by its back D-ring when not in use to help it keep its shape.

3.2. Donning a Pullover Front D-Ring Harness

1. Release and unbuckle leg straps if connected.
2. Hold harness by back D-ring and rotate so the front D-ring faces you.
3. Grasp shoulder straps below the front D-ring and place head through the center of the harness.
4. Spin the harness 180 degrees and adjust so shoulder straps are vertical, front D-ring is mid-chest, and back D-ring is between shoulder blades.
5. Pull leg strap between legs and connect. Repeat with the second leg strap. Tighten leg straps snugly.
6. Adjust shoulder straps using friction buckles until snug.
7. Readjust harness fit for snugness and full range of movement. Secure excess strap.
8. Verify correct harness fit.

3.3. Donning a Ms. Miller Harness (570 / E570)

1. Hold harness by back D-ring. Shake to allow straps to fall in place.
2. Release and unbuckle chest and leg straps if connected.
3. Step through the waist strap and slip shoulder straps over shoulders so the back D-ring is between shoulder blades.
4. Pull leg strap between legs and connect. Repeat with the second leg strap. Tighten leg straps snugly.
5. Tighten waist strap snugly.
6. Connect chest strap and position in the mid-chest area, 6” (152mm) to 8” (203mm) below the trachea. Tighten to keep shoulder straps taut.
7. Readjust harness fit for snugness and full range of movement. Secure excess strap.
8. Verify correct harness fit.

4.0 Using a Full-Body Harness

4.1. SRD-P Integrated Connector Element

Some harnesses have a factory-installed SRD-P connector below the Dorsal D ring for connecting Miller SRD-P devices. Compatible connections include Miller G2 and Miller Pin style harness connectors (17D-1, 17D-2). Not compatible with rebar hooks or snap hooks.

4.2. Use of Attachment Elements (D-Rings/Web Loops)

• Dorsal Attachment Element (Back D-Ring/Web Loop): Primary fall arrest attachment unless an alternate is allowed. Also used for travel restraint or rescue. Directs load through shoulder and thigh straps. Results in an upright body position post-fall.
• CAUTION: Use only soft loops and carabiners with soft loop attachments. If using a snap hook with a soft loop, it must be ANSI compliant with a gate strength of at least 3,600 lb (16 kN). CSA standards do not allow snap hooks with soft loops.
• Sternal Attachment Element (Chest Area Front D-Ring): Alternative fall arrest attachment where dorsal attachment is inappropriate and fall is only possible feet-first. Limits free fall to 2 ft (0.6m). Used for ladder climbing with guided fall arresters, work positioning, and rope access. Results in a cradled body position post-fall. Consider models with fixed sternal attachments to prevent choking risk.
• Frontal Attachment Element: Used for ladder climbing with guided fall arresters (feet-first falls only) or work positioning. Results in a sitting body position. Ensure fall is feet-first if used for fall arrest.
• Shoulder Attachment Element and Shoulder D-Rings: Used as a pair for rescue and entry/retrieval. Not for fall arrest. Use with a yoke to keep shoulder straps separate.
• Waist, Rear Attachment Element: Used solely for travel restraint. Not for fall arrest. Subject to minimal loading through the waist.
• WARNING: Never use shoulder, rear-waist, hip, or suspension seat attachment elements for fall arrest. Do not use the rear-waist attachment for purposes other than travel restraint.
• Hip Attachment Elements and Side D-Rings: Used as a pair solely for work positioning. Not for fall arrest. Caution against using hip attachments to store unused lanyard legs to prevent tripping or adverse loading.
• Suspension Seat Attachment Elements: Used as a pair solely for work positioning. Not for fall arrest. Used for prolonged suspension activities.
• Suspension Loop Attachment Elements: Used as a pair solely for work positioning.

WARNING: Always ensure the connecting device snap hook (or other connector) is compatible with the harness D-ring, properly engaged, closed, and locked.

IMPORTANT NOTE: An improper or incomplete engagement can occur if the D-ring inside diameter is close to the snap hook width. This can lead to the snap hook sitting only inside the D-ring, which is unsafe and likely to come apart during a fall arrest.

5.0 Use of Other Harness Features

• Pull-Free Lanyard Rings (Lanyard Parking Attachments): Used to store unused lanyard legs to reduce tripping and entanglement hazards.
• CAUTION: Do not attach unused lanyard legs to work positioning elements or other structural elements unless approved by a competent person and manufacturer.
• Elastic Keepers and Web Finials: Control loose ends of webbing straps. Secure excess webbing in keepers or use web finials.
• CAUTION: Do not allow webbing straps to hang freely as they can get caught in machinery or cause accidental disengagement of an adjuster.
• D-Ring Extension: Some specialty harnesses have a dorsal D-ring extension for fall arrest attachment. Store in the designated elastic keeper when not in use.
• CAUTION: Do not use the dorsal D-ring and extension simultaneously for fall arrest. Account for the extension length when calculating fall clearance.

Using a Body Belt

A body belt shall be used for positioning or travel restraint only. It may be used with a full-body harness, but fall arrest attachment elements on the harness must be used for fall protection.

WARNING: Do not use a body belt for fall arrest.

6.0 Calculating Fall Clearance Distance

Calculating required fall clearance distance is essential to avoid contact with a lower level. Refer to connecting device instructions for comprehensive information. Use the Miller Fall Clearance Calculator online: www.millerfalltraining.com/fallclearance/

Fall Clearance Calculation Guidelines:

• Full-body harness stretch is limited to 18 in. (457.2mm). Include harness stretch, connector length, user body settling, and other factors. Honeywell recommends a 3 ft. (0.9m) safety/stretch factor.
• Add D-ring extension length to the calculation if used.
• Shock absorbers elongate during fall arrest; use maximum elongation distance from product labels.

SHOCK-ABSORBING LANYARD FALL CLEARANCE CALCULATION

Required Fall Clearance (RFC) = Length of Lanyard (LL) + Max. Elongation/Deceleration Distance (MED) + Height to Worker’s Back D-Ring (H) + 3 ft. (0.9m) Safety/Stretch Factor (SF)

SELF-RETRACTING LIFELINE FALL CLEARANCE CALCULATION

Required Fall Clearance (RFC) = Maximum Arrest Distance (MAD) + [Non-Standing Work Position Factor (NSF)]* + [Swing Fall Factor (SFF)]* + 3 ft. (0.9m) Safety/Stretch Factor (SF)

*The self-retracting lifeline calculation assumes the user is standing directly below the anchor point; otherwise, additional clearance is required. Refer to I267--Miller Self-Retracting Lifelines User Instruction Manual for more information.

Questions? Contact Honeywell Technical Service: 1-800-873-5242 (press 4)

7.0 Inspection and Maintenance

Users must comply with all manufacturer instructions for inspection, maintenance, and storage. Refer to ANSI/ASSP Z359.2 for user inspection, maintenance, and storage guidelines.

7.1. Harness and Body Belt Inspection

Inspect equipment before each use and by a competent person at least annually for:

• Absence or illegibility of markings/labels.
• Absence of any elements affecting form, fit, or function.
• Defects or damage to strap or ropes (fraying, unsplicing, unlaying, kinking, knotting, roping, broken or pulled stitches, excessive elongation, chemical attack, soiling, abrasion, alteration, needed or excessive lubrication, aging, wear). Inspect webbing by bending it in an inverted “U” to detect damaged fibers or cuts.
• Defects or damage to hardware elements (cracks, sharp edges, deformation, corrosion, chemical attack, excessive heating, alteration, wear).
• D-Ring: Should pivot freely.
• Tongue Buckles/Grommets: Tongues should be free of distortion, overlap the frame, and move freely. Rollers should turn freely. Inspect for loose, distorted, or broken grommets. Webbing should not have additional punched holes.
• Pivot Link Feature: Inspect for free movement, ensure components are not bent, corroded, damaged, or missing fasteners. Ensure webbing is secured and free from damage/wear.
• Cam Buckles: Ensure the cam mechanism is free of debris and engages webbing properly.
• Friction and Slotted Mating Buckles: Outer and center bars must be straight. Pay attention to corners and attachment points.
• Quick-Connect Buckles: Ensure dual-tab release mechanism is free of debris and engages properly. Tug on both halves to confirm secure connection.
• Defects or damage to integral pads (D-ring pad, chest strap adjuster pads), including cracks, breaks, or excessive wear.
• Evidence of deployed or activated fall load indicators.

Fall Load Indicators:

• D-Ring Pad Load Indicator: Pad has built-in indicators. If exposed to fall arrest forces, the pad will be broken or stretched between the arrows.
• Webbing Load Indicator: Folds sewn into shoulder straps below the back D-ring pad. If exposed to fall arrest forces, stitching will rip, and webbing will unfold.

WARNING: If inspection reveals defects, damage, inadequate maintenance, or evidence of exposure to fall arrest forces, tag equipment as “unusable,” remove from service, or have it corrected by the manufacturer before return to service.

7.2. Maintenance and Storage

Basic care prolongs service life. Clean harnesses periodically with a sponge and mild soap/detergent solution. Hang to dry away from excessive heat, steam, or prolonged sunlight. Store equipment to preclude damage from environmental factors (temperature, light, UV rays, moisture, oil, chemicals). Honeywell recommends hanging the harness by its back D-ring to maintain shape and prevent tangling.

Equipment needing maintenance shall be tagged as unusable and removed from service.

8.0 Preventing Suspension Trauma

Suspension trauma can occur within minutes after a fall. Prompt rescue and post-fall suspension relief devices (e.g., Miller Relief Step™ Safety Device) can help. A conscious user can deploy a relief device to remove leg tension, freeing blood flow and delaying suspension intolerance.

Using the Miller Relief Step Safety Device: Provides support and enhances blood circulation by allowing the user to move and flex leg muscles until rescue. Small and lightweight, it attaches to any brand full-body harness.

9.0 Cleaning and Maintenance

• Clean the harness with a damp cloth. Never use acid, solvents, or solvent-based products.
• Allow to dry in a well-ventilated area, away from heat sources.
• Store away from humidity and ultraviolet light.
• Avoid storage with direct sun exposure.
• Avoid corrosive, excessively hot, or refrigerated atmospheres.

10.0 Transportation, Storage, and Packaging

During transport, store PPE away from heat, dampness, corrosive atmospheres, and UV rays. Harnesses are sold in rot-proof, waterproof plastic packaging with instructions.

Appendices

APPENDIX A: REFERENCE IMAGES

Contains images related to D-Ring Pad Load Indicator and SRD-P integrated connector Element.

APPENDIX B: HOW TO WEAR THE HARNESS

Provides visual guidance on wearing the harness.

APPENDIX C: LABEL PACK

Details on product labels, including meaning of labeling elements (product reference, materials, date of manufacture, lot/serial number, applicable standard, country of origin, RFID tag).

Harness Size Chart

Provides a chart correlating height and weight with harness sizes (XS, S/M, L/XL, UNIV, XXL, 3/4XL).

INSPECTION AND MAINTENANCE LOG

A log for recording inspection and maintenance details, including date, items noted, corrective action, and approval.