8mm Permanent

Horizontal Lifeline
Fall Arrest/Fall Restraint System

Installation Instruction Manual

5908260 Rev. A
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 SIT 5908279 Rev. B
SAFETY INFORMATION EN
Please read, understand, and follow all safety information contained in these instructions prior to the use of this Horizontal System.
FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY OR DEATH.

These instructions must be provided to the user of this equipment. Retain these instructions for future reference.

Intended Use:
This Horizontal System is intended for use as part of a complete personal fall protection system.

Use in any other application including, but not limited to, material handling, recreational or sports related activities, or other activities not described in
the User Instructions, is not approved by 3M and could result in serious injury or death.

This system is only to be used by trained users in workplace applications.

! WARNING
This Horizontal System is part of a personal fall protection system. It is expected that all users be fully trained in the safe installation and operation of
their personal fall protection system. Misuse of this device could result in serious injury or death. For proper selection, operation, installation,
maintenance, and service, refer to these User Instructions and all manufacturer recommendations, see your supervisor, or contact 3M Technical Service

• To reduce the risks associated with installing a Horizontal System which, if not avoided, could result in serious injury or death:
- Do not connect to the system while it is being installed.
- The substrate or structure to which the anchorage connector is attached must be able to sustain the static loads specified for the anchor in the
orientations permitted in the User Instructions.
- Ensure this system is installed under the supervision of an OSHA-defined Qualified Person, an Authorized Person, or a 3M certified installer.
- Use only cables or rail described and approved in the Product Instructions.
- Always wear a personal fall protection system when installing a horizontal system.
- Always use appropriate energy absorbers per requirements in the Product Instructions for your system.
- (CABLE SYSTEMS) Use proper safety procedures and appropriate personal protective equipment when handling cable.
- (CABLE SYSTEMS) Never rigidly mount Zorbit energy absorber to the structure or stanchion. Zorbit must be mounted such that it can pivot and
move freely.

• To reduce the risks associated with working with a Horizontal System which, if not avoided, could result in serious injury or death:
- Inspect the system before each use, at least annually, and after any fall event. Inspect in accordance with the User Instructions.
- If inspection reveals an unsafe or defective condition, remove the system from service and repair or replace according to the User Instructions.
- Any system that has been subject to fall arrest or impact force must be immediately removed from service and all components must be
inspected by a Competent Person prior to being used again.
- Ensure system is appropriate for the number of simultaneous users.
- Work as closely to the horizontal lifeline as possible to prevent swing fall and limit fall clearance requirements. Refer to connecting device User
Instructions for more information.
- Ensure that fall protection systems/subsystems assembled from components made by different manufacturers are compatible and meet the
requirements of applicable standards, including the ANSI Z359 or other applicable fall protection codes, standards, or requirements. Always
consult a Competent or Qualified Person before using these systems.

• To reduce the risks associated with working at height which, if not avoided, could result in serious injury or death:
- Ensure your health and physical condition allow you to safely withstand all of the forces associated with working at height. Consult with your
doctor if you have any questions regarding your ability to use this equipment.
- Never exceed allowable capacity of your fall protection equipment.
- Never exceed maximum free fall distance of your fall protection equipment.
- Do not use any fall protection equipment that fails pre-use or other scheduled inspections, or if you have concerns about the use or suitability
of the equipment for your application. Contact 3M Technical Services with any questions.
- Some subsystem and component combinations may interfere with the operation of this equipment. Only use compatible connections. Consult
3M prior to using this equipment in combination with components or subsystems other than those described in the User Instructions.
- Use extra precautions when working around moving machinery (e.g. top drive of oil rigs) electrical hazards, extreme temperatures, chemical
hazards, explosive or toxic gases, sharp edges, or below overhead materials that could fall onto you or the fall protection equipment.
- Use Arc Flash or Hot Works devices when working in high heat environments.
- Avoid surfaces and objects that can damage the user or equipment.
- Ensure there is adequate fall clearance when working at height.
- Never modify or alter your fall protection equipment. Only 3M or parties authorized in writing by 3M may make repairs to the equipment.
- Prior to use of fall protection equipment, ensure a rescue plan is in place which allows for prompt rescue if a fall incident occurs.
- If a fall incident occurs, immediately seek medical attention for the fallen worker for the worker who has fallen.
- Do not use a body belt for fall arrest applications. Use only a Full Body Harness.
- Minimize swing falls by working as directly below the anchorage point as possible.
- If training with this device, a secondary fall protection system must be utilized in a manner that does not expose the trainee to an unintended
fall hazard.
- Always wear appropriate personal protective equipment when installing, using, or inspecting the device/system.

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  Prior to installation and use of this equipment, record the product identification information from the ID label in the
Inspection and Maintenance Log (Table 2) at the back of this manual.

PRODUCT DESCRIPTION:
Figure 1 illustrates typical 8mm Permanent Horizontal Lifeline (HLL) systems. The Permanent Horizontal Lifeline can be Wall
Mounted (Figure 1-1), Floor/Post Mounted (Figure 1-2), or Overhead (OH) Mounted (Figure 1-3) for Fall Restraint or Fall Arrest
applications: Fall Restraint systems (Figure 2-1) prevent the user from reaching fall hazards (roof edges, etc.). Fall Arrest
systems (Figure 2-2) allow access to fall hazards but safely arrest fall forces and minimize injury in the event of a fall.

Components of the 8mm Permanent Horizontal Lifeline are identified in Figure 1 and specified in Table 1. The 8mm
Permanent Horizontal Lifeline is a tensioned 8mm stainless steel Cable Lifeline (A) terminated between End Anchor Brackets
(B) and Connectors (C). One or both ends of the Lifeline are also terminated with an Energy Absorber (D) that indicates system
tension for installation and inspection, limits forces on the system, and absorbs energy in a fall arrest. Intermediate Brackets (E)
and Corner Brackets (F) allow for longer and multi-directional cable spans while reducing fall clearance requirements. Travelers
(G) attach around the Lifeline and provide moving anchorage connection points for the user’s Personal Fall Arrest or Personal Fall
Restraint system.

 Technical Data Sheets: See the associated Technical Data Sheets for illustrations and additional details regarding all
parts specified in Table 1.

Table 1 – Specifications

CABLE LIFELINE SPECIFICATIONS:

Minimum Breaking
Figure 1 Part Number Description Material Strength kN (lb)
7240211 8mm 7x7 Stainless Steel Cable 316 Stainless Steel 38.7 (8,700)
A
7240212 8mm 1x19 Stainless Steel Cable 316 Stainless Steel 47 (10,600)
7234012 Hex Joiner 316 Stainless Steel 38 (8,540)
7241432 End Stopper Black Urethane
Metal Insert

END ANCHOR BRACKET SPECIFICATIONS:

Figure 1 Part Number Description Material Minimum Breaking Strength
7240122 Straight Eye 316 Stainless Steel 45 (10,000)
B
Nylon
7241417 Anchor Plate Standard 316 Stainless Steel 45 (10,000)
Nylon

END CONNECTOR SPECIFICATIONS:

Figure 1 Part Number Description Material Minimum Breaking Strength
7234011 Hex Swage Toggle 316 Stainless Steel 38 (8,540)
C
7241430 Hex Swage Stud, Pass Through 316 Stainless Steel 38 (8,540)
7234246 Hex Swage Toggle with Shoulder for End Stopper 316 Stainless Steel 38 (8,540)

ENERGY ABSORBER SPECIFICATIONS:

Minimum Peak Average
Breaking System Deployment Deployment Total
Strength Tension Force Force Elongation
Figure 1 Part Number Description Material kN (lb) kN (lbf) kN (lbf) kN (lbf) m (ft)
7241422 11kN Peak Force, 0.8kN 316 Stainless 38 (8,540) 0.8 (180) 11 (2,500) 9 (2,020) 1.2 (4)
D
System Tension Energy Steel
Absorber
7241424 19kN Peak Force, 0.8kN 316 Stainless 38 (8,540) 0.8 (180) 19 (4,270) 16 (3,600) 0.6 (2)
System Tension Energy Steel
Absorber (Not for North
America)
7241425 19kN Peak Force, 5kN 316 Stainless 38 (8,540) 5 (1,125) 19 (4,270) 16 (3,600) 0.6 (2)
System Tension Energy Steel
Absorber (Not for North
America)
7241426 19kN Peak Force, 0.8kN 316 Stainless 38 (8,540) 0.8 (180) 19 (4,270) 16 (3,600) 1.2 (4)
System Tension Energy Steel
Absorber (North America
Only)
7241427 19kN Peak Force, 5kN 316 Stainless 38 (8,540) 5 (1,125) 19 (4,270) 16 (3,600) 1.2 (4)
System Tension Energy Steel
Absorber (North America
Only)
7241428 Dampener, 5kN 316 Stainless 38 (8,540) 5 (1,125)
Steel
7241429 Dampener/Tension 316 Stainless 38 (8,540) 0.8 (180)
Indicator, 0.8 kN Steel
Continued on next page....

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 Table 1 – Specifications

INTERMEDIATE BRACKET SPECIFICATIONS:

Minimum
Breaking
Strength Lifeline Tensioning
Figure 1 Part Number Description Material kN (lb) kN (lb)
7241412 Intermediate Bracket 316 Stainless Steel 38 (8,543) 0.8 (180) or 5 (1,125)
E
7241413 Variable Intermediate Bracket 316 Stainless Steel 30 (6,744) 0.8 (180) or 5 (1,125)
7241414 Variable Mount Angle Intermediate Bracket 316 Stainless Steel 24 (5,400) 0.8 (180) or 5 (1,125)
7241415 45 Degree Intermediate Bracket 316 Stainless Steel 24 (5,400) 0.8 (180) or 5 (1,125)
 Maximum Entry/Exit Angle: The maximum angle at which the HLL cable can enter or exit each Intermediate Bracket is 15°.

CORNER BRACKET SPECIFICATIONS:

Minimum
Breaking
Strength Lifeline Tensioning
Figure 1 Part Number Description Material kN (lb) kN (lb)
F 7241406 90 Wall & OH Internal Mount 316 Stainless Steel 38 (8,540) 0.8 (180) or 5 (1,125)

7241407 90 Wall & OH External Mount 316 Stainless Steel 38 (8,540) 0.8 (180) or 5 (1,125)

7241408 90 Post internal Mount 316 Stainless Steel 22.2 (5,000) 0.8 (180)

7241409 45 Wall & OH Internal Mount 316 Stainless Steel 38 (8,540) 0.8 (180) or 5 (1,125)

7241410 45 Wall & OH External Mount 316 Stainless Steel 38 (8,540) 0.8 (180) or 5 (1,125)

7241411 45 Post Internal Mount 316 Stainless Steel 22.2 (5,000) 0.8 (180)

7241525 90 Wall External Corner Mount 316 Stainless Steel 38 (8,540) 0.8 (180) or 5 (1,125)

7241526 90 Wall Internal Corner Mount 316 Stainless Steel 38 (8,540) 0.8 (180) or 5 (1,125)

7241570 45 Wall Internal/External Corner Mount 316 Stainless Steel 38 (8,540) 0.8 (180) or 5 (1,125)

 Maximum Entry/Exit Angle: The maximum angle at which the HLL cable can enter or exit each Corner Bracket is 15°.

TRAVELER SPECIFICATIONS:
Minimum Breaking
Figure 1 Part Number Description Material Strength kN (lb) Capacity
7241420 Detachable Traveler - No Wheels Stainless Steel 22.2 (5,000) 1 Person up to 140 kg (310 lbs)
G
including clothing, tools, etc.
per Traveler
7241421 Overhead Traveler Stainless Steel 22.2 (5,000) 1 Person up to 140 kg (310 lbs)
including clothing, tools, etc.
per Traveler

SYSTEM SPECIFICATIONS:
Anchorage Structure supporting the 8mm Permanent Horizontal Lifeline System must be analyzed and verified by the Certified Installer1
for the resulting loads based on the system configuration, energy absorbing component, and number of users.

Capacity 1 Person up to 140 kg (310 lbs) including clothing, tools, etc. per Traveler unless otherwise specified by the documentation
from the Certified Installer or on the System Tag. The Certified Installer documentation will also specify the total number of
users allowed per system.

Operating -50° C - 120° C

Temperature (-58° F - 248° F)

Standards EN 795:2012 Class C, CENTS 16415:2013 Class C, OSHA 1926.502, AS/NZS 1891.2:2001, ANSI Z359.62, and CSA Z259.162

TOOL SPECIFICATIONS:
Tensioning All 8 mm Lifelines: Tensioning Tool, 3M Part 7241431
Tools 0.8 kN (180 lbf) Tensioned Lifelines: Drill Driver
5 kN (1,125 lbf) Tensioned Lifelines (General Use): Impact Driver with 165 Nm (120 lbf-ft) Minimum Torque
5 kN (1,125 lbf) Tensioned Lifelines (Heavy Use): Impact Driver with 300 Nm (220 lbf-ft) Minimum Torque

Swaging Hex Swage Dies: 10 mm Bite, 3M Part 7241122 Recommended

Tools Hand Compression Tool (Swager): 38 kN (8,543 lbf) Minimum Swage Strength
Power Compression Tool (Power Swager): Milwaukee M18™ Force Logic™ 12 Ton Utility Crimper, PN 2778-22 (or
equivalent 12 Ton Power Swager):
Swage Test Tool: 7241126 Cable and Eyebolt Tester Kit

1 3M Certified Installer: A person certified by 3M with extensive knowledge, training, and experience in the fall protection and rescue field who is capable of designing,
analyzing, evaluating, and specifying fall protections and rescue systems to the extent required by applicable regional and national standards.
2 ANSI Z359.6, CSA Z259.16: This system meets these design requirements when designed by a professional and is inclusive of a full documentation package as
specified in ANSI Z359.6 or CSA Z259.16.

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1.0 PRODUCT APPLICATION
1.1 PURPOSE: 3M Engineered Systems provide permanent anchorage for Personal Fall Arrest Systems (PFAS) and Personal
Fall Restraint Systems (PFRS). They typically employ a flexible or rigid anchor line with mobile anchorage connection
points to ensure user connection along the entire length of the system.

1.2 SUPERVISION: Installation of the Engineered System1 must be supervised by a Certified Installer2.

1.3 INSTALLATION DOCUMENTATION: The Engineered System is designed by a 3M Certified Installer to meet the specific
requirements of the product application and location. On completion of the installation, the Certified Installer will provide
an Installation Packet including the following:

System Documentation System Certificate System Label

The Certified Installer will provide as a
minimum:
• Design information including: End
Loads, Intermediate Loads, Cable
Deflection, Fabrication Detail,
Maximum Number of Users, and
specifics regarding User Equipment
and Test Requirements.
• User Instruction Manual
• Product Warranty
• Installation Serial Number
• Rescue Plan explaining how to rescue
someone in the event of a fall (Fall
Arrest installations only). This is
an additional service for which the
Installer may require an additional
charge.
The System Certificate is signed by a
representative of the Installation Company
and will include the following detail:
• Location of the Installation
• Unique Identification Number
• Number and Length of Systems
• Maximum number of Users per Span
and per System
• Type and Maximum Length of Lanyards
specified
• Installation Date
• Date of Next Required Service
• Name and Contact Detail for the
Installation Company
• Name of the Installation Engineer and/
or Supervisor
The System Label is located at the entrance
point to the system and will include the
following detail:
• Maximum Number of Users per Span
and per System
• Type and Maximum Length of Lanyards
specified
• Installation Date and details regarding
the Installation Company
• Next Service Date
• System Serial Number
• Minimum Ground Clearance
• Contact Detail for the Installation
Company

1.4 TRAINING: This equipment must be installed and used by persons trained in its correct application. It is the
responsibility of the users and installers of this equipment to ensure they are familiar with these instructions, trained in
the correct care and use of this equipment, and are aware of the operating characteristics, application limitations, and
consequences of improper use of this equipment.

1.5 LIMITATIONS: Always consider the following limitations when designing and installing the Engineered System:

• Anchorage: Structure on which the Engineered System is mounted must meet the Anchorage specifications defined
in Table 1 and the 3M™ DBI-SALA® Installed Systems Calculation Software.

• Fall Path and SRL Locking Speed: A clear path is required to assure positive locking of an SRL. Situations which do
not allow for an unobstructed fall path should be avoided. Working in confined or cramped spaces may not allow the
body to reach sufficient speed to cause the SRL to lock if a fall occurs. Working on slowly shifting material, such as
sand or grain, may not allow enough speed buildup to cause the SRL to lock.

• Hazards: Use of this equipment in areas with environmental hazards may require additional precautions to prevent
injury to the user or damage to the equipment. Hazards may include, but are not limited to: heat, chemicals,
corrosive environments, high voltage power lines, explosive or toxic gases, excessive vibration, moving machinery,
sharp edges, or overhead materials that may fall and contact the user or Personal Fall Arrest System.

• Fall Clearance: There must be sufficient clearance below the user to arrest a fall before the user strikes the ground
or other obstruction. Fall Clearance is influenced by the following factors:

• Deceleration Distance • Worker Height • Elevation of Anchorage Connector

• Free Fall Distance • Movement of Harness Attachment Element • Connecting Subsystem Length
Check the Certified Installer’s Post-Installation Documentation for specifics regarding system design and fall clearance
calculation. Changes in system location, equipment placement, etc. require review and revision of original clearance
calculations. Contact the Certified Installer or 3M Fall Protection for assistance.
• Swing Falls: Swing Falls occur when the anchorage point is not directly above the point where the fall occurs (see
Figure 3). The force of striking an object while swinging from the pendulum effects of a Swing Fall can cause serious
injury (Figure 3-1). Swing Falls can be minimized by limiting the horizontal distance between the user and the
anchorage point (H). In a Swing Fall, the total vertical fall distance will be greater than if the user had fallen directly
below the anchorage point, thus increasing Fall Clearance required to safely arrest the user’s fall (Figure 3-2). See
the PFAS manufacturer’s instructions for details regarding Swing Falls and Fall Clearance calculation.

• Sharp Edges: The Engineered System must be installed so deflection of the anchor line in a fall arrest does not bring
the anchor line into contact with a sharp edge or any other article that may damage the anchor line. Avoid working
where Lifeline or Lanyard components of the attached Personal Fall Arrest System (PFAS) can contact or abrade
against unprotected sharp edges (see Figure 4). Where contact with a sharp edge is unavoidable, cover the edge with
protective material (A).

1 Engineered System: An application specific fall protection system designed, analyzed, evaluated, specified, and installed by a 3M Certified Installer.
2 Certified Installer: A person certified by 3M with extensive knowledge, training, and experience in the fall protection and rescue field who is capable of designing,
analyzing, evaluating, and specifying fall protection and rescue systems to the extent required by applicable regional and national standards.

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2.0 SYSTEM CONSIDERATIONS
2.1 RESCUE PLAN: When using the Engineered System and connecting subsystem(s), the employer must have a rescue
plan and the means at hand to implement and communicate that plan to users, authorized persons3, and rescuers4. A
trained, on-site rescue team is recommended. Team members should be provided with the equipment and techniques to
perform a successful rescue. Training should be provided on a periodic basis to ensure rescuer proficiency.

 The Rescue Plan may be provided by the Certified Installer. In which case, the Rescue Plan will be include in the
System Documentation provided on completion of installation.

2.2 INSPECTION FREQUENCY: The Engineered System must be inspected by the 3M certified Installer after installation and
by the User before each use5. Inspection procedures are described in the “Inspection and Maintenance Log” included in this
Installation Manual and the User Manual. Additionally a Periodic Examination must be performed by a 3M Certified Installer
at intervals of no more than one year. See the “Certified Installer Inspection Schedule” for guidelines. Results of each
Certified Installer Inspection should be recorded on copies of the Inspection and Maintenance Log.

 Extreme Conditions: Harsh environments, corrosive atmosphere, thermal changes, excessive vibration, prolonged
use, etc.) will require more frequent inspections by the Certified Installer. See the “Certified Installer Inspection
Schedule” for guidelines. Where the Certified Installer determines that extreme conditions require increased frequency
of Periodic Examinations, that requirement will be stated in the System Documentation and System Certificate provided
by the Certified Installer.

2.3 AFTER A FALL: If the Engineered System is subjected to the forces of arresting a fall, it must be removed from the field
of service immediately and replaced or recommissioned by a Certified Installer.

2.4 PERSONAL FALL ARREST SYSTEM: Personal Fall Arrest Systems (PFAS) used with the Engineered System must meet
applicable Fall Protection standards, codes, and requirements. The PFAS shall incorporate a Full Body Harness and limit
Maximum Arresting Force (MAF) to the following values:

MAF for CE Systems MAF for OSHA Systems

PFAS with Shock Absorbing Lanyard 6 kN (1,350 lb) 8 kN (1,800 lb)
PFAS with Self Retracting Device 6 kN (1,350 lb) 8 kN (1,800 lb)
 Engineered Systems: PFAS used with Engineered Systems must also meet the requirements specified on the
Certificate and System Label provided by the Certified Installer.

Table 2 – Certified Installer Inspection Schedule

Type of Use Application Examples Conditions of Use Periodic Examination/
Certification Frequency
Infrequent to Light Use Residential and Commercial Good Conditions, Indoors or At least Annually
buildings where the system is Protected Non-Coastal Outdoor
mounted directly to structural Use, Clean Environments
steel or masonry.
Commercial Construction, Harsh Storage Conditions, Quarterly or when not used
Manufacturing Facility, Oil and Dirty Environment, Corrosive Quarterly, at least prior to
Gas, Mining, Foundry Atmosphere, Extreme each use.
Temperatures, Adjacent to or on
Heavy Equipment or Cranes.
Moderate to Heavy Use Residential and Commercial Good Conditions, Indoors or At least Annually, but
buildings where the system is Protected Non-Coastal Outdoor dependent on ability of users
mounted directly to structural Use, Clean Environments to access system for Pre-Use
steel or masonry. Visual Inspection5.
Commercial Construction, Harsh Storage Conditions, Semi-annually to Quarterly
Manufacturing Facility, Oil and Dirty Environment, Corrosive depending upon severity
Gas, Mining, Foundry Atmosphere, Extreme of application and ability of
Temperatures, Adjacent to or on users to access system for
Heavy Equipment or Cranes. Pre-Use Visual Inspection5.
Severe to Continuous Use Residential and Commercial Good Conditions, Indoors or At least Annually, but
buildings where the system is Protected Non-Coastal Outdoor dependent on ability of users
mounted directly to structural Use, Clean Environments to access system for Pre-Use
steel or masonry. Visual Inspection5.
Commercial Construction, Harsh Storage Conditions, Quarterly to Monthly
Manufacturing Facility, Oil and Dirty Environment, Corrosive depending upon severity
Gas, Mining, Foundry Atmosphere, Extreme of application and ability of
Temperatures, Adjacent to or on users to access system for
Heavy Equipment or Cranes. Pre-Use Visual Inspection5.
3 Authorized Person: A person assigned by the employer to perform duties at a location where the person will be exposed to a fall hazard (otherwise referred to as the
“user for purposes of these instructions).
4 Rescuer: Person or persons other than the rescue subject acting to perform an assisted rescue by operation of a rescue system.
5 Pre-Use Visual Inspection: Systems mounted high above the user or in other locations that are dangerous or difficult to inspect may require more frequent Certified
Installer inspections in place of User inspections prior to each use. Where the Certified Installer determines that User Pre-Use Visual inspections should be replace by
additional Certified Installer inspections, that requirement will be stated in the System Documentation and System Certificate provided by the Certified Installer.

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2.5 COMPONENT COMPATIBILITY: 3M FALL Protection equipment is designed for use with 3M approved components and
subsystems only. Substitutions or replacements made with non-approved components or subsystems may jeopardize
compatibility of equipment and may effect the safety and reliability of the complete system.

2.6 CONNECTOR COMPATIBILITY: Connectors are considered to be compatible with connecting elements when they
have been designed to work together in such a way that their sizes and shapes do not cause their gate mechanisms to
inadvertently open regardless of how they become oriented. Contact 3M if you have any questions about compatibility.
Connectors (hooks, carabiners, and D-rings) must be capable of supporting at least 22.2 kN (5,000 lb). Connectors must
be compatible with the anchorage or other system components. Do not use equipment that is not compatible. Non-
compatible connectors may unintentionally disengage (see Figure 5). Connectors must be compatible in size, shape,
and strength. If the connecting element to which a snap hook or carabiner attaches is undersized or irregular in shape, a
situation could occur where the connecting element applies a force to the gate of the snap hook or carabiner (A). This force
may cause the gate to open (B), allowing the snap hook or carabiner to disengage from the connecting point (C). Self-
locking snap hooks and carabiners are required.

2.7 MAKING CONNECTIONS: Snap hooks and carabiners used with this equipment must be self-locking. Ensure all
connections are compatible in size, shape and strength. Do not use equipment that is not compatible. Ensure all
connectors are fully closed and locked.
3M connectors (snap hooks and carabiners) are designed to be used only as specified in each product’s user’s instructions.
See Figure 6 for examples of inappropriate connections. Do not connect snap hooks and carabiners:
A. To a D-ring to which another connector is attached.
B. In a manner that would result in a load on the gate.

 Large throat snap hooks should not be connected to standard size D-rings or similar objects which will result in
a load on the gate if the hook or D-ring twists or rotates, unless the snap hook is equipped with a 16 kN (3,600 lb)
gate. Check the marking on your snap hook to verify that it is appropriate for your application.

C. In a false engagement, where features that protrude from the snap hook or carabiner catch on the anchor, and
without visual confirmation seems to be fully engaged to the anchor point.
D. To each other.
E. Directly to webbing or rope lanyard or tie-back (unless the manufacturer’s instructions for both the lanyard and
connector specifically allows such a connection).
F. To any object which is shaped or dimensioned such that the snap hook or carabiner will not close and lock, or that
roll-out could occur.
G. In a manner that does not allow the connector to align properly while under load.

8
3.0 INSTALLATION

 3M Engineered System Installation: The 8mm HLL Permanent Horizontal Lifeline is an Engineered HLL System
designed, analyzed, and specified by a 3M Certified Installer for a specific location and product application. Installation
of the 8mm HLL System must be supervised by the 3M Certified Installer. Changes in system location, equipment
placement, etc. will require review and revision of original specifications. Contact the Certified Installer or 3M Fall
Protection for assistance.

Installation procedure will vary with the application and location of the 8mm Permanent Horizontal Lifeline (HLL), but
basic steps for installing the 8mm HLL are as follows:
1. Mount End Anchor Brackets, Intermediate Brackets, and Corner Brackets at the planned locations.
2. Starting at the entrance point to the system, thread the Cable Lifeline through all Intermediate Brackets and Corner
Brackets.
3. At the entrance point to the system, terminate the end of the Cable Lifeline with the planned End Connector and
Energy Absorber (if needed at each end of the lifeline) and connect the Cable Lifeline to the End Anchor Bracket.
4. If the HLL system requires Overhead Travelers, thread all Overhead Travelers on the free end of the Cable Lifeline.
Detachable Travelers can be installed by the User prior to use of the system.
5. At the far end of the system: connect the planned Energy Absorber and Pass Through End Connector to the End
Anchor Bracket, thread the Cable Lifeline through the Pass Through End Connector, tension the Cable Lifeline, and
then swage the Pass Through End Connector onto the cable with a Hex Swager.
6. Inspect all system swages.
7. Complete and Install the System Label at the entrance point to the system.

The proceeding sections detail installation of the components specified in Table 1. Additional information is available in the
8mm Permanent Horizontal Lifeline Technical Data Sheets.

3.1 END ANCHOR BRACKETS: Minimum Grade A4-70 M16 (or 5/8 in) Fasteners should be used to mount End Anchor
Brackets to structure at a recommended torque of 50 Nm (37 ft-lbf). Mounting must support at least twice the load
values stated in the technical report generated by the 3M DBI-SALA Installed Systems Calculation Software for the system
layout, components, number of users, and SRL or Lanyard connecting device. Mounting orientations and installation are
as follows:

Wall Mount Floor Mount Post Mount Overhead Mount

7240122 √ √ √ √
7241417 √ √ √

1. Mark and drill mounting holes to 2. Secure the End Anchor Bracket 3. Torque fasteners to
the depth and diameter specified to structure as recommended manufacturer’s specification or
in the fastener manufacturer’s in the fastener manufacturer’s recommended 50 Nm (37 ft-lbf).
documentation. documentation.

9
3.2 INTERMEDIATE BRACKETS: Minimum Grade A4-70 M12 ( or 1/2 in) Fasteners should be used to mount Intermediate
Brackets to structure at a recommended torque of 50 Nm (37 ft-lbf). Mounting must support a bracket load of 24 kN
(5,400 lbf) perpendicular to the lifeline. Mounting orientations and installation are as follows:

Overhead Mount
Wall Mount Floor Mount Post Mount Overhead Mount (pitched)
7241412 √ √ √
7241413 √ √ √
7241414 √ √ √ √ √
7241415 √ √ √

1. Mark and drill a mounting hole to 2. Secure the End Anchor Bracket 3. Torque fastener to manufacturer’s
the depth and diameter specified to structure as recommended specification or recommended 50
in the fastener manufacturer’s in the fastener manufacturer’s Nm (37 ft-lbf)..
documentation. documentation.

3.3 CORNER BRACKETS: Minimum Grade A4-70 M12 (or 1/2 in)Fasteners should be used to mount Corner Bracket to
structure at a recommended torque of 50 Nm (44 ft-lbf). Mounting must support bracket load of 38 kN (8,550 lbf) in the
plane of the lifeline and a load of 24 kN (5400 lbf) perpendicular to the lifeline. 45° and 90° Corner Brackets are available
for internal or external corners on 0.8 kN or 5 kN tensioned systems:

Internal
Corner Brackets Wall Mount Floor Mount Post Mount Overhead Mount
7241406 90° √ √ √
7241408 90° √ √
7241409 45° √ √ √
7241411 45° √ √
7241526 90° √
7241570 45° √

10
External
Corner Brackets Wall Mount Floor Mount Overhead Mount
7241407 90° √ √ √
7241410 45° √ √ √
7241525 90° √
7241570 45° √

1. If necessary, reposition the Bracket Mounts for 2. Mark and drill mounting holes to the depth and
Overhead (A), Wall (B), or Floor (C) mounting. Torque diameter specified in the fastener manufacturer’s
the larger M12 fasteners to 50 Nm (37 ft-lbf). Torque documentation.
the smaller M8 fasteners to 15 Nm (11 ft-lbf).

3. Secure the Corner Bracket to structure as 4. Torque fasteners to manufacturer’s specification or

recommended in the fastener manufacturer’s recommended 50 Nm (37 ft-lbf)..
documentation.

11
3.4 CABLE LIFELINES: Cable Lifelines come in custom lengths of 7 x 7 or 1 x 19 - 8 mm Stainless Steel Cable. 1 x 19 cable
is recommended for Overhead HLL systems where stiffer cable with less flex is needed.

8 mm 7 x 7 Stainless Steel Cable 8 mm 1 x 19 Stainless Steel Cable

7240211 √
7240212 √
7234012 Hex Joiner For swaging together sections of lengths of 8 mm Cable.
7241432 End Stopper Prevents travelers from colliding with Lifeline end
terminations.

1. Starting at the entrance point 2. Where additional lengths of cable 3. At the entrance point, swage the
to the system, thread the Cable are needed, swage cable ends required End Connector onto the
Lifeline through all Intermediate together with a Hex Joiner. See cable end. See Swaging.
Brackets and Corner Brackets. Swaging.

4. Secure the Lifeline to the End
Anchor Bracket with the End
Connector and Energy Absorber
(if required). See End Connectors
and Energy Absorbers.
5. At the far end of the HLL, connect
the specified Energy Absorber and
End Connector to the End Anchor
Bracket. See End Connectors and
Energy Absorbers.
6. On Overhead HLL systems with
the Overhead Traveler, install
the Overhead Travelers on the
detached end of the Lifeline. See
Travelers.

7. Insert the free end of the Lifeline 8. Where specified, install End
through the Pass Through Hex Stoppers on the Lifeline cable.
Swage Stud End Connector,
tension the Lifeline cable (see
Tensioning), and then swage the
cable in the End Connector (see
Swaging).

12
3.5 TRAVELERS: Detachable Travelers or Overhead Travelers provide moving anchorage connection points for the users’
Personal Fall Arrest or Personal Fall Restraint systems. The Detachable Traveler can be installed and removed by the user.
The Overhead Traveler is permanent and must be installed by the Certified Installer before the 8mm HLL is terminated at
both ends.

Wall Mount Floor/Post Mount Overhead Mount

7241420
Detachable
√ √

7241421
Overhead
√

1. Press in the Locking Pin Buttons
on each side of the Traveler and
rotate the Bottom Portion down
to open the Traveler.
2. Hang the Top Portion of the
Traveler over the Lifeline Cable
with the slot in the Traveler
facing the Cable Tubes on any
Intermediate Brackets and Corner
Brackets.
3. Close the Bottom Portion around
the cable. The Locking Pin
Buttons will snap out to their
locked position.

1. Align the Traveler so the slot in the Traveler faces the 2. Insert the free end of the Lifeline Cable through the
Cable Tubes on any Intermediate Brackets and Corner slot in the Traveler so the Traveler Wheels ride on top
Brackets. of the cable.

13
3.6 END CONNECTORS AND ENERGY ABSORBERS: Use End Connectors to terminate each end of the Cable Lifeline. A
Hex Swage Toggle is used where the Lifeline can be anchored directly to the End Anchor Bracket without tensioning and
an Energy Absorber. If an Ensd Stopper is needed, a Hex Swage Toggle with Shoulder can be used. A Pass Through Hex
Swage Stud is used where the Lifeline requires tensioning and an Energy Absorber.

End
Connectors Hex Swage Toggle Pass Through Hex Swage Stud Hex Swage Toggle with Shoulder
7234011 √
7241430 √
7234246 √

System Peak Arrest

Energy Tension Force
Absorbers kN (lbf) kN (lbf) Energy Absorber Dampener/Tension Indicator
7241422 0.8 (180) 11 (2,500) √
7241424 0.8 (180) 19 (4,270) √
7241425 5 (1,125) 19 (4,270) √
7241426 0.8 (180) 19 (4,270) √
7241427 5 (1,125) 19 (4,270) √
7241428 5 (1,125) √
7241429 0.8 (180) √

1. Fully insert the end of the Cable
Lifeline in the Swage Terminal on
the Hex Swage Toggle.
2. Swage the cable in the Hex
Swage Toggle with a Hex Swager.
See Swaging.
3. Remove the Toggle Pin from
the Hex Swage Toggle and then
secure the Hex Swage Toggle to
the End Anchor Bracket with the
Clevis Pin, Castle Nut, and Split
Pin.

14
 1. Secure the Energy Absorber to the End Anchor 2. Attach the Pass Through Hex Swage Stud to the
Bracket with the Clevis Pin, Castle Nut, and Split Pin. Energy Absorber with the Clevis Pin, Castle Nut, and
Split Pin.

3. Thread the end of the Cable Lifeline through the 4. Tension the Cable Lifeline (see Tensioning) and then
Swage Terminal on the Pass Through Hex Swage swage the cable in the Pass Through Hex Swage Stud
Stud. with a Hex Swager (see Swaging).

3.7 TENSIONING: When all components of the 8mm Permanent Horizontal Lifeline are installed, tension the Cable Lifeline to
the required System Tension, 0.8 kN (180 lbf) or 5 kN (1,125 lbf) with the Tensioning Tool and Energy Absorber. Tension
0.8 kN (180 lbf) systems with a standard Drill Driver. An Impact Driver is requred to tension 5 kN (1,125 lbf) systems.
See Table 1 - Tool Specifications for Drill Driver and Impact Driver requirements. Procedures for tensioning the 8mm
Permanent Horizontal Lifeline are as follows:

 Dropped Object Protection: The Tensioning Tool is equipped with a 3M Fall Protection for Tools Bungee Tether.
The D-Ring on the Tether must be connected to a separate Anchorage Connection Point NOT ON the users person.

B
A

A
C
C
C

1. Position the Tensioning Tool on the Lifeline Cable and
Pass Through Hex Swage Stud:
A. Loosen and then rotate the Locking Knob outward
from the Cable Clamp.
B. Open the Cable Clamp.
C. Rotate the Cable Latchs open.
D. Position the Tensioning Tool over the Cable
and Swage Terminal with the lip on the Swage
Terminal flush against the Cable Latch and the
Cable resting in the groove in the Cable Clamp.
2. Secure the Tensioning Tool on the Lifeline Cable and
Pass Through Hex Swage Stud:
A. Close the Cable Camp over the Cable.
B. Rotate and then tighten the Locking Knob to
secure the Cable Clamp an the Cable.
C. Rotate the Cable Latchs closed.
Contnued ...

15
 kN
19 kN
(4270 lb)

Weather

Weather
Warm

Cold
B

3. Tension the Cable Lifeline and then swage the Cable End in the Pass Through Hex Swage Stud:

A. Tension the Lifeline Cable to the required System Tension (0.8 kN or 5 kN) with the recommended Drill Driver
or Impact Driver (see Table 1 - Tool Spedcifications). When properly tensioned, the Shoulder Washer on the
Energy Absorber Tension Spring will be positioned in the Green Zone () on the Energy Absorber Tension
Label. The Shoulder Washer should be in the left 1/3 of the Green Zone on warm weather installations or in
the right 2/3 of the Green Zone on cold weather installations.
B. Apply one Swage to the Swage Terminal on the Pass Through Hex Swage Stud, remove the Tensioning Tool,
and then swage the Swage Terminal five more times (see Swaging).
C. Trim excess cable extending outside of the Pass Through Hex Swage Stud.

3.8 SWAGING: Use only 3M supplied 8 mm 7x7 or 1x9 Stainless Steel Cable as the Cable Lifeline in 8mm
Permanent Horizontal Lifeline Systems (see Table 1 - Cable Lifeline Specifications). Swage the required End Connector
onto each end of the Lifeline Cable to a minimum strength of 38 kN (8,543 lbf) with a Hex Swager and 3M Part 7241122
10 mm Bite Die:

Hex Swaging Table

Cable Swage Die Swage Bites Bite Gap (A) Width Across Flats (B)
7x7 7241122 6 discountinuous 1 mm - 1.5 mm (0.04 in - 0.06 in) 11.2 mm - 11.9 mm (0.44 in - 0.47 in)

1 x 19 7241122 6 discountinuous 1 mm - 1.5 mm (0.04 in - 0.06 in) 11.4 mm - 12.4 mm (0.45 in - 0.49 in)

A
B A
B

Part Number, Batch Number, and Swage Bite Dimensions are etched on the side of the swage part.

16
 A 1

A 1

1. CLOSED END SWAGE TERMINALS: Insert the the 2. Swage the Swage Terminal once on the connector end
Lifeline Cable in the barrel of the Swage Terminal to of the barrel (A).
the full depth of the terminal. Mark the cable at the
end of the Swage Terminal for reference that the If present on the cable, remove the Tensioning Tool.
cable doesn’t back out of the Swage Terminal during
swaging.

PASS THROUGH SWAGE TERMINALS: Thread the

Lifeline Cable through the barrel of the Swage
Terminals so the end extends out the connector end of
the terminal.

1 2 3 4 5 6 B

1 2 3 4 5 6 B

3. Swage the barrel of the Swage Terminal five more
times progressing toward the lip or chamfer at the
end of the Swage Terminal (B). Each succesive bite
should be gapped as specified in the Hex Swaging
Table with the last bite finishing just short of the
shoulder on the Swage Terminal.
4. After all 6 swages are completed, measure across the
flats of each bite with a Caliper to ensure they are
within the range specified in the Hex Swaging Table.
5. Pull test all swages to 19 kN (4,270 lbf). Hold load for
3 minutes without any slippage.

17
4.0 INSPECTION
4.1 INSPECTION FREQUENCY: The 8mm HLL Permanent Horizontal Lifeline must be inspected by the Certified Installer
after installation and at the intervals defined in Section 2. Inspection procedures are described in the “Inspection
and Maintenance Log” (Table 2). Inspect all other components of the Fall Protection System per the frequencies and
procedures defined in the manufacturer’s instructions.
4.2 INSPECTION RECORDS: Results of each Certified Installer inspection should be recorded on copies of the Inspection and
Maintenance Log. The date for the next required Certified Installer inspection should be recorded on the System Label.

 RFID Tag: Some Horizontal Lifeline (HLL) systems are equipped with a Radio Frequency Identification (RFID) Tag.
The RFID Tag can be used in conjunction with a Handheld Reading Device to simplify inspection and inventory control
and provide records for you fall protection equipment. Contact 3M or visit 3M.com/FallProtection for details.

4.3 DEFECTS: If inspection reveals an unsafe or defective condition, do not use the 8mm HLL System. Follow employer
recommended Lockout/Tagout procedures to remove the system from service and contact the 3M Certified Installer for
inspection and service. Do not attempt to repair the system. Only 3M or parties authorized in writing by 3M may make
repairs to this equipment.

4.4 PRODUCT LIFE: The functional life of the 8mm HLL system is determined by work conditions and maintenance. As long
as the product passes inspection criteria, it may remain in service.

5.0 MAINTENANCE, SERVICING, STORAGE

5.1 CLEANING: Periodically clean the systems metal components with a soft brush, warm water, and a mild soap solution.
Ensure all components are thoroughly rinsed with clean water after cleaning.

 Contaminants: Although highly resistant to chemicals and environmental conditions, avoid contaminating the 8mm
HLL and Travelers with acids, bitumen, cement, paint, cleaning fluids, etc. If the equipment contacts acids or other
caustic chemicals, remove from service and wash with water and a mild soap solution. Inspect per the “Inspection and
Maintenance Log” (Table 2) before returning to service.

5.2 SERVICE: Only 3M or Certified Installers authorized in writing by 3M Fall Protection may make repairs to this equipment.
If the 8mm HLL System has been subject to fall force or inspection reveals an unsafe or defective conditions, remove the
system from service and contact 3M Fall Protection or a 3M Certified Installer regarding replacement or repair.

18
 Table 3 – Inspection and Maintenance Log
Inspection Date: Inspected By:
Certified
Components: Inspection: (See Section 1 for Inspection Frequency) Installer
System Label and Inspect the System Label and System Certificate. Confirm that system use will comply with all of the
System Certificate following criteria:
 The System Certificate is valid and system certification is current. The system should be certified
annually or at the intervals specified by the Certified Installer. Do not use the system if system
certification is not current.
 The Maximum Number of Users is not exceeded.
 Correct Personal Protective Equipment (PPE) will be used (including proper Lanyard Length).
 Ground Clearance is still the same as specified on the System Label and there is no risk of collision in
the event of a fall (including Swing Fall hazards).
Traveler Visually inspect the Traveller for damage or wear. Ensure the Traveller closes securely and can not slip off
the HLL Wire Rope, Intermediate Brackets, and Corner Brackets.
Energy Absorber Visually inspect the Energy Absorber for signs of previous deployment. The Coils (A) should be tightly
(Figure 1) rolled with no tearing of metal between holes.
Visually inspect the Tension Indicator (B) to ensure the HLL is properly tensioned with Shoulder Washer at
the end of the Tension Spring positioned within the Green Zone (√) on the Tension Label.
HLL Wire Rope Visually inspect the HLL Wire Rope for cuts, kinks (A), broken wires (B), bird-caging (C), welding splatter,
(Figure 2) (D) corrosion, chemical contact areas, or severely abraded areas. Wire Rope must be replaced by the
Certified Installer if there are six or more randomly distributed broken wires in one lay, or three or more
broken wires in one strand in one lay. A “lay” of wire rope is the length of wire rope it takes for a strand
(the larger groups of wires) to complete one revolution or twist along the rope. Replace the wire rope
assembly if there are any broken wires within 25 mm (1 inch) any swaged component.
Brackets and Visually inspect all Brackets and End Anchors for wear or damage. Make sure they are securely attached to
End Anchors the Anchorage Structure.

Swaged Fittings Pull test all swages to 19 kN (4,270 lbf). Hold load for 3 minutes without any slippage.

Labels Verify that all labels are securely attached and are legible.

PPE and Other Additional Personal Protective Equipment (Harness, Lanyard, etc) that used with the 8mm HLL
Equipment Permanent Horizontal Lifeline Fall Arrest/Fall Restraint System should be inspected per the manufacturer’s
instructions.

1 2

kN
19 kN
(4270 lb)
B
+120°C

0°C
-50°C

C
9513583 Rev. C

A
B
D

Serial Number(s): Date Purchased:

Model Number: Date of First Use:

Corrective Action/Maintenance: Approved By:

Date:
Corrective Action/Maintenance: Approved By:
Date:
Corrective Action/Maintenance: Approved By:
Date:
Corrective Action/Maintenance: Approved By:
Date:
Corrective Action/Maintenance: Approved By:
Date:
Corrective Action/Maintenance: Approved By:
Date:
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3M.com/FallProtection/DOC