Trylon TSF COUGAR Operating instructions

ISO 9001 Registered
CSA Z259.2.1-98 & ANSI Z359.1-2007
[Canada & USA] Revision date: April 27, 2012
User Installation & Instruction Manual
Manual #4.957.0000.R02
Utilizing a Full Body
Harness attach the
Cougar Slider only at
this Sternum
Connection Point.

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Table of Contents Page
1.0 Forward 3
2.0 General Warnings 4
3.0 About the Cougar Cable System 4
4.0 Attaching the Cable and Hardware 5
5.0 Safety Cable Design Specifications 6
6.0 Safety Cable Care 6
7.0 Use and Limitations on Use –Climbing Cougar Safety Cable System 6
8.0 Training 7
9.0 Inspection of the Safety Cable System (other than Slider) 7
10.0 Certification of Safety Cable System 7
11.0 About the Cougar Safety Cable Slider 8
12.0 Use and Limitations on Use –Attaching the Cable Slider to a Cable 8
13.0 Care and Maintenance of Slider 9
14.0 Inspection of Slider 9
15.0 Cable Slider Inspection Guidelines 9
16.0 Labels / Markings 10
17.0 Slider to Cable Installation Steps 11
18.0 Installation Instructions for Cougar Cable Systems 12
19.0 Installation Drawings for Cougar Ladder Cable Systems 13
20.0 Installation Drawings for All-Weld Guyed with Mid Panel Step Horizontals 14
21.0 Installation Drawings for All-Weld Guyed without Mid Panel Step Horizontals 15
22.0 Installation Drawings for Cougar Monopole Cable Systems 16
23.0 Installation Drawings for Cougar Wood Pole Cable Systems 17
24.0 Installation Drawings for Cougar SuperTitan Cable Systems 18
25.0 Installation Drawings for Cougar SuperTitan MAX Cable Systems 19
26.0 Inspection and Maintenance Log 20
27.0 Warranty 22

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SAFETY CABLE SYSTEM INSTRUCTIONS
1.0 FORWARD
These instructions describe the installation and the use of the Trylon TSF COUGAR Safety Cable System. They should
be used as part of a fall protection employee training program as required by the regulations governing occupational
safety as well as the applicable standards of CSA, and ANSI. It is the employer’s responsibility to ensure that all users
are trained in the proper use, inspection and maintenance of the Cougar Cable Slider System.
IMPORTANT: If you have questions on the installation, application, use, or maintenance of this equipment, contact
Trylon TSF. If additional instructions are required, supplemental clarification will be provided.
Before using this equipment, the product identification information shown on the installation and service labels should
be recorded in the maintenance log in Section 27 of this manual. If the system includes a Slider, record serial number in
the maintenance log as well.
All safety cable systems and components are to be used under the safety standards in place in the jurisdiction in which
you are working. These instructions are not meant to modify or supersede any local or federal safety standards.
These instructions must be provided to all users. Follow the manufacturer’s instructions for safety equipment used with
this system.
The Cougar Cable System must be attached to a suitable fixed, permanent climbing structure conforming to US ANSI
A14.3-2008 or equivalent structure with a capacity of supporting a static load of 5,000 lbs (22kN).
WARNING
This manual is intended to be used as part of an employee fall-
protection program including training and supervision in accordance
with local regulatory authorities and the applicable voluntary
standards of the Canadian Standards Association (CSA) and the
American National Standards Institute (ANSI).
All persons using or installing this equipment must read, understand
and follow all instructions before the installation or use of the system.
Failure to do so may result in serious injury or death. DO NOT use
this equipment unless you are properly trained.
!

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2.0 GENERAL WARNINGS
2.1 Follow these instructions for the proper use, inspection and maintenance of this safety equipment.
2.2 Failure to follow both the manufacturer’s instructions and the safety standards in the jurisdiction
may result in serious injury or death.
2.3 Alterations substitutions or misuse of this product may result in serious injury or death.
2.4 Any Trylon TSF COUGAR CABLE SLIDER which has been used during a fall arrest incident
should not be used afterwards and should be replaced. As well, the whole system: top and bottom
cable support brackets, cable and all terminations will need to be replaced at once. Until a full
replacement of the system is implemented you should not ascend or descend on a system that has
been subjected to a fall.
2.5 All equipment must be inspected before each use according to the manufacturer’s instructions. Do
not use if the Cable Slider or any part of the System appears to be damaged.
2.6 Do not remove or deface any product labels or warnings.
2.7 To minimize the potential for accidental disengagement, a competent person must ensure system
compatibility.
2.8 Use caution when installing the Cougar Safety Cable System. Wear personal protective equipment,
including safety glasses and steel-toed shoes. Use personal fall arrest systems when exposed to a fall
hazard. Use caution when installing Cougar Safety Cable Systems near power lines. Cougar cables
are conductive. Do not connect to a partially installed System.
3.0 ABOUT THE COUGAR SAFETY CABLE SYSTEM
The Cougar Cable Slider System is a fall arrest system designed to travel freely with the movement of the worker on a
steel cable in a vertical or near-vertical plane (± 3°) while ascending or descending only. The Slider component of that
system will automatically engage on the lifeline in the event of a fall and lock so as to arrest the fall.
To move freely when ascending or descending with the Cougar Safety Cable Slider, center your torso with the Slider
and slightly pull back thereby releasing the lever in order to allow the climber to travel freely up or down the Safety
Cable.
The Cougar Cable System is designed to provide years of trouble free operation and will operate as intended if Trylon
TSF guidelines are followed.
Trylon TSF’s Cougar Cable System is designed to function as an integrated system. Introduction of non-compatible
components may impair performance. CSA/ANSI certification for the system is valid only if the system is installed
using only the manufacturer’s components and in accordance with manufacturer’s instructions.
See subsequent page titled Section 11.0 “ABOUT THE COUGAR SAFETY CABLE SLIDER” for acceptable
conditions where the Trylon Cougar Slider may be used on Safety Cable systems manufactured by others.

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4.0 ATTACHING THE CABLE AND HARDWARE
Each complete system comes with a cable system and a Slider unit. The cable system includes an upper cable support
bracket, a lower cable support bracket, cable, shackle, karabiner, and hardware and tension spring.
Trylon TSF offers (2) different types of cable; the standard is a 3/8” diameter 7x19 strand galvanized aircraft cable,
with a optional 3/8” diameter 7x19 strand stainless steel cable Type 302/304.
The cable support brackets and associated hardware are designed to attach to ladder rungs or other structures as per the
installation drawings attached. For ease of climbing it is recommended that the cable support brackets be centered on
the ladder rungs, allowing the maximum space for hands and feet when climbing and descending the ladder. This will
also help prevent a pendulum effect if a fall occurs.
The lower cable support bracket is installed as close to ground level as possible, with the “hook” end at the bottom.
Ensure that you attach the bottom bracket to two rungs of the ladder. The hook end has provision for attaching the
turnbuckle and spring arrangement used for tensioning the cable. Attach the turnbuckle to the hook end of the cable
support and then affix the spring to the turnbuckle. It is a good idea to center the turnbuckle housing on the threaded
rods. Extend the distance between the threaded rod ends to allow maximum take up of slack upon tensioning.
The top cable support bracket is installed at the top of the ladder. Ensure that you attach the bracket to the top two
rungs of the ladder. The hook end of the top bracket is always installed at the top for two reasons. With the hook end
at the top, the user gets the most use from the cable. More importantly, the bracket is designed to absorb energy in the
event of a fall, reducing shock loads on the person falling. This energy absorption is accomplished by a bending action
in the cable support bracket. Never install the top bracket upside down (i.e. hook at the bottom).
The upper end of the cable assembly includes a factory-formed eye termination with a proper sized thimble. A wire
rope thimble and u-bolt clamps are provided to terminate the cable at the lower end. The upper end of the cable is
attached to the top bracket with a shackle supplied in the system. Install the cotter pin to prevent loosening of the bolt.
The lower end of the cable is attached directly to the spring, which fits snugly on the thimble.
After the cable has been attached at the top end, you can terminate the bottom end of the cable. First fit the cable onto
the 3/8” thimble, attach the cable clamps provided, install with the spring and then tension the spring to eliminate any
slack in the cable. This is to remove unnecessary side-to-side flexing of the cable. The spring will allow for thermal
expansion and contraction of the tower and some side loads on the cable from wind and / or climbing action. Cut excess
cable off the bottom end.
Intermediate cable guides (stand-off brackets) are supplied that secure the cable to prevent it from chafing against the
ladder in windy conditions and to prevent the cable from vibrating. These cable guides are fastened to the ladder rungs.
Approximate spacing for the guides is 25 ft intervals. Stagger the cable guide spacing from 23 to 27 ft at random
intervals to cancel the tendency for harmonic vibration of the cable under certain wind conditions. To bypass the cable
guides with the Slider, remove the cable from the guide you are passing by pulling the cable from the guide (DO NOT
REMOVE CABLE SLIDER FROM THE CABLE TO PASS CABLE GUIDES). It is recommended that you re-insert
the cable in the guides as you pass them. No tools are needed to insert or remove the cable from the guides, just push
and pull the cable as needed.
Avoid contacting the vertical lifeline (safety cable) with sharp edges, protruding bolts, electrical and other hazards that
could cause damage.

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5.0 SAFETY CABLE DESIGN SPECIFICATIONS
The safety cable will experience a 0.09% elongation under a 8 kN load in dry conditions
The safety cable will experience a 0.09% elongation under a 8 kN load in wet conditions
6.0 SAFETY CABLE CARE
Avoid exposure to corrosive or other chemical hazards which the safety cable is not designed to withstand. Do not use
harsh detergents, chemicals or pressure washers. Ensure that the safety cable is kept clean at all times.
7.0 USE AND LIMITATIONS ON USE - CLIMBING COUGAR SAFETY CABLE SYSTEMS
Trylon TSF’s Cougar Cable System is intended to arrest personnel only (not material or equipment), should they (the
individual) slip or fall while climbing a fixed ladder.
The design load capacity is based on maximum user’s weight, including tools and clothing of 310 lbs (140.6 kg). DO
NOT EXCEED THIS WEIGHT.
Trylon TSF’s fall protection systems must NOT be used as a work positioning device or lifeline while working.
Such a practice is strictly prohibited. The Cougar Cable System is only approved for fall protection while
ascending or descending. A back-up fall arrest system is required when transitioning on and off the Cable
System at a height.
Workers should always tie off to an appropriate anchorage structure by means of a lanyard while working or resting, in
accordance with the relevant safety standards. The anchor point for such a lanyard should be above the user to prevent
a pendulum fall.
You are required to use with this System a properly certified full body harness with a frontal D-ring attachment
at the sternum (chest) certified for ladder climbing (CSA Z259.10-06,Class “AL”).
Make sure that clothing, the harness itself and the length of any D-rings or connectors supplied with the harness do not
impede the locking mechanism on the cable Slider.
Attach the Slider to your harness with a CSA or ANSI certified karabiner (according to the jurisdiction). Do not use a
second karabiner or any other devices such as a short lanyard, chain, link or clevis to connect with the Slider. The
attachment from the sternum D-ring to the Slider must not exceed 0.15 m (6 inches) in length. Under a worst case
fall with the Slider on the cable below the climber, the climber may fall a total of 30 inches representing a maximum 2
inch Slider slippage and 16 inches for the bend of the top bracket that provides the shock absorption and 12 inches for
the Slider travel. In addition there may be some harness stretch. Harness stretch is based on the climber’s harness
selection.
The Cougar Safety Cable System is designed to arrest the fall of a single person at a time although multiple users can
use the system to access the work place. Only one climber can actively use the system at one time. All other climbers
must be tied-off appropriately. Contact the factory for applications requiring more than one climber at a time.
The climber should ensure that the safety cable avoids contact with sharp edges and/or abrasive surfaces.
This system is not suitable for use where the worker is positioned on an unstable surface, fine grain material, or
particulate.

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8.0 TRAINING
Climbers should fully familiarize themselves with these instructions and the inspection, operation, maintenance and
limitations of the system before ascending the tower. Training should be conducted periodically without exposing the
trainee to a fall hazard.
All climbers should ensure that the correct certified (CSA Z259.10-06, Class “AL”) body harness which includes a
sternum connection point is properly fitted according to the manufacturer’s instructions and ensures that it does not
interfere with arresting features of the fall protection system. All instructions and warnings provided with the body
harness must be read and understood before using the fall protection system. A proper harness fit also helps ensure that
the climbing action of the Slider on the wire rope is smooth and reduces the potential to “snag”. Snagging is a nuisance
to climbers, although not a safety hazard. A body belt is NOT approved or recommended for use with the Cougar
Cable System. Climber MUST use a harness with a sternum connection point.
Make certain all applicable hazards are properly addressed to provide climber safety. Factors such as hazardous power
lines, antenna radiation, physical obstructions, icing, frost and the climber’s knowledge, ability and health all determine
the usage of this equipment.
9.0 INSPECTION OF SAFETY CABLE STSTEM (OTHER THAN SLIDER)
Ensure the anchorage system can support a minimum load of 5000 pounds. CERTIFICATION IS APPLICABLE TO
THE SAFETY CABLE SYSTEM ON THE STRUCTURE ONLY. NEITHER THE MANUFACTURER NOR CSA
HAS INVESTIGATED THE ANCHORAGE SYSTEM.
The System should be inspected by the user prior to every use and by a competent person other than the user at least
twice per year. The Safety Cable Kit Model number should be recorded as per Section 27.0 and the Inspection and
Maintenance Log maintained.
Trylon TSF provides a 3/8” diameter 7x19 strand galvanized aircraft cable system or a 3/8” diameter 7x19 strand
stainless steel cable system. Before climbing, check the diameter of the cable. The Trylon TSF Cougar Slider itself is
designed to operate safely on either 3/8” or 5/16” cable.
When checking the System, inspect the ladder mounting, the cable mounting, the condition of the cable and related
components. Ensure that the cable is kept clean and free of any oil, contaminants or other similar substances.
Ensure that the cable and mounting system is properly attached and has not been tampered with or vandalized. Check
that the cable is not slack and is properly tensioned and does not show signs of corrosion. Make sure that the ladder is
securely fastened.
If a component is worn or suspected faulty, immediately notify your supervisor and do not attempt to use it. Any faulty
components must be removed from service and permanently disabled before discarding.
10.0 CERTIFICATION OF SAFETY CABLE SYSTEM
CSA and ANSI certification applies to 3/8” safety cable systems.
The Cougar Slider is CSA and ANSI certified for both 3/8” and 5/16” cable systems.

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11.0 ABOUT THE COUGAR SAFETY CABLE SLIDER
Maximum movement of the Cougar Slider along the cable will not exceed 6 inches (150 mm) when dynamically tested
within the requirements of the CSA/ANSI Standard.
Cougar Sliders are supplied as part of the Cougar Safety Cable System. As a stand-alone item, the Slider may be
utilized on certified fall protection systems made by others, provided the system meets all these criteria:
i. Cable system is ANSI and/or CSA certified (according to the jurisdiction) and has been properly installed and
maintained.
ii. top cable support bracket includes a shock absorbing mechanism which reduces the maximum arrest force on a
worker to 8kN [1,800lbs] or less.
iii. the type of safety cable (lifeline) is either:
3/8” or 5/16” diameter, 7x19 strand galvanized aircraft cable or
3/8” diameter, 1x7 solid core EHS (guy strand) or
3/8” or 5/16” diameter, 7x19 strand stainless steel cable
The Slider must be utilized with a CSA or ANSI certified karabiner (according to the jurisdiction). The attachment
from the sternum D-ring to the Slider should not exceed 0.15 M (6 inches) in length.
Trylon TSF’s Cougar Safety Slider must NOT be used as a work positioning device or lifeline while working.
Such practice is strictly prohibited.
Users of Cougar Safety Cable systems must have a rescue plan in place and the means to execute it in the
event of an accidental fall.
12.0 USE AND LIMITATIONS ON USE –ATTACHING THE CABLE SLIDER TO A CABLE
Attaching the Slider to the cable can be easily accomplished with one hand. For specific details, refer to the section
17.0 “SLIDER TO CABLE INSTALLATION STEPS”.
When installing the Slider onto a cable, ensure the cable is either 3/8” or 5/16” diameter and meets the criteria
mentioned in the paragraph above. Once the Slider is attached to the cable and the karabiner is hooked into the Slider,
it is impossible for the cable and Slider to become separated in the course of normal climbing. If you can force the
cable to disengage from the Slider with the karabiner in place, check your cable and Slider unit for wear.
If you attempt to incorrectly install the Slider upside down on the cable, the arrow engraved on the unit will now be
pointing to the ground. You will be able to fit the Slider onto the cable, BUT, you will not be able to hook the
karabiner through the Slider attachment hole. The SafetyLok™ orientation lockout feature incorporated into the Slider
will prevent attachment of the karabiner if the Slider is installed upside down. Thus a worker cannot attach onto their
harness. Never attach the Slider on to the Safety Cable with the “UP” arrow pointing downward. In this position
the Slider will not effectively lock on to the Safety Cable should a fall occur.
The Slider should not be attached to more than one (1) personal fall arrest system.
When possible the Cougar Slider should be positioned above the user to prevent pendulum fall
CSA and ANSI certification is applicable to the device only. CSA and ANSI have not investigated the anchorage
system.

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13.0 CARE AND MAINTENANCE OF SLIDER
Little maintenance is anticipated on your Cougar Slider unit. All components are made from stainless steel which
resists corrosion. All components are riveted together.
Avoid exposure to corrosive or other chemical hazards which the Slider is not designed to withstand. If the Slider
becomes contaminated from mud, dirt, oily substances or other contaminants, or if Slider movement becomes erratic or
“sticky”, wash in clean soapy water and air dry the unit. Free movement of the mechanism is critical to the proper
operation of the unit. Do not use harsh detergents, chemicals or pressure washers. After cleaning, the unit should be
rinsed in clear water and allowed to air dry naturally. No lubrication is necessary.
When not using the Slider, store it in a clean dry place with limited exposure to the following:
Sunlight Corrosive chemicals or conditions Excessive heat Harmful fumes
The lower end of the lifeline shall have a termination that prevents the fall arrester from passing through that
termination. When the line is installed, the bottom end shall have a counterweight to provide stiffness.
14.0 INSPECTION OF SLIDER
A visual inspection of the Slider is required before each use. Detailed inspections should be conducted on a regularly
scheduled basis as determined by the user and in compliance with local or federal safety standards. There should be a
minimum of two (2) detailed inspections per year by a competent person other than the climber.
Always check the Slider before ascending the ladder to ensure it runs freely and locks properly onto the cable (see Step
5 in Section 17.0 titled “SLIDER TO CABLE INSTALLATION STEPS”).
If a component is worn or suspected faulty, immediately notify your supervisor and do not attempt to use it.
Any worn components must be removed from service and permanently disabled before discarding.
15.0 CABLE SLIDER INSPECTION GUIDELINES
Inspect all components and fasteners of the Slider for bends, cracks and deformities. Operation of the
lever mechanism must be free and smooth.
Inspect the Cable Slider body for excess wear on the inside where the cable passes through.
Inspect the spring to ensure it is secure and of sufficient strength to lock arresting lever down.
If inspection reveals an unsafe or a defective condition, remove the Slider immediately from service and
permanently disable and discard the Slider.

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16.0 LABELS / MARKINGS: COUGAR SLIDER
LABELS / MARKINGS: SAFETY CABLE per Drawing 1702023

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Notes/Best Practice:
1. Climbers should tie off the Slider when they are
detached from it and working elsewhere on the
structure. This is an extra precaution to avoid
the unlikely event of the Slider “slipping” down
the cable during extreme vibrations caused by
other climbers on the structure or wind
2. A snug, proper-fitting certified harness with a
sternum D ring is critical for ensuring the
smoothest possible climb without “snagging”.
A slack, improperly adjusted harness could
have the effect of preventing the pivot arms
from fully opening in ascent or descent, thus
leading to unwanted snagging.
17.0 SLIDER TO CABLE INSTALLATION STEPS
Step 1: Step 2:
Hold the Slider so that the engraved arrow Squeeze the top and the bottom of
on the Slider is pointing upwards as above. the pivot arms as shown.
(b)
Step 3:
Step 4:
Place the Slider onto the 3/8” or 5/16” safety cable. The Slider should rest on the cable like this.
Step 5: Attach a CSA or an ANSI certified karabiner (according to the
Jurisdiction) to the Slider. The attachment from the sternum D ring to the
Slider should not exceed 0.15 M (6 in) in length. With the karabiner installed, the
Slider cannot be removed from the cable. To ensure the Slider is functioning
properly, pull down on karabiner to duplicate a fall arresting situation. Slider
should grab the safety cable immediately.
To remove the Slider from the cable, begin with Step 2 and follow with Step 3.
(a)

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18.0 COUGAR SAFETY CABLE SYSTEM INSTALLATION ……

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19.0 COUGAR SAFETY CABLE SYSTEM INSTALL FOR LADDERS _

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20.0 COUGAR SAFETY CABLE SYSTEM INSTALL FOR ALL-WELD GUYED WITH MID
PANEL STEP HORIZONTALS

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21.0 COUGAR SAFETY CABLE SYSTEM INSTALL FOR ALL-WELD GUYED WITHOUT MID
PANEL STEP HORIZONTALS

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22.0 COUGAR SAFETY CABLE SYSTEM INSTALLATION FOR MONOPOLES

17
23.0 COUGAR SAFETY CABLE SYSTEM INSTALLATION FOR WOOD POLES

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24.0 COUGAR SAFETY CABLE SYSTEM INSTALLATION FOR SUPERTITAN TOWERS

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25.0 COUGAR SAFETY CABLE SYSTEM INSTALLATION FOR SUPERTITAN MAX TOWERS

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26.0 INSPECTION AND MAINTENANCE LOG
DATE OF MANUFACTURE:_____________________________________________________
CABLE KIT MODEL NUMBER AS SUPPLIED: _____________________________________
LIFE LINE MODEL NUMBER: ____________________________________________________
DATE PURCHASED: ____________________________________________________________
SITE/LOCATION NAME: ________________________________________________________
INSPECTION
DATE
STATUS OF
ITEMS
CORRECTIVE
ACTIONS
MAINTENANCE
PERFORMED
PERFORMED
BY: