Pacific Scientific T5-2002-104-00 – Aircraft Cable Tensiometer – 30-300 lbs. – 1/16", 3/32", & 1/8"

Yes, the National Stock Number (NSN) for the Pacific Scientific T5-2002-104-00 Cable Tensiometer is 6635-00-508-2700. This confirms that the unit meets military and government procurement standards and is commonly used in regulated aviation and defense environments.

Using the correct riser is critical. Each cable size requires a specific riser height to ensure accurate tension readings. The Calibration Card supplied with the unit provides guidance on riser selection, and mismatched risers can cause false readings or even damage the tensiometer.

Yes, it can be used on both coated and uncoated cables, but the riser must match the outer diameter of the cable. When working with coated cables (such as those used externally on helicopters), note the increased thickness and choose the appropriate riser accordingly. This helps ensure reliable readings and instrument longevity.

For the most accurate readings, it's recommended to take three to five measurements at slightly different locations along the same cable. This accounts for the uneven surface of stranded cables and helps minimize reading discrepancies. The average of these values gives a more reliable tension reading.

It is not recommended to use this tensiometer to adjust rig loads on systems equipped with automatic cable tension regulators. Adjustments should be based on the aircraft's service manual and environmental temperature guidelines in such systems. While the tensiometer may be used to verify cable tension, it should not be the primary adjustment method.

Overloading the dial beyond the “100” mark may cause permanent damage to the instrument. Always close the trigger slowly when applying the tensiometer to a tight cable and monitor the pointer to ensure it stays within the readable range. This is particularly important for avoiding calibration drift or mechanical failure.

If visibility is restricted, you can lock the pointer in place before removing the tensiometer from the cable. Press the small locking lever on the upper left side of the device after applying tension and before releasing the trigger. This captures the tension reading, which can then be read after removal.

No, the orientation does not affect readings. The unit provides accurate tension measurements regardless of whether it's used in a vertical, horizontal, or angled position. This flexibility makes it ideal for tight or awkward cable routing in various aircraft configurations.

The tensiometer must be calibrated using the same cable type on which it will be used. It's typically calibrated on flexible 7x7 or 7x19 aircraft cable. Periodic calibration checks against a known standard or dead-weight system are recommended to ensure continued accuracy, especially after heavy use or exposure to harsh environments.

The dial itself provides arbitrary readings from 0 to 100, which must be converted using the Calibration Card included with the unit. The card displays a table showing dial readings and their corresponding tension values in pounds for specific cable sizes. Always use the correct column for the cable under test.

This model is calibrated specifically for flexible aircraft cables that conform to MIL-DTL-83420. If you're working with non-flexible cables, such as those conforming to MIL-DTL-87161, a different tensiometer or calibration process may be required for accurate readings.

The T5-2002-104-00 has three operating ranges: 30–200 lbs for 1/16", 3/32", and 1/8" cables; 30–300 lbs for 5/32" and 3/16" cables; and 30–300 lbs for 7/32" and 1/4" cables. All three ranges are documented on the individual factory calibration chart included with the unit.

All three models cover the same seven cable sizes (1/16"–1/4") but are calibrated for progressively higher tension ranges. The -101-00 tops out at 25–150 lbs on its largest cable group, the -103-00 at 30–200 lbs, and the -104-00 reaches 30–300 lbs across five of its seven cable size groups. Choose the model whose upper range best matches the primary cable tension specifications in your aircraft's maintenance manual.

Annual recalibration is the standard interval, or sooner following any overload event, mechanical shock, or drop — all of which can cause spring fatigue or mechanical drift that affects reading accuracy. Pilot John International's ISO 17025-accredited calibration laboratory performs recalibration of Pacific Scientific T5 series tensiometers to original manufacturer specifications, issuing a fully traceable calibration certificate upon completion. Whether your program operates under FAA oversight, a DOD contract, or an ISO 9001 quality management system, PJi's lab provides the documentation your compliance requirements demand. Visit pilotjohn.com/calibration to learn more or request service.

Every unit ships with risers #1, #2C, and #3; an individual factory calibration chart; a calibration certificate; and a foam-lined zippered hard carrying case.