Pacific Scientific T5-2002-104A-00 Aircraft Cable Tensiometer – 30 to 300 lbs, 1/16" to 1/4"

The Pacific Scientific T5-2002-104A-00 Cable Tensiometer measures cable tension in aircraft control systems ranging from 1/16” to 1/4" in diameter, with a range of 30 to 300 lbs. It ensures proper tensioning of flight control cables to maintain precision and safety in aircraft operation. The tool is widely used during maintenance, rigging, and inspections to verify that control systems meet manufacturer specifications.

Each tensiometer uses interchangeable risers that correspond to specific cable diameters. Using the incorrect riser can lead to inaccurate readings and potential damage to the instrument. The correct riser number is provided on the calibration card, which must always match the instrument’s serial number to ensure accurate measurements.

Yes. The instrument can be used on both coated and uncoated aircraft cables, provided the riser matches the outer diameter of the cable, including its coating. When measuring coated cables, the riser size must be adjusted accordingly, and this selection should be documented on the calibration label for future reference.

The T5-2002-104A-00 is factory-calibrated on standard preformed aircraft cables with 7×7 or 7×19 construction, conforming to MIL-DTL-83420. It’s optimized for flexible wire rope but can also be recalibrated for non-flexible cables such as those meeting MIL-DTL-87161, commonly used in specific aircraft like the A-10 and F-15. Calibration on the same cable type ensures maximum accuracy during use.

The orientation of the instrument – vertical, horizontal, or any angle in between – does not affect accuracy. Its internal spring mechanism is designed to deliver consistent tension readings regardless of position, allowing technicians flexibility when working in tight or awkward spaces.

Never allow the dial pointer to exceed the 100 mark on the indicator scale. Closing the trigger too quickly on a high-tension cable can overload the internal spring. To avoid permanent damage, apply pressure slowly and watch the pointer carefully during each reading.

Due to the uneven surface of stranded cables, technicians should take three to five readings at slightly different points along the same cable and calculate the average. This practice minimizes the effects of strand irregularities, providing a more precise tension value.

The T5-2002-104A-00 features a pointer-lock mechanism that allows the reading to be retained even when the dial is not visible. By pressing the small lever on the upper left-hand side of the instrument before releasing the trigger, the pointer locks in place, allowing the operator to remove the tool and read the measurement afterward.

No. It should not be used to adjust cable systems that incorporate automatic tension regulators, as the readings may not reflect true tension due to self-compensating mechanisms. Instead, follow the aircraft manufacturer’s procedure for setting regulator tension based on ambient temperature and system specifications.

Calibration should be verified annually or sooner if the tensiometer has been dropped, overloaded, or exposed to harsh conditions. Recalibration ensures the spring and dial assembly remain within specified tolerances. PJi offers expert calibration services for Pacific Scientific cable tensiometers, as well as a wide range of other precision instruments and equipment.

While the tensiometer itself is not significantly affected by temperature, cable tension can vary with environmental conditions. For optimal results, measurements should be taken at or adjusted to standard maintenance temperatures, as cable elasticity changes slightly with variations in heat and humidity.

Operators should secure the adjustable wrist strap to prevent accidental drops and verify that the brake lever rod is unlocked before use. Always check for correct riser installation and inspect for damage prior to clamping onto a cable. Following these precautions helps maintain accuracy and protects both the instrument and the technician.

Yes, the Pacific Scientific T5-2002-104A-00 Cable Tensiometer is supplied with two precision risers that correspond to specific cable diameter ranges. These risers are essential for obtaining accurate tension readings, as each one ensures proper alignment and load distribution on the cable.

The key difference is in the tension range for the smallest cable size group. The T5-2002-104-00 steps down to 30–200 lbs for 1/16", 3/32", and 1/8" cables, while the T5-2002-104A-00 holds a uniform 30–300 lb range across all three cable size groups. The -104A-00 also uses a different calibration card (T615-115 vs. T595-104) and ships with two risers rather than three.

It supports all seven standard aircraft cable diameters: 1/16", 3/32", 1/8", 5/32", 3/16", 7/32", and 1/4". The 30–300 lb range applies uniformly across all seven sizes.

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 affecting 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.