Pacific Scientific T5-2002-401-00 - Cable Tensiometer - 10-150 lbs. - 1/16" to 1/4"
The Pacific Scientific T5-2002-401-00 is the broadest-coverage dual-calibration British/CWT model in the T5-2002 sub-series — the instrument for maintenance programs that work on aircraft spanning the widest spread of British CWT cable specifications. Where the T5-2002-301-00 covers 3–45 CWT, the T5-2002-401-00 extends that coverage to include 10, 15, 20, 25, and 70 CWT cable sizes, covering the full range from 10 CWT through 70 CWT. It simultaneously cross-reads on all standard American inch cable sizes from 1/16" through 1/4", making it the single instrument that handles both British-spec and American-spec aircraft without any hardware changes. Two calibration cards ship with every unit: T594-101 for standard inch readings and T610-401B for CWT readings — select the card for the aircraft being serviced and read tension directly from the dial.
When Standard CWT Coverage Isn't Enough
Most British/CWT tensiometers cover the 3–45 CWT range that corresponds to the cable sizes used on the majority of British-specification aircraft. But certain older British aircraft, specialist military platforms, and Commonwealth aerospace applications use 70 CWT cables — a size that falls outside the coverage of the T5-2002-301-00 and T5-2002-304-00. The T5-2002-401-00 is the only T5-2002 model that extends CWT coverage all the way to 70 CWT, while maintaining the same light-to-mid tension range (10–150 lbs) and standard inch cross-read capability as the T5-2002-101-00. The tension ranges — 10–100 lbs on 1/16"/3/32"/1/8" and 10/15 CWT; 15–150 lbs on 5/32"/3/16" and 15/20/25 CWT; and 25–150 lbs on 7/32"/1/4" and 70 CWT — are all mapped on calibration cards T594-101 and T610-401B. Like every T5 instrument, it operates with zero temperature error and requires no preliminary adjustments — ready for use immediately in any environmental condition.
The Widest CWT Coverage in the T5-2002 Sub-Series
- 10–70 CWT coverage — the broadest CWT range in the T5-2002 sub-series, including 70 CWT not covered by the -301-00 or -304-00
- Dual-calibration — reads British CWT and standard inch cable sizes on the same instrument with the same riser set
- CWT cable sizes covered: 10, 15, 20, 25, and 70 CWT
- Standard inch cross-read: 1/16", 3/32", 1/8", 5/32", 3/16", 7/32", and 1/4"
- Two calibration cards included — T594-101 (inch) and T610-401B (CWT); select the card for the aircraft specification
- Zero temperature error — calibration-stable from extreme cold to high heat, no adjustment required
- Pointer lock brake lever — retains reading before removal in confined or low-visibility areas
- One-handed operation — complete a cable tension check in seconds
- No batteries or electronics — fully mechanical, always ready
- Complete kit — risers #1, #2C, #3; both calibration cards; calibration certificate
Technical Specifications
- Tension Range (Low): 10 – 100 lbs
- Tension Range (Mid): 15 – 150 lbs
- Tension Range (High): 25 – 150 lbs
- Standard Inch Cable Sizes (Low): 1/16", 3/32", 1/8"
- Standard Inch Cable Sizes (Mid): 5/32", 3/16"
- Standard Inch Cable Sizes (High): 7/32", 1/4"
- CWT Cable Sizes (Low): 10, 15 CWT
- CWT Cable Sizes (Mid): 15, 20, 25 CWT
- CWT Cable Sizes (High): 70 CWT
- CWT Range: 10 CWT through 70 CWT
- Calibration Type: Dual — Standard Inch & British CWT
- Calibration Cards: T594-101 (standard inch) & T610-401B (CWT); both included
- Indicator: Black dial indicating
- Temperature Stability: Zero temperature error; operates from -53°C to 71°C
- Pointer Lock: Yes — brake lever rod
- Risers Included: #1, #2C, #3
- Origin: Made in the USA
- Warranty: 1 year on new units
Typical Applications
- Maintenance on British-origin and Commonwealth aircraft with CWT cables from 10 through 70 CWT
- Older British aircraft and specialized military platforms with 70 CWT cable specifications
- British military and Commonwealth defense aviation maintenance programs
- Multinational MRO facilities servicing the widest spread of British CWT cable specifications
- Programs requiring both 10–70 CWT and 1/16"–1/4" inch coverage from a single instrument
- Post-repair and return-to-service verification on British-specification aircraft
Pacific Scientific T5-2002-401-00 Calibration
The T5-2002-401-00 should be recalibrated on a scheduled basis — annually at minimum, and immediately following any overload event, mechanical shock, or drop. As a dual-calibration instrument covering both British CWT and standard inch cable specifications, maintaining accuracy across both calibration profiles is essential to airworthiness compliance on every aircraft type it serves. Pilot John International operates an ISO 17025-accredited calibration laboratory capable of recalibrating Pacific Scientific T5 series tensiometers — including dual-calibration CWT models — to original manufacturer specifications, issuing a fully traceable calibration certificate upon completion. Whether your maintenance program operates under FAA oversight, UK CAA requirements, a DOD contract, or an ISO 9001 quality management system, PJi's lab delivers the traceability and documentation your compliance requirements demand. Learn more about PJi's ISO 17025 Calibration Services →
| General Information | |
|---|---|
| Part # | T5-2002-401-00 |
| Manufacturer | Pacific Scientific |
| Manual 1 | View Manual |
| Shipping Information | |
|---|---|
| Product Weight | 1.6 lbs. |
| Product Dimensions | 10 x 7 x 3 in. |
| Schedule B | 9027893500 |
| ECCN | EAR99 |
| Specifications | |
|---|---|
| Cable Sizes — CWT (Cross-Read) | 10, 15 CWT (Low); 15 CWT (Mid-A); 20, 25 CWT (Mid-B); 70 CWT (High) |
| Cable Sizes — Inch (Primary) | 1/16", 3/32", 1/8" (Low); 5/32", 3/16" (Mid); 7/32", 1/4" (High) |
| Calibration Cards | T594-101 (standard inch) & T610-401B (CWT); both included |
| Calibration Certificate | Included |
| Calibration Type | Dual — Standard Inch & British CWT |
| CWT Range Covered | 10 CWT through 70 CWT |
| Indicator Type | Black Dial Indicating |
| Manufactured | USA |
| Pointer Lock | Yes — brake lever rod for retained readings |
| Risers Included | #1, #2C, #3 |
| Temperature Stability | Zero temperature error; operates in extreme heat and cold |
| Tension Range (High) | 25 – 150 lbs |
| Tension Range (Low) | 10 – 100 lbs |
| Tension Range (Mid-A) | 15 – 150 lbs |
| Tension Range (Mid-B) | 15 – 150 lbs |
| Warranty | 1 Year (new units) |
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AIRCRAFT COMPATIBILITY
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QUESTIONS & ANSWERS
The Pacific Scientific T5-2002-401-00 Cable Tensiometer measures cable tension on aircraft control systems ranging from 1/16" to 1/4" in diameter and from 10 to 150 lbs of tension. It ensures that flight control cables meet specified load requirements during rigging, adjustment, and inspection. This model supports both flexible and coated aircraft cables compliant with MIL-DTL-83420 standards.
Accurate readings depend on using the correct riser, which corresponds to the diameter of the cable being tested. Each tensiometer includes a calibration card that links riser size, dial reading, and actual cable tension in pounds. Using a mismatched riser can lead to inaccurate readings or potential damage to the instrument.
Yes. The T5-2002-401-00 can measure tension on coated or uncoated flexible cables, provided that the riser matches the cable’s outer diameter, not its inner strand size. This adjustment compensates for variations in coating thickness, ensuring accurate readings.
The tensiometer is factory-calibrated using standard preformed aircraft cables with 7×7 or 7×19 construction. It’s optimized for flexible control cables but can be recalibrated for non-flexible cable types such as those conforming to MIL-DTL-87161, used on some aircraft models like the A-10 or F-15.
No. The indicator dial orientation – whether held horizontally, vertically, or at any angle – does not affect accuracy. The spring-balanced design maintains consistent readings regardless of the operator’s position or working environment.
Never allow the dial pointer to exceed the 100 mark on the scale. Closing the trigger too quickly on a high-tension cable can overload the internal spring and permanently damage the tensiometer. Operators should close the trigger slowly and monitor dial movement closely during use.
For the best results, take three to five readings along slightly different points of the same cable and calculate the average. This method compensates for minor variations in the surface of stranded aircraft cables, particularly those 5/32" or larger, improving precision and repeatability.
The T5-2002-401-00 includes a pointer-locking mechanism for hard-to-reach locations. Before releasing the trigger, push the small lever on the upper left-hand side of the instrument to lock the pointer in place. The operator can then remove the tool and read the value afterward without losing accuracy.
No. The T5-2002-401-00 should not be used for adjustment on cable systems that include automatic tension regulators. These systems self-adjust based on temperature and load conditions, meaning readings taken with a tensiometer can be misleading. Instead, follow the aircraft service manual for proper rigging procedures.
Calibration is verified by comparing readings against a dead-weight standard or a hydraulic test machine. Annual recalibration is recommended, or sooner if the unit is dropped, subjected to overload, or used in harsh conditions. PJi offers expert calibration services for Pacific Scientific cable tensiometers, as well as a wide range of other precision instruments and equipment.
Extreme environmental conditions can alter the elasticity and tension values of cables. While the instrument itself is not temperature-sensitive, cable tension varies with ambient conditions; therefore, readings should be taken at standard maintenance temperatures or adjusted according to the manufacturer's tables. Keeping the device clean and dry prevents corrosion and maintains long-term accuracy.
Operators should wear the provided wrist strap to prevent accidental drops and always ensure the brake lever is unlocked before placing the tensiometer on a cable. Avoid using the tool on energized systems or non-aircraft applications outside its specified range. Proper handling and routine care maximize accuracy and service life.
The T5-2002-401-00 covers 10, 15, 20, 25, and 70 CWT cables — a range of 10 CWT through 70 CWT. The T5-2002-301-00 covers 3, 5, 10, 15, 25, 35, and 45 CWT. The -401-00 is the correct choice when your aircraft uses 70 CWT cables or when the specific CWT groupings on your aircraft match the -401-00's calibration profile more closely than the -301-00's. If you are unsure which model is correct for your aircraft, consult the aircraft maintenance manual for the cable specification and contact PJi for assistance.
Yes. The T5-2002-401-00 cross-reads accurately on standard inch cable sizes from 1/16" through 1/4" using calibration card T594-101. For standard inch applications it is functionally equivalent to the T5-2002-101-00, with the additional benefit of CWT calibration for British-specification aircraft.
Two cards ship with every unit: T594-101 for standard American inch cable readings and T610-401B for British CWT cable readings. Before taking a measurement, identify whether the cable is specified in inch or CWT sizing, select the appropriate card, and use it to convert the dial reading to actual tension in pounds.
Annual recalibration is the standard interval, or sooner following any overload event, mechanical shock, or drop. Pilot John International's ISO 17025-accredited calibration laboratory performs recalibration of Pacific Scientific T5 series tensiometers — including dual-calibration CWT models — to original manufacturer specifications, issuing a fully traceable calibration certificate. Visit pilotjohn.com/calibration to learn more or request service.
Every unit ships with risers #1, #2C, and #3; calibration cards T594-101 and T610-401B; and a calibration certificate.
