Pacific Scientific T5-2004-113-00 Cable Tensiometer – 1/16" to 1/8", 10-100 lbs

The Pacific Scientific T5-2004-113-00 Cable Tensiometer is designed to measure tension in aircraft control cables ranging from 1/16" to 1/8" in diameter and up to 100 lbs of tension. It ensures proper control system rigging and verifies cable performance in accordance with aviation standards, such as MIL-DTL-83420. Accurate tension readings are crucial for maintaining precise flight control and ensuring system safety.

Using the correct riser is critical to ensuring accurate readings and preventing damage to the tensiometer. Each T5 unit includes a calibration card that specifies the proper riser for each cable size. Using an incorrect riser can yield inaccurate tension readings or even cause permanent damage to the instrument’s internal components.

Yes, it can. When working with coated cables, operators must select a riser that matches the outer diameter of the coated cable rather than the bare strand diameter. This adjustment compensates for the added coating thickness and prevents inaccurate tension results.

The tensiometer should be calibrated using the same type of cable on which it will be used – typically flexible aircraft control cables of 7x7 or 7x19 construction. Calibration should be verified against a dead-weight setup or a hydraulic test machine to confirm accuracy across the entire measurement range. Matching the instrument’s calibration to the actual operating cable ensures consistent, reliable readings.

Inaccurate readings can result from using the wrong riser, measuring non-flexible cables with a flexible-calibrated unit, or allowing the indicator dial to exceed its 100 mark. Additionally, dirt, corrosion, or inconsistencies in cable coating can affect the results. For best accuracy, take three to five readings along different sections of the cable and calculate an average.

automatic tension regulators, as these systems dynamically adjust load and can produce misleading readings. Instead, follow the aircraft’s maintenance manual instructions for regulator-based tensioning, then verify with the T5 as a secondary check.

No. The orientation of the indicator dial – whether vertical, horizontal, or angled – does not affect measurement accuracy. The internal spring mechanism and dial are designed to deliver consistent results, regardless of the instrument's position during use.

When the dial cannot be viewed, the pointer-locking mechanism can be used. Before removing the instrument from the cable, push the small lever on the upper left-hand side to lock the pointer in place. This allows the reading to be taken after removal without losing the measurement.

Never allow the pointer to exceed the 100 mark on the dial. Doing so may permanently damage the internal measuring spring. When working with high-tension cables, close the trigger slowly and watch the dial carefully as the load is applied.

For accuracy and compliance, recalibration is recommended annually or after any mechanical shock or suspected overload has occurred. PJi offers expert calibration services for Pacific Scientific cable tensiometers, as well as a wide range of other precision instruments and equipment.

The T5-2004-113-00 is best suited for light to medium-duty cable systems, such as flight control linkages, flap systems, and landing gear actuators. It may not be appropriate for non-flexible cables or heavy structural applications, which require models with different tension ranges or calibration standards.

Regular maintenance includes cleaning contact points, checking the brake lever rod for smooth operation, and keeping the unit stored in its case when not in use. Operators should also wear the provided adjustable wrist strap to prevent drops or impacts during use, which can cause calibration drift.

The T5-2004-113-00 has two defining characteristics that set it apart from every other model in the T5-2000 series. First, it has a fixed, permanently installed Riser #1 — there are no interchangeable risers, eliminating the riser selection step and removing any possibility of riser selection error affecting a reading. Second, it covers only the three smallest cable sizes (1/16", 3/32", 1/8") and is calibrated specifically for the 10–100 lb range where secondary control and trim cable systems operate. It is purpose-built for low-tension secondary cable work, not general-purpose primary control cable rigging.

Pacific Scientific's service documentation notes that accuracy and safety factor both improve when maintenance programs use a dedicated low-tension instrument for secondary control systems rather than a single tensiometer for all cable types. At low tension values — below 30 lbs — a riser selection error on a multi-riser instrument can represent a significant percentage error relative to the actual cable tension. The T5-2004-113-00's fixed riser eliminates that error source entirely, producing more accurate and repeatable readings on secondary control cable inspections.

It can physically be placed on primary control cables within its size range, but it is not the appropriate instrument for that purpose. Its 10–100 lb ceiling means it will over-range on most primary control cable tension specifications. It is designed and recommended specifically for secondary control systems where tensions stay within the 10–100 lb range.

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 fixed-riser models — to original manufacturer specifications, issuing a fully traceable calibration certificate. Visit pilotjohn.com/calibration to learn more or request service.