Pacific Scientific T5-8002-105-00 Cable Tensiometer

The Pacific Scientific T5-8002-105-00 is the highest-range model in the T5-8002 sub-series — the instrument that delivers both the maximum tension ceiling of the T5-8000 platform and full coverage of all seven standard aircraft cable diameters from 1/16" through 1/4". With tension ranges of 30–200 lbs on 1/16", 3/32", and 1/8" cables, and 30–400 lbs on 5/32"/3/16" and 7/32"/1/4" cables, it extends 100 lbs beyond any other T5-8002 model on the mid and large cable groups — covering the upper primary control cable tension zone found on larger turboprops, business jets, rotary-wing platforms, and military aircraft. Listed under NSN 6635-00-527-6507 and carrying the U.S.A.F. C5 designation, it is the T5-8000 series counterpart to the T5-2002-105-00, sharing calibration card T594-105 and identical tension ranges on the heavier-duty T5-8000 platform.

The T5-8000 Platform at Maximum Range

The T5-8000 series is built heavier and more robustly than the T5-2000 series — approximately 1 lb / 0.45 kg versus 0.77 lb / 0.35 kg — making it the preferred platform in demanding MRO environments, heavy maintenance operations, and programs with high-frequency continuous tensiometer use. The T5-8002-105-00 combines that platform robustness with the broadest tension and cable size coverage in the T5-8002 sub-series. Each unit ships factory-calibrated with its own individual calibration card (T594-105), which maps every dial reading to actual tension in pounds for all three ranges and all seven cable sizes — a direct chart lookup with no secondary calculations required. Zero temperature error means accuracy is unaffected by ambient conditions from extreme cold to high heat, with no preliminary adjustments needed between uses. The riser set for this model is #1 for 1/16"–1/8" cables, #2C for 5/32"–3/16" cables, and #3 for 7/32"–1/4" cables — with Riser #3A available as an alternate for Riser #3, particularly useful for coated cable applications.

Maximum Tension. Maximum Cable Coverage. T5-8000 Robustness.

• 30–400 lb upper range — highest tension ceiling in the T5-8002 sub-series, covering 5/32"–1/4" cables
• All seven standard cable sizes — 1/16", 3/32", 1/8", 5/32", 3/16", 7/32", and 1/4"
• T5-8000 heavier-duty platform — ~1 lb / 0.45 kg; built for demanding MRO and heavy maintenance environments
• Calibration card T594-105 — same card as T5-2002-105-00; direct dial-to-pounds conversion for all ranges and sizes
• NSN 6635-00-527-6507 — available through government and military supply channels
• U.S.A.F. C5 designation — qualified for military aviation maintenance programs
• Riser #3A compatibility — may be used in lieu of Riser #3 for coated cable applications
• Zero temperature error — calibration-stable from -53°C to 71°C, 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

Technical Specifications

• Tension Range (Low): 30 – 200 lbs
• Tension Range (Mid): 30 – 400 lbs
• Tension Range (High): 30 – 400 lbs
• Cable Sizes (Low Range): 1/16", 3/32", 1/8"
• Cable Sizes (Mid Range): 5/32", 3/16"
• Cable Sizes (High Range): 7/32", 1/4"
• Series Platform: T5-8000 (approx. 1 lb / 0.45 kg)
• Calibration Card: T594-105 (individual unit chart included)
• NSN: 6635-00-527-6507
• USAF Designation: C5
• Riser — 1/16", 3/32", 1/8": Riser #1
• Riser — 5/32", 3/16": Riser #2C
• Riser — 7/32", 1/4": Riser #3 (Riser #3A may be used in lieu of Riser #3)
• Indicator: Black dial indicating
• Temperature Stability: Zero temperature error; operates from -53°C to 71°C
• Pointer Lock: Yes — brake lever rod
• Origin: Made in the USA
• Warranty: 1 year on new units

Typical Applications

• High-tension primary flight control cable rigging up to 400 lbs on large turboprops and business jets
• Rotary-wing and helicopter primary control cable tension verification above 300 lbs
• Military aircraft flight control maintenance (U.S.A.F. C5; NSN 6635-00-527-6507)
• High-frequency MRO operations where T5-8000 platform robustness is preferred
• Programs requiring the highest T5-8000 range across the full seven-size cable spread
• Coated cable applications where Riser #3A geometry is operationally preferred

Pacific Scientific T5-8002-105-00 Calibration

The T5-8002-105-00 should be recalibrated on a scheduled basis — annually at minimum, and immediately following any overload event, mechanical shock, or drop. As the highest-range model in the T5-8002 sub-series, used on primary flight control cables at the upper end of the T5 tension range, maintaining calibration currency is especially critical to safe rigging outcomes. Pilot John International operates an ISO 17025-accredited calibration laboratory capable of recalibrating Pacific Scientific T5-8000 series tensiometers to original manufacturer specifications, issuing a fully traceable calibration certificate upon completion. Whether your maintenance program operates under FAA oversight, 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 →