Pacific Scientific T5-8005-110-00 Aircraft Cable Tensiometer – 300 to 1,600 lbs, 3/16" to 5/16"

The T5-8005-110-00 Cable Tensiometer is designed to measure the tension of aircraft control cables ranging from 3/16" to 5/16" in diameter with a working range of approximately 300 to 1,600 lbs. It enables aviation technicians to accurately set and verify the tension of control cables, ensuring safe flight operations. This precision tool is widely used across commercial, military, and general aviation maintenance programs.

For the most accurate results, always use the correct riser as indicated on the calibration card that matches the instrument’s serial number. The T5-8005-110-00 typically uses riser #2C or #3A, depending on the cable size and tension range. Using an incorrect riser or calibration card may result in false readings and potentially cause internal damage to the device.

Yes, the T5-8005-110-00 can measure both coated and uncoated cables, as long as the riser corresponds to the total outer diameter of the cable, including its coating. When measuring coated cables, record the riser used on the calibration chart or certification label to ensure traceability and accurate future calibrations. OPTI Manufacturing emphasizes using the same cable type for calibration and field measurements to maintain consistency.

This tensiometer is factory-calibrated for flexible aircraft cables that meet MIL-DTL-83420 standards, typically featuring 7×7 or 7×19 strand construction. It can also be recalibrated for non-flexible cables built to MIL-DTL-87161 specifications if required. This makes it suitable for various aircraft applications, including flight control, brake, and trim systems.

The orientation of the instrument does not affect accuracy, meaning it can be used vertically, horizontally, or at any angle. This flexibility is particularly useful for maintenance technicians working in confined or awkward spaces within aircraft structures. The T5-8000 series was designed with a mitten grip to provide better ergonomics and stability in these conditions.

The T5-8005-110-00 features a pointer-lock brake lever that allows the technician to retain the dial reading for later observation. Simply push the brake lever rod forward before releasing the trigger to hold the reading in place. After the reading is noted, release the lever to reset the pointer for the next measurement.

For consistent performance, OPTI Manufacturing recommends annual calibration or sooner if the unit is dropped, overloaded, or exposed to harsh environments. Calibration ensures that the internal mainspring, gears, and pointer 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.

Never allow the pointer to move past the “100” mark on the dial, as this can permanently deform the mainspring and affect accuracy. Close the trigger slowly on high-tension cables to monitor pointer movement. The instrument should also always be stored in its protective carrying case when not in use to avoid accidental damage.

Routine maintenance includes cleaning, lubrication, and visual inspection every six months. Use a mild solvent to clean internal components and lubricate with Dow Corning #33 grease or an equivalent aviation-grade lubricant. Avoid using high-pressure air to dry components, as this can damage the delicate hairspring assembly.

A tensiometer is considered “out of calibration” when average readings differ by more than ±2 points from the values shown on its calibration chart. This can result from overloading, improper riser use, or mechanical wear and tear. If calibration drift occurs, the unit should be returned to OPTI Manufacturing for evaluation and recalibration.

No. The T5-8005-110-00 should not be used to adjust cables equipped with automatic tension regulators, as these systems self-adjust for environmental conditions. External readings may be misleading and do not accurately reflect the true system tension. Always refer to the aircraft’s service manual for proper rigging procedures in such cases.

Both instruments are T5-8005 series models on the Ref C platform covering 3/16"–5/16" cable sizes with identical riser configurations and 50 lb reading intervals. The difference is tension range: the T5-8005-109-00 covers 250–1300 lbs; the T5-8005-110-00 covers 300–1600 lbs. The -110-00 starts 50 lbs higher and extends 300 lbs beyond the -109-00's ceiling. Choose the -110-00 when primary cable tension specifications exceed 1300 lbs; choose the -109-00 when 1300 lbs is sufficient. The -110-00 also carries the USAF C7 designation and NSN 6635-00-530-1130, which may be required by military procurement programs.

The C7 designation indicates the T5-8005-110-00 has been qualified by the U.S. Air Force for use in aircraft maintenance programs requiring this specific designation. It is the highest confirmed USAF designation across the standard T5-8000 series line, reflecting the extreme tension range and heavy-duty platform of the T5-8005 sub-series. Military procurement programs specifying a "USAF C7 tensiometer" should reference this model by NSN 6635-00-530-1130.

The T5-8005 sub-series uses Riser #2 for 3/16" cable across all models, while the T5-8003 sub-series uses Riser #2C for the same cable size. The riser selection reflects the different deflection geometry required at the extreme tension levels of the T5-8005 range. Using Riser #2C on a T5-8005 model for 3/16" cable will produce inaccurate readings. This is one of the most important operational distinctions between the two sub-series, and technicians transitioning from T5-8003 instruments must always confirm riser selection against calibration card T597-110 Rev. N before taking measurements.

The T5-8005-111-00 covers 500–2000 lbs on 3/16"–1/4" cable sizes, making it the highest-range model in the standard T5 product line. Note that the -111-00 drops 5/16" from the cable size coverage compared to the -110-00.

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 T5-8005 series tensiometers to original manufacturer specifications, issuing a fully traceable calibration certificate. Visit pilotjohn.com/calibration to learn more or request service.