Pacific Scientific T5-8008-106-00 Aircraft Cable Tensiometer – 40-600 lbs, 1/8" to 1/4"

The T5-8008-106-00 Cable Tensiometer is designed for measuring tension in aircraft control cables with diameters ranging from 1/8" to 1/4". It helps ensure that aircraft control systems are rigged and maintained to exact tension specifications, which is critical for safe and responsive flight control. The tool delivers accurate readings across a tension range of 40 to 600 lbs, making it suitable for both general aviation and military applications.

For accurate results, always install the correct riser indicated on the calibration card that accompanies your tensiometer. The calibration card is unique to each instrument and matches its serial number. Using the incorrect riser or calibration chart can result in inaccurate readings and may void the unit’s calibration warranty.

Yes. The T5-8008-106-00 can measure both coated and uncoated cables, provided the riser size matches the cable’s outer diameter (including any protective coating). When using coated cables, the riser used should be recorded on the calibration label or chart to maintain traceability and ensure continued accuracy during future calibrations.

This model is factory-calibrated for flexible wire rope aircraft control cables built to MIL-DTL-83420 specifications, commonly using 7×7 or 7×19 construction. It can also be recalibrated for non-flexible cables that meet MIL-DTL-87161 standards. Using the tensiometer on the same cable type for which it was calibrated ensures optimal accuracy.

The tensiometer’s readings are independent of orientation, ensuring accuracy is maintained regardless of whether the device is held vertically, horizontally, or at any angle. This makes it ideal for use in tight or hard-to-reach spaces, such as within aircraft control system bays or tail sections.

Avoid allowing the pointer to move past the “100” mark on the dial during a measurement. Overloading the instrument can cause permanent deformation of the spring, resulting in inaccurate readings. When measuring high-tension cables, always close the trigger slowly and observe the dial to ensure readings remain within the calibrated range.

The T5-8008-106-00 features a built-in pointer-lock mechanism that lets technicians retain readings when the dial isn’t visible. By pushing forward the brake lever rod located on the top-left of the case before releasing the trigger, the pointer locks in place, allowing the user to safely remove and read the measurement afterward.

OPTI Manufacturing recommends recalibrating the T5-8008-106-00 every 12 months, or sooner if the tool has been dropped, overloaded, or exposed to contaminants. Calibration ensures that the mainspring and dial assembly remain within acceptable tolerance. PJi offers expert calibration services for Pacific Scientific cable tensiometers, as well as a wide range of other precision instruments and equipment.

No. Cable tensiometers should not be used to adjust or verify systems that include automatic tension regulators, as these systems self-compensate for temperature and pressure variations. In such cases, follow the aircraft manufacturer’s procedures and use the tensiometer only for post-adjustment verification if required.

Routine maintenance includes cleaning, lubrication, and inspection every six months. Remove the dial cover and pointer. Clean the internal parts with an approved solvent, and relubricate using Dow Corning #33 grease or an equivalent. Always avoid using high-pressure air during cleaning, as this can damage the internal hairspring assembly.

If the pointer doesn’t return to zero after a reading, the issue may be caused by binding or debris in the sleeve assembly. Cleaning and realigning the linkage rod typically resolves this. Persistent zero drift may indicate that the unit is out of calibration and requires servicing.

Both instruments cover 40–600 lbs and use the same calibration card (T596-106), but differ in three key ways. The T5-8003-106-00 is built on the heavier Ref C mitten-grip platform and covers six cable sizes (1/8"–5/16"), including the 5/16" cable size with Riser #3A. The T5-8008-106-00 is built on the lighter Ref B platform (~1 lb / 0.45 kg, same as T5-8002 sub-series) and covers four cable sizes (1/8"–1/4") — 5/16" is not supported. If 5/16" cable coverage is required, the T5-8003-106-00 is the correct choice. If 5/16" is not needed and Ref B platform construction is specified or preferred, the T5-8008-106-00 is appropriate.

Yes. Pacific Scientific's service manual explicitly states that if a replacement for the inactive T5-4008-106-00 is required, order the T5-8008-106-00. The two instruments share the same calibration card (T596-106), tension range, and cable size coverage. Tooling records, calibration lab documentation, and maintenance program equipment lists referencing T5-4008-106-00 should be updated to reflect the T5-8008-106-00 as the current active equivalent.

The T5-8008-106-00 uses consistent 20 lb reading intervals throughout the full 40–600 lb range on all four supported cable sizes. This is the finest consistent reading interval available in the T5-8000 series at this tension level — particularly useful for tension verification work in the 40–300 lb zone where fine resolution matters most.

No. The T5-8008-106-00 covers 1/8", 5/32", 3/16", and 1/4" cables only. If your maintenance program requires 5/16" cable coverage in the 40–600 lb range, the T5-8003-106-00 (Ref C platform, six cable sizes including 5/16") is the appropriate instrument.

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 T5-8008 series tensiometers to original manufacturer specifications, issuing a fully traceable calibration certificate. Visit pilotjohn.com/calibration to learn more or request service.