Optimanufacturing T60-1001-C8-1A Installation and operating instructions

SOP-TN-002 Rev. Q
T60 Operations and Service Manual
OPERATION & SERVICE MANUAL FOR
CABLE TENSIOMETER
T60 SERIES
PART NUMBERS:
T60-1001-C8-1A (NSN: 6635-00-530-1128)
T60-1001-C9-1A (NSN: 6635-00-530-1129)
T60-1002-C8-00 (BRITISH MODEL FOR CWT CABLES)
T60-1002-C9-00 (BRITISH MODEL FOR CWT CABLES)

SOP-TN-002 Rev. Q
T60 Operations and Service Manual
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TABLE OF CONTENTS
INTRODUCTION AND DESCRIPTION ....................................................................................................................................2
1-1. INTRODUCTION...................................................................................................................................... 2
1-2. PURPOSE -.............................................................................................................................................. 2
1-3. DESCRIPTION -....................................................................................................................................... 2
1-4. WARRANTY -........................................................................................................................................... 2
Table 1- Type Identification ..............................................................................................................................................2
SPECIAL SERVICE TOOLS ....................................................................................................................................................3
2-1. SPECIAL SERVICE TOOLS .................................................................................................................... 3
PREPARATION FOR USE, STORAGE, and SHIPMENT ........................................................................................................3
3-1. PREPARATION FOR USE ...................................................................................................................... 3
3-2. PERFORMANCE –.................................................................................................................................. 3
3-3. STORAGE................................................................................................................................................ 3
3-4. SHIPMENT -............................................................................................................................................. 3
Figure 1.1- Wrist Band......................................................................................................................................................3
Figure 1- Cable Tensiometer, Typical...............................................................................................................................4
SECTION IV................................................................................................................................................................ 4
OPERATION INSTRUCTIONS ................................................................................................................................................4
4-1. GENERAL INSTRUCTIONS .................................................................................................................... 4
4-2. OPERATING INSTRUCTIONS -.............................................................................................................. 5
4-3. MEASURING CABLE DIAMETERS......................................................................................................... 5
Figure 2- T60 Cable Diameters ........................................................................................................................................5
4-4. TAKING CABLE TENSION READINGS, TYPE C8 ................................................................................. 6
Figure 3- Preset Instructions, Type C8 .............................................................................................................................6
4-5. TAKING TENSION READINGS, TYPE C9 -............................................................................................ 7
Figure 3.5- Preset Instructions, Type C9 ..........................................................................................................................7
4-6. DIFFICULT LOCATIONS ......................................................................................................................... 7
4-7. ACCURACY - ........................................................................................................................................... 7
Table 2- T60 Accuracy Tolerance.....................................................................................................................................7
4-8. TYPE OF CABLE - ................................................................................................................................... 8
4-9. USE OF CALIBRATION BAR - ................................................................................................................ 8
Figure 4- Calibration Bar Instruction.................................................................................................................................8
4-10. OVERLOAD - ........................................................................................................................................... 8
SECTION V................................................................................................................................................................. 9
PERIODIC INSPECTION, MAINTENANCE, AND LUBRICATION...........................................................................................9
5-1. GENERAL - .............................................................................................................................................. 9
Table 3- Lubrication Chart ................................................................................................................................................9
SECTION VI................................................................................................................................................................ 9
TROUBLE SHOOTING ............................................................................................................................................................9
6-1. GENERAL - .............................................................................................................................................. 9
6-2. SERVICE TROUBLES AND REMEDIES - .............................................................................................. 9
Table 4- Trouble Shooting Chart ......................................................................................................................................9
SECTION VII............................................................................................................................................................. 10
CALIBRATION .......................................................................................................................................................................10
7-1. EQUIPMENT REQUIRED -.................................................................................................................... 10
7-2. DISASSEMBLY PRIOR TO CALIBRATION - ........................................................................................ 10
7-3. CALIBRATION - ..................................................................................................................................... 10
7-4. INDICATOR CABLE SIZE - .................................................................................................................. 11
Table 5- STD Cable Size to British (CWT) Cable Size Equivalents................................................................................11
SECTION VIII............................................................................................................................................................ 12
GROUP ASSEMBLY PARTS LIST.........................................................................................................................................12
Figure 6- Cable Tensiometer, Type C8 and C9 ..............................................................................................................12
Table 6 Part List ............................................................................................................................................................ 13

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SECTION I
INTRODUCTION AND DESCRIPTION
1-1. INTRODUCTION -This publication is issued as the basic Manual of Operation and Service
Instructions for Types C8 and C9 Cable Tensiometers manufactured by OPTI Manufacturing Corp.,
Luquillo, Puerto Rico USA. The equipment covered are listed in table 1. Instructions contained in this
publication apply to both types listed, unless specifically noted otherwise.
1-2. PURPOSE -The cable Tensiometer are designed for use in accurate rigging of airborne control cables
1-3. DESCRIPTION -Used extensively, it is considered the standard of the industry in many countries,
and has proven it’s durably under long and continual service. Each instrument is suitable for use over a
wide range of tension measurements and different cable sizes.
Firm positive 3-point cable grip prevents dislodgement when instrument hanging free on control cable.
The T60 requires no alternate riser for the various size cables. There are no losable parts in the T60.
The instrument is always ready for instant use. An easy to operate, accurate, built-in gage eliminates
guess work as to size of cable to be tested. Simple, comfortable lever grip permits one hand operation
without operator fatigue. In severe cold, service mittens or gloves may be worm without any loss
efficiency of operation.
A simple lock holds dial pointer at exact reading on cables in areas where instrument cannot be seen.
A touch unlocks the pointer preparatory for the next reading. Large, clear numerals make readings
easy and accurate. Bezel is easily turned to the correct zero setting for the proper cable size,
determined by the gage in the handle head. The T60 is a durable precision instrument and is not
damaged by use on cable tensions beyond its range.
The cable Tensiometer is a hand-held instrument. A jaw is located at the top of instrument. Actual
contact on the cable is made by the riser block and the two sectors located in the jaw. A sliding yoke
slides up the frame of the instrument to provide a measuring force. A dial indicator is located at the
bottom of the instrument to give the actual tension indication. An actuating handle is pivoted at the
center of the instrument and is motivated by a trigger spring within the body of the Tensiometer. A
pointer lock button is situated just above the dial indicator and a handle latch is located on the left side
of the frame to engage the detent notch of the actuating handle. (See figure 1)
1-4. WARRANTY -The T60 cable Tensiometer has a warranty to the original customer for a period of (1)
one year on new units and (6) six months for repaired units from the invoice date. This warranty is to
ensure the cable Tensiometer is free of defects in materials and workmanship under correct and
normal use. The warranty can be void if the unit has been tampered, altered, dropped or damaged by
an accident.
All returns must have a Return Material Authorization (RMA) number. In order to obtain a RMA, please
contact our Quality Department via email, [e-mail], or via fax: [phone].
Table 1- Type Identification
TYPE
MFR’S
PART NUMBER
CABLES
RANGE
Type C8
T60-1001-C8-1A
1/16”, 3/32”, 1/8”
10 to 200 lbs.-tension
5/32”, 3/16”
30 to 200 lbs.-tension
7/32”, 1/4”
80 to 200 lbs.-tension
British
T60-1002-C8-00
3 CWT, 5 CWT,10 CWT
10 to 200 lbs.-tension
15 CWT, 25 CWT
30 to 200 lbs.-tension
35 CWT, 45 CWT
80 to 200 lbs.-tension
Type C9
T60-1001-C9-1A
1/8”, 5/32”, 3/16”, 7/32”, 1/4”
150 to 450 lbs.-tension
British
T60-1002-C9-00
10CWT, 15CWT, 25CWT, 35CWT, 45CWT
150 to 450 lbs.-tension

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32
CABLE TENSIOMETER
PACIFIC SCIENTIFIC
1
16 3
32
1
8
3
16 7
32
1
4
POUNDS TENSION
10
20
30
40
50 60 70 80
90
100
110
120
130
140
150
200
125+
125-
5
1
4
3
16
1
16
1
8
SECTION II
SPECIAL SERVICE TOOLS
2-1. SPECIAL SERVICE TOOLS - No special tools are required for service or maintenance of the cable
Tensiometer.
SECTION III
PREPARATION FOR USE, STORAGE, and SHIPMENT
3-1. PREPARATION FOR USE - The cable Tensiometer is shipped by the manufacturer in its own
carrying case and is ready for use, for avoid damage on common use, the operator shall be use the
Wrist Band adjustable, see figure 1.1. Each time the cable Tensiometer is used it shall be removed
from the case and the serial number stamped on the nameplate checked against the serial number on
the tab of the calibration bar.
3-2. PERFORMANCE –The Tensiometer shall be capable for use under extreme conditions of heat or
cold without affecting the accuracy of readings, the operating temperature range are -65⁰F to 160⁰F
(-53⁰C to 71⁰C.)
3-3. STORAGE - When the cable Tensiometer is not in use it must be placed in its carrying case. There
are no special instructions or precautions relative to storage.
3-4. SHIPMENT - If the cable Tensiometer is to be shipped, it shall be placed in its carrying case and
packed in such a manner as to avoid damage by common carrier.
Figure 1.1- Wrist Band

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T60 Operations and Service Manual
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Figure 1- Cable Tensiometer, Typical
SECTION IV
OPERATION INSTRUCTIONS
4-1. GENERAL INSTRUCTIONS - Each time the instrument is removed from its case for use check the
serial number on the nameplate to ascertain that it agrees with the serial number on the calibration
bar. Before using the instrument check the calibration by means of the calibration bar. (See paragraph
4-9.)
Warning: Cable Tensiometers should not be used for adjusting the rig load in a cable system where an automatic
cable tension regulator is installed. All such cable systems should be rigged by adjusting them so that the
pointer on the cable tension regulator scale indicates the correct number based on the surrounding temperature
as indicated on the chart provided by the aircraft Maintenance Manual. The Tensiometer may be used to check
the tension so obtained, but it must be remembered that the actual cable tension will vary from the nominal
depending on the errors in the instrument itself, manufacturing tolerance of springs in the regulators, rate of the
regulator spring, and condition of the control cable. Cable tension readings taken on a regulated control system
therefore can be misleading and can result in damage through improper rigging.
UP
DOWN BOTTOM
RIGHT
TOP
LEFT
CALIBRATION BAR
RISER
CABLE GAGE
POINTER LOCK BUTTON
PRESET ACTUATING
DIAL FACE
RING
HANDLE LATCH
POINTER UNLOCK
BUTTON
ACTUATING HANDLE
CABLE GAGE STOP PIN
SECTOR
JAW BASE
TAB
32
CABLE TENSIOMETER
PACIFIC SCIENTIFIC
1
16 3
32
1
8
3
16 7
32
1
4
POUNDS TENSION
10
20
30
40
50 60 70 80
90
100
110
120
130
140
150
200
125+
125-
5
1
4
3
16
1
16
1
8
9"
228.6mm
41
2"
114.3mm
2"
50.8mm
INSTRUCTIONS
1- PRESET DIAL TO
CABLE DIA.(NOTE
RANGE LARGER DIA.)
2- CLAMP ON CABLE
SEVERAL PLACES AND
AVERAGE READINGS.
3- TO KEEP DIAL
READING PRESS
BUTTON,
REVERSE
TO RE-
LEASE
CABLE
TENSIOMETER
PATENTS:
2,592,868
D - 157032
MADE IN
U.S.A.
T60040
11
2"
38.1mm
11
2"
38.1mm
FRONT VIEW
Not Scale
REAR VIEW SIDE VIEW
Not Scale Not Scale
T60 TENSIOMETER
Net Weight: 1.58 lb. / .72 kg.
Shipping Weight: 3 lbs. / 1.36 kg.

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32
CABLE TENSIOMETER
PACIFIC SCIENTIFIC
1
16 3
32
1
8
3
16 7
32
1
4
POUNDS TENSION
10
20
30
40
50 60 70 80
90
100
110
120
130
140
150
200
125+
125-
5
1
4
3
16
1
16
1
8
HANDLE
CABLE
STOP PIN
HANDLE
32
CABLE TENSIOMETER
PACIFIC SCIENTIFIC
1
16 3
32
1
8
3
16 7
32
1
4
POUNDS TENSION
10
20
30
40
50 60 70 80
90
100
110
120
130
140
150
200
125+
125-
5
1
4
3
16
1
16
1
8
1
8" Ø EXAMPLE
CABLE SIZE
INDICATOR
32
CABLE TENSIOMETER
PACIFIC SCIENTIFIC
1
16 3
32
1
8
3
16 7
32
1
4
POUNDS TENSION
10
20
30
40
50 60 70 80
90
100
110
120
130
140
150
200
125+
125-
5
1
4
3
16
1
16
1
8
a b c
LATCH
SIZE GAGE
CABLE SIZE
1
4
3
16
1
16
1
8
4-2. OPERATING INSTRUCTIONS - Either the right- or left-hand may be used to operate this
instrument. The handle latch retains the actuating handle. The latch is automatically released when
the actuating handle is squeezed. To re-latch the actuating handle, the handle must be squeezed
firmly against the side of the Tensiometer and the handle latch pushed up from the bottom against its
spring load and held in the extended position while the actuating handle is slowly released against the
handle latch. The latch end will be retained in the detent socket provided in the actuating handle.
Note: When operating the instrument handle, the handle should never be allowed to snap open; it should be
released gradually, allowing the unit to clamp firmly on the cable.
4-3. MEASURING CABLE DIAMETERS
Figure 2- T60 Cable Diameters
a. With the actuating handle in the latched position, move the cable size gage to the left against the
cable stop pin. See Figure 2a.
b. Release handle latch by squeezing the actuating handle. Retain the actuating handle unlatched
against the side of the Tensiometer. Place the instrument on the cable, making certain that the
cable is squarely aligned in the jaws and resting on the sectors and riser block. Care should be
taken that the cable is resting flat against the jaw base. Slowly release the actuating handle,
allowing the sectors to slide up and grip the cable. Remove all restraint from the actuating handle.
See figure 2b.
c. Remove Tensiometer from the cable by returning the actuating handle to the latched position. The
black line opposite the position on the cable size gage indicates the cable diameter. See figure 2c.
Warning: When re-latching actuating handle, verify that the latch is positioned in the detent socket before
releasing the handle. If this is not done, the handle will be allowed to snap open with possible personal injury.

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4-4. TAKING CABLE TENSION READINGS, TYPE C8
a. Preset dial by rotating the knurled rim of the dial indicator until the pointer is directly over the line
corresponding to the cable diameter.(See Figure 3a)
Figure 3- Preset Instructions, Type C8
Note: Shown figure is for reference purpose, actual dial may vary.
NOTE 1: An examination of the dial will indicate that for the larger size cables there are two rows preset lines.
One row is identified by 125-; the other row is identified by 125+. When measuring tensions below 125 pounds
use the lower line; when measuring tensions in excess of 125 pounds use the high line. (See Figure 3b)
NOTE 2: When used the cable coated type, you shall preset the dial in cable’s O.D. including coated insulation.
For example if your 5/32” coated cable has an OD of 7/32” then the dial pointer preset shall be in the 7/32” mark
and not on the 5/32”. To obtain the cable OD measurement you may use the instrument’s integrated cable size
gauge and procedure sec. 4-3.
b. Release the handle latch by squeezing the actuating handle. Retain the actuating handle unlatched
against the side of the Tensiometer. Place the instrument on the cable, making certain that the
cable is squarely aligned in the jaws and against the jaw base. Slowly release the actuating handle,
allowing the sectors to slide up and grip the cable. Remove all restraint from the actuating handle.
c. With the Tensiometer clamped on the cable the tension is read directly by the pointer position on
the dial face.
d. To remove the Tensiometer compress the actuating handle firmly against the side of the
Tensiometer and latch the handle in position with the handle latch.
SET POINTER OVER CENTER OF LINE
WHEN READING TENSION LOADS
IN EXESS OF 125 POUNDS.
LESS THAN 125 POUNDS.
SET POINTER DIRECTLY
OVER CENTER OF
LINE TO THE CABLE DIAMETER
3a
3b
1
16 3
32
1
85
32
3
16 7
32
1
4
20
30
40
50 60 70
80
90
100
110
120
130
140
150
210
180
PACIFIC
CABLE TENSIOMETER
POUNDS TENSION
125+
125-
210
125+
SET POINTER OVER CENTER OF LINE
WHEN READING TENSION LOADS
10

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4-5. TAKING TENSION READINGS, TYPE C9 -The Type C9 cable Tensiometer is used in the same
manner as the Type C8 with the following exception: the larger size cables have two rows of preset
squares, one row identified by 250-, the other row identified by 250+. When measuring cable tensions
below 250 pounds use corresponding squares in the row indicated by 250- and conversely, for the
opposite condition, use 250+.(See Fig. 3.5)
Figure 3.5- Preset Instructions, Type C9
Note: Shown figure is for reference purpose, actual dial may vary.
4-6. DIFFICULT LOCATIONS - When taking readings among closely grouped cables or in awkward or
blind locations, let the actuating handle remain open with the instrument clamped on the cable. While
in this position, press the pointer lock button down. Remove the Tensiometer by compressing the
actuating handle against the case and remove. The dial indicator pointer will be locked in a position
directly over the tension reading obtained on the cable. To release this reading, press up on the
pointer unlock button.
Note: Do not attempt to take cable tension readings with the pointer lock button pressed down. If the pointer
lock button is depressed during a tension reading, a false reading will result due to the friction of the brake
mechanism.
4-7. ACCURACY - Because of the uneven surface of stranded cable, slight variations in reading may occur
on the same cable at the same tension. This is especially true of 5/32-inch diameter cable and larger.
To obtain the greatest possible accuracy, take three to five readings at slightly different locations on
the cable. Average these readings to obtain the maximum degree of accuracy. Is consider “out of
tolerance”if not meet with the specification of following table 2:
Table 2- T60 Accuracy Tolerance
MODEL
RANGE
(LBS-TENSION)
ACCURACY (+/-)
T60-C8
10-200
±5% of indicator or one minor division from dial scale whichever is
greater, values taken from dial scale average reading.*
T60-C9
150-450
±5% of indicator or one minor division from dial scale whichever is
greater, values taken from dial scale average reading.*
1
8
5
32 3
16
7
32 1
4
450
400
350
300
250 200
150
100
250-
250+
250-
250+
300
SET POINTER OVER CENTER OF LINE
WHEN READING TENSION LOADS
IN EXESS OF 250 POUNDS.
SET POINTER DIRECTLY
OVER CENTER OF
LINE TO THE CABLE DIAMETER
SET POINTER OVER CENTER OF LINE
WHEN READING TENSION LOADS
LESS THAN 250 POUNDS.
PACIFIC
CABLE TENSIOMETER
POUNDS TENSION

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*Due principally to the uneven surface of the stranded cables, slight variations in readings may occur on the
same cable at the same tension. If closest possible accuracy is desired take three or five readings at slightly
different locations on the cable and average them.
4-8. TYPE OF CABLE - The cable Tensiometer is calibrated for use on standard, multiple-strand, aircraft
cable of 7 x 7 or 7 x 19 stranding in sizes of 1/16, 3/32, and 7 x 19 stranding for 1/8 through 1/4
inch diameter on cable. Do not attempt to use the cable Tensiometer on cables of a different
construction. Cables construction and specification in accordance with MIL-DTL-83420, general
specification for flexible wire rope for aircraft control cables. See TABLE 5 for British Equivalent. The
Tensiometer instrument shall be calibrated on the same type of cables on which the Tensiometer
instrument will be used (such as coated cables used externally on helicopters). The T60 series cable
Tensiometer are standard calibrated on Flexible, wire rope, for aircraft control cables. Flexible cables,
either coated or non-coated, shall conform to MIL-DTL-83420. Most Aircraft systems use the Flexible
cable. Some aircraft, (A-10 and F-15), use both Flexible and Non-Flexible cables. A Tensiometer
instrument calibrated on Flexible cable will not give accurate tension readings when measuring Non-
Flexible cable. Non-Flexible cables shall conform to MIL-DTL-87161, (Supersedes MIL-W87161 & MIL-W-
5693). Again, the Tensiometer instrument shall be calibrated on the same type of cables on which the
Tensiometer instrument will be used.
4-9. USE OF CALIBRATION BAR - A Calibration bar is supplied with each Tensiometer. This provides
an immediate means of checking the accuracy of the instrument while in use. The calibration bar has
been carefully checked to read the load marked on the identification tab. The identification tab also
carries the serial number of the instrument for which that particular calibration bar is provided. To
check calibration proceed as follows:
a. Preset the indicator dial face to the smallest cable size listed, 1/16 for C8 and 1/8 for C9, 3cwt for
C8 and 10cwt for C9 British models.
b. Grasp the calibration bar identification tab in the left hand.
c. Place the bar in the instrument with the identification tab facing the user, and the right end of the
bar flush with the edge of the instrument. See Figure 4.
Figure 4- Calibration Bar Instruction
CALIBRATION BAR
FLUSH TO THIS
SURFACE
UP
DOWN BOTTOM
RIGHT
TOP
LEFT
RISER
CABLE GAGE
POINTER LOCK BUTTON
PRESET ACTUATING
DIAL FACE
RING
HANDLE LATCH
POINTER UNLOCK
BUTTON
ACTUATING HANDLE
CABLE GAGE STOP PIN
SECTOR
JAW BASE
TAB
(under this cover)
d. Slowly release the actuating handle, allowing the jaws to grip the calibration bar. Note the reading
on the dial indicator. The reading obtained in this manner should correspond with the reading
marked on the identification tab within +/- 2 % of the value marked. The Tensiometer’s serial
number shall be marked on the bar.
Caution: The TEST BAR shall be placed flush against the riser faces such that the faces of the risers are parallel
with the test bar.
4-10. OVERLOAD - The cable Tensiometer is a durable precision instrument and cannot be damaged by
use on cables loaded in excess of the amount indicated by the dial on the Tensiometer.

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SECTION V
PERIODIC INSPECTION, MAINTENANCE, AND LUBRICATION
5-1. GENERAL - No periodic inspection, maintenance, or lubrication is required for cable Tensiometers.
As a matter of general practice, the instrument should be kept clean at all times. Particular attention
should be paid to the two sectors and the riser block to see that they are always free from foreign
matter. The instrument as shipped by the manufacturer has been lubricated. In the event that repairs
are made as outlined in Section VI, lubrication should be accomplished as listed in table 3. Method of
application is a light wipe.
*Explanation: D. C. #33: Dow Corning Grease #33 fluid type or equivalent to NATO G-395 fluid type per MIL-
PRF-81322.
Table 3- Lubrication Chart
FIG. 6
INDEX NO.
LUBRICATION*
LOCATION
20
D.C. #33
Both sides
23
D.C. #33
On OD of pins and flat face
26
D.C. #33
ID and OD
29
D.C. #33
OD
32
D.C. #33
OD
38
D.C. #33
OD
40
D.C. #33
OD
SECTION VI
TROUBLE SHOOTING
6-1. GENERAL - The instrument will be free from trouble such as would be caused by nominal use. The
instrument, however, can be damaged by mistreatment and improper usage. If a detail part of the
instrument becomes damaged or broken, disassemble the instrument in the order of the index
numbers indicated on the exploded view, Figure 6. All detail parts of the instrument are so integrated
that in order to perform a disassembly operation it is necessary that disassembly be started with index
number 1 and continued in numerical sequence. The only exception to this is the latch mechanism (37
through 40, Figure 6). Reassembly is the opposite of disassembly. Whenever the instrument has been
disassembled, it must be recalibrated. (See Section VII.)
6-2. SERVICE TROUBLES AND REMEDIES - (See table 4) a listing of common troubles together with
their probable causes and remedies is presented as a trouble-shooting chart, table 4.
Table 4- Trouble Shooting Chart
TROUBLE
PROBABLE CAUSE
(See Figure 6)
REMEDY
Tensiometer reads high
Faulty dial indicator (35)
Replace dial indicator and calibrate
Tensiometer reads low
Weak trigger spring (29)
Replace trigger spring and calibrate
Dirt and foreign matter between frame
(41) and sectors (24)
Clean and reassemble
Worn out sectors (24) or riser Block (5)
Replace sectors and riser block; then
calibrate
Faulty dial indicator (35)
Replace dial indicator and calibrate
Pointer lock will not function
Switch spring (30) broken
Replace switch spring and calibrate
Handle latch will not lock
handle in close position
Handle latch spring (39) weak or
broken
Replace latch spring. Do not calibrate