How Do I Measure a Control Cable?

When replacing a worn or broken control cable, getting the measurement right is critical. Even a small error can mean poor fitment, incorrect travel, or system failure—especially in demanding environments like agriculture, construction, trucking, and heavy plant equipment.

At Industrial & Cable Group, we regularly help customers replace control cables across Australia, and the good news is: once you know what to look for, measuring a control cable is straightforward.

Step 1: Check for a Part Number First

Before measuring anything, always inspect the existing cable.

Many control cables have:

• A part number heat stamped on the outer conduit

• A brand marking (such as Morse® or Teleflex® style identifiers)

If you can identify the part number, a direct replacement is often available without further measurement.

If not, you’ll need to measure the cable manually.

Step 2: Measure Tip to Tip (Overall Length)

The most important measurement is the overall cable length.

To do this:

• Measure from one end fitting tip to the other end fitting tip

• Follow the natural routing of the cable as much as possible

• Do not shorten or straighten excessively if the cable has bends in its installed position

Most industrial control cables are measured tip-to-tip, but always confirm if your application has exceptions.

This is especially important in:

• Agricultural machinery (tractors, harvesters)

• Earthmoving equipment (excavators, loaders)

• Trucking and transport systems

• Construction machinery

• Fixed plant and industrial equipment

Step 3: Identify the Cable End Types

Next, identify what fittings are on each end of the cable.

Common end types include:

• Threaded bulkhead fittings

• Clamp or grooved ends

• Clevis or eyelet style connections

• Ball joint connections

Knowing the end types ensures the replacement cable will physically connect to your existing control system without modification.

Step 4: Determine Cable Series (Rod Size Matters)

Control cables are also defined by their internal rod size and construction series.

Industrial & Cable Group typically supplies:

• 30 Series – 3/16” rod

• 40 Series – 1/4” rod

• 60 Series – 5/16” rod
  (Some series also available in metric equivalents)

Matching the correct series is essential for:

• Load handling

• Travel accuracy

• Long-term durability in high-vibration environments

Step 5: Confirm Required Travel Length

The travel length is how far the inner cable moves from full in to full out.

Standard travel ranges include:

• 25mm

• 50mm

• 75mm

• 100mm

• Up to 150mm

Incorrect travel selection can cause:

• Incomplete throttle response

• Poor hydraulic valve control

• Unsafe or inconsistent machine operation

Step 6: Understand the Application Environment

Control cables are not one-size-fits-all. The environment plays a major role in selection.

Industrial & Cable Group cables are commonly used in:

• Agriculture – tractors, irrigation systems, harvesters

• Earthmoving – loaders, graders, excavators

• Transport & trucking – gear shift and control systems

• Construction – cranes, compactors, machinery controls

• Industrial plant equipment – valves, actuators, and mechanical control systems

Our cables are designed for high vibration, harsh weather, and continuous heavy-duty use.

Step 7: When in Doubt, Send Photos

If you cannot confidently identify measurements, the fastest solution is:

• Take clear photos of both ends

• Include the full cable length

• Send them to the supplier for matching assistance

As noted in our technical guidance, this is often the quickest way to ensure a correct replacement, especially for older or non-standard cables. (Industrial and Cable Group)

Summary: The 4 Key Things You Need

To correctly measure a control cable, you always need:

• Overall tip-to-tip length

• End fitting types

• Cable series (rod size)

• Required travel distance

Once you have these, you can confidently order a direct replacement suited to your machine and application.

Final Thought

Control cables are critical components in machinery used across Australia’s toughest industries. Getting the measurement right ensures reliability, safety, and smooth operation—whether you're running farm equipment, heavy earthmoving machinery, or transport systems.

At Industrial & Cable Group, we build every cable to order, ensuring it matches your exact requirements for performance and durability.