Pacific Scientific T5-8203-108-00 Cable Tensiometer

The Pacific Scientific T5-8203-108-00 is the definitive standard T5 instrument for 3/8" aircraft control cable tension measurement — calibrated for 200 to 1000 lbs on 3/8" cable exclusively, using Riser #3B throughout on calibration card T597-8203-108. Listed under NSN 6635-00-905-6213, it is the only standard T5 model that reaches 1000 lbs on 3/8" cable. The only other standard T5 instrument covering 3/8" cable is the T5-8003-209-00 (200–400 lbs) — the T5-8203-108-00 extends that coverage by 600 lbs, reaching the high-tension primary control cable zone where large transport-category aircraft, heavy military platforms, and specialized aerospace systems specify their largest-diameter cable systems. The T5-8203 sub-series is its own distinct designation in Pacific Scientific's service documentation, separate from every other T5-8000 sub-series, built specifically for this 3/8" high-tension application.

The Only Standard T5 Reaching 1000 lbs on 3/8" Cable

The T5-8203-108-00 shares the 200–1000 lb range and 50 lb reading intervals of the T5-8003-108-00, but where the -108-00 covers 3/16"–5/16" cables, the T5-8203-108-00 is calibrated exclusively for 3/8" cable. Riser #3B is used for every measurement — there is no riser selection between cable sizes because only one cable size is supported. This simplifies the measurement workflow significantly: place the instrument on the 3/8" cable, read the dial, reference calibration card T597-8203-108 for the 3/8" column, obtain the tension in pounds. The only comparable 3/8" instrument in the standard T5 line — the T5-8003-209-00 — covers 200–400 lbs on 1/4", 5/16", and 3/8" cables using Riser #4. The T5-8203-108-00 surpasses that ceiling by 600 lbs, is dedicated exclusively to 3/8", and uses the heavier Riser #3B geometry required for accurate readings at 3/8" cable diameters in the 400–1000 lb zone. Zero temperature error means the instrument is accurate from -53°C to 71°C without any preliminary adjustments.

Single Cable. Single Purpose. Maximum Precision.

• 200–1000 lb range on 3/8" cable — the highest range available for 3/8" cable in the standard T5 line
• 3/8" cable only — dedicated single-cable-size specialist; no riser selection required between measurements
• Riser #3B throughout — used for every measurement; unique to this model and T5-8103-406-00
• 50 lb reading intervals — consistent resolution across the full 200–1000 lb range
• Calibration card T597-8203-108 — purpose-specific for 3/8" cable at this tension range
• NSN 6635-00-905-6213 — available through government and military supply channels
• T5-8203 Ref C platform — dedicated sub-series designation; heavy-duty construction for high-tension 3/8" cable work
• 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 overhead areas
• No batteries or electronics — fully mechanical, always ready

Technical Specifications

• Tension Range: 200 – 1000 lbs
• Cable Size: 3/8" only
• Riser: Riser #3B (used throughout; no riser selection required)
• Reading Interval: 50 lbs throughout 200–1000 lb range
• Series Platform: T5-8203 Ref C
• Calibration Card: T597-8203-108
• NSN: 6635-00-905-6213
• Operating Temperature: -53°C to 71°C
• Temperature Stability: Zero temperature error
• Pointer Lock: Yes — brake lever rod
• Origin: Made in Puerto Rico by OPTI Manufacturing
• Warranty: 1 year on new units

Typical Applications

• Transport-category aircraft with 3/8" primary control cables at tensions from 200 to 1000 lbs
• Large military aircraft where 3/8" cable systems are specified at high primary control tensions
• Heavy aerospace platforms requiring 3/8" cable tension verification above 400 lbs
• Government and military procurement programs (NSN 6635-00-905-6213)
• Post-repair and return-to-service verification on high-tension 3/8" primary cable systems
• MRO facilities maintaining heavy transport-category and military aircraft with 3/8" cable systems

Pacific Scientific T5-8203-108-00 Calibration

The T5-8203-108-00 should be recalibrated on a scheduled basis — annually at minimum, and immediately following any overload event, mechanical shock, or drop. As the only standard T5 instrument calibrated for 3/8" cable above 400 lbs, maintaining calibration currency on this model is especially critical — for programs relying on it as the sole instrument for high-tension 3/8" cable work, an out-of-calibration reading on a primary flight control cable has direct airworthiness implications with no readily available backup instrument in the standard T5 line. Pilot John International operates an ISO 17025-accredited calibration laboratory capable of recalibrating Pacific Scientific T5-8203 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 →