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## Aluminum Wire Terminals 

The aluminum terminal lugs should be crimped to aluminum wire only. The tongue of the aluminum terminal lugs, or the total number of tongues of aluminum terminal lugs when stacked, should be sandwiched between two flat washers when terminated on terminal studs. Spacers or washers should not be used between the tongues of terminal lugs. Special attention should be given to aluminum wire and cable installations to guard against conditions that would result in excessive voltage drop and high resistance at junctions that may ultimately lead to failure of the junction. Examples of such conditions are improper installation of terminals and washers, improper torsion (torquing of nuts), and inadequate terminal contact areas. 

## Pre-Insulated Splices 

Pre-insulated terminal lugs and splices must be installed using a high-quality crimping tool. Such tools are provided with positioners for the wire size and are adjusted for each wire size. It is essential that the crimp depth be appropriate for each wire size. If the crimp is too deep, it may break or cut individual strands. If the crimp is not deep enough, it may not be tight enough to retain the wire in the terminal or connector. Crimps that are not tight enough are also susceptible to high resistance due to corrosion buildup between the crimped terminal and the wire. [Figure 9-155] 

## Crimping Tools 

Hand, portable, and stationary power tools are available for crimping terminal lugs. These tools crimp the barrel to the conductor, and simultaneously form the insulation support to the wire insulation. [Figure 9-156] 

## Emergency Splicing Repairs 

Broken wires can be repaired by means of crimped splices, by using terminal lugs from which the tongue has been cut off, or by soldering together and potting broken strands. These repairs are applicable to copper wire. Damaged aluminum wire must not be temporarily spliced. These repairs are for temporary emergency use only and should 

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be replaced as soon as possible with permanent repairs. Since some manufacturers prohibit splicing, the applicable manufacturer’s instructions should always be consulted. 

## Junction Boxes 

Junction boxes are used for collecting, organizing, and distributing circuits to the appropriate harnesses that are attached to the equipment. [Figure 9-157]  Junction boxes are also used to conveniently house miscellaneous components, such as relays and diodes. Junction boxes that are used in high-temperature areas should be made of stainless steel. 

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