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Connecting Terminal Lugs to Terminal Blocks

Filed Under: Engine Ignition and Electrical Systems

Terminal lugs should be installed on terminal blocks in such a manner that they are locked against movement in the direction of loosening. [Figure 4-109]

Figure 4-109. Connecting terminals to terminal block.
Figure 4-109. Connecting terminals to terminal block.

Terminal blocks are normally supplied with studs secured in place by a plain washer, an external tooth lockwasher, and a nut. In connecting terminals, a recommended practice is to place copper terminal jugs directly on top of the nut, followed with a plain washer and elastic stop nut, or with a plain washer, split steel lockwasher, and plain nut.

Aluminum terminal lugs should be placed over a plated brass plain washer, followed with another plated brass plain washer, split steel lockwasher, and plain nut or elastic stop nut. The plated brass washer should have a diameter equal to the tongue width of the aluminum terminal lug. Consult the manufacturer’s instructions for recommended dimensions of these plated brass washers. Do not place any washer in the current path between two aluminum terminal lugs or between two copper terminal lugs. Also, do not place a lockwasher directly against the tongue or pad of the aluminum terminal.

To join a copper terminal lug to an aluminum terminal lug, place a plated brass plain washer over the nut that holds the stud in place; follow with the aluminum terminal lug, a plated brass plain washer, the copper terminal lug, plain washer, split steel lockwasher and plain nut or self-locking, all metal nut. As a general rule, use a torque wrench to tighten nuts to ensure sufficient contact pressure. Manufacturer’s instructions provide installation torques for all types of terminals.

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