NSI Industries AL4/0-38 - 1 HoleStandard BarrelAluminum Compression Lug4/0 AWG -3/8 Bolt Standard BarrelAluminum Compression Lugs is a type ofaluminum compression connector that is produced from high conductivityaluminum tubing.Center stop assures proper cable installation.They are tin-plated to provide corrosion resistance and are marked with die index and color coded for easy reference. Listed for 35KV maximum when properly installed.
NSI Industries

AL4/0-38

UPC: 662381030108


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Overview

NSI Industries AL4/0-38 Aluminum Compression Lug (SKU: AL4/0-38) is a high-conductivity, tin-plated aluminum connector engineered for reliable 4/0 AWG cable terminations in industrial and utility applications. Manufactured from thick-walled aluminum tubing with a center stop for precise cable insertion, this lug ensures consistent crimp performance and long-term corrosion resistance. The barrel dimensions are 0.441" OD x 0.252" ID x 0.390" length, with a 3/8" mounting hole and 0.150" tongue thickness. Designed for 600V maximum operation (2000V per UL486B), this lug is UL486A/B and cULus listed for wire connectors up to 35kV when installed per cable manufacturer specifications. The tin-plated finish provides low contact resistance and environmental protection, while color-coded caps and die index markings simplify tool selection and installation verification. Compatible with NSI N1240 and N121D crimp tools, this lug supports expanded wire ranges (4-6 AWG) when used with the NSI N12ID dieless compression tool. Ideal for grounding, bonding, and power distribution systems in commercial, industrial, and utility installations where aluminum conductors require secure, high-integrity terminations.
  • High-conductivity aluminum construction with thick walls for reliable current transfer
  • Tin-plated finish for corrosion resistance and low contact resistance
  • Center stop ensures proper cable insertion and consistent crimp performance
  • Color-coded caps and die index markings for easy tool selection and installation
  • UL486A/B and cULus listed for wire connectors up to 35kV (600V max operation)
  • Compatible with NSI N1240, N121D, and N12ID crimp tools
  • Barrel dimensions: 0.441" OD x 0.252" ID x 0.390" length
  • Mounting hole: 3/8", tongue thickness: 0.150"

Specifications

Application
Terminate, Splice, Tap Power Connectors
Cable Size
4/0 AWG (STR)
Color
White
Connection Type
Compression Lug
Environmental Conditions
90 C
Finish
Tin Plated Bronze
Material
Aluminum
Mounting
3/8 Mounting Hole
Number Of Holes
1
Size
4/0 AWG
Size
L=3.42 - W=1.14 - OD=.838 - ID=.551
Special Features
4/0 AWG (STR) - 3/8 Mounting Hole
Standard
UL486A/B
Stud Size
3/8 IN
Type
Standard Barrel - One Hole
Voltage Rating
35 kV
Voltage Rating
600 V
Warranty
1 Year
Package Dimensions (L x W x H)
3.429 IN x 1.15 IN x 0.839 IN
Package Dimensions (L x W x H)
8.7097 cm x 2.921 cm x 21.3106 mm
Package Weight (Imperial)
1.380 L
Package Weight (Metric)
0.626 kg
Mechanical Crimp Tool with 5/8 Inch Nose Die APPLICATIONS: Designed for use with wide range and H-Tap connectors. It has fiberglass handles and comes with "O" and "D" Nose Dies. It has an output of 4.5 tons.

OD581

Mechanical Crimp Tool with 5/8 Inch Nose Die APPLICATIONS: Designed for use with wide range and H-Tap connectors. It has fiberglass handles and comes with "O" and "D" Nose Dies. It has an output of 4.5 tons.
O' Die for OD581 Mechanical Crimp Tool

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U-Type Compression Die - Pink 1/0 AWG Copper - 2 AWG Aluminum U-Shaped Compression Dies are for use with the NSi-12 Compression Tool and Other Tools. See Cross-Reference Chart below.

CD6A

U-Type Compression Die - Pink 1/0 AWG Copper - 2 AWG Aluminum U-Shaped Compression Dies are for use with the NSi-12 Compression Tool and Other Tools. See Cross-Reference Chart below.
U-Type Compression Die - Black 2/0 AWG Copper U-Shaped Compression Dies are for use with the NSi-12 Compression Tool and Other Tools. See Cross-Reference Chart below.

CD7

U-Type Compression Die - Black 2/0 AWG Copper U-Shaped Compression Dies are for use with the NSi-12 Compression Tool and Other Tools. See Cross-Reference Chart below.
Non-Insulated Parallel Splice Connector For Wire Range 6 For Circular Mil Range 20,800-33,100 Length .5 Diameter .365,Metallic

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Power Distribution Block (1) 2/0-14 AWG Primary (6) 4-14 AWG Secondary Power Distribution Blocks are made of high strength, high-conductivity aluminum alloy and are mounted in a high-strength glass-filled polyester base. Each block can stand alone or combine with other blocks to form a multi-block set.

AS-K1-H6

Power Distribution Block (1) 2/0-14 AWG Primary (6) 4-14 AWG Secondary Power Distribution Blocks are made of high strength, high-conductivity aluminum alloy and are mounted in a high-strength glass-filled polyester base. Each block can stand alone or combine with other blocks to form a multi-block set.
PVC Coated Junction Box, 12 Inch X 12 Inch X 6 Inch, 14 Gauge, Gray

A1212SC-G

PVC Coated Junction Box, 12 Inch X 12 Inch X 6 Inch, 14 Gauge, Gray
Molded Junction Box, Length 4 Inch x Width 4 Inch x Depth 2 Inch, Material Polycarbonate, Color Gray

E989NNJ-5-HD

Molded Junction Box, Length 4 Inch x Width 4 Inch x Depth 2 Inch, Material Polycarbonate, Color Gray
Combine high performance with compact dimensions: - 1000 V AC / DC IEC 600 V UL, - Opt for the best marking visibility thanks to the up-front, flat marker zone, which lets you mark up to eight digits or increase the font size.

1SNK705010R0000

Combine high performance with compact dimensions: - 1000 V AC / DC IEC 600 V UL, - Opt for the best marking visibility thanks to the up-front, flat marker zone, which lets you mark up to eight digits or increase the font size.
Combine high performance with compact dimensions: - 1000 V AC / DC IEC 600 V UL, - Opt for the best marking visibility thanks to the up-front, flat marker zone, which lets you mark up to eight digits or increase the font size.

1SNK705030R0000

Combine high performance with compact dimensions: - 1000 V AC / DC IEC 600 V UL, - Opt for the best marking visibility thanks to the up-front, flat marker zone, which lets you mark up to eight digits or increase the font size.

How to Install and Crimp NSI AL Aluminum Compression Connectors

Select the correct aluminum compression lug or splice connector, prepare the conductor, and crimp it using the specified approved tool and die set. Follow the strip-length and crimp-count requirements to ensure a secure, code-compliant connection.

Tools needed:

Wire brush, Approved crimp tool (NSI N12ID, N1240 series, Greenlee EK/RK/HK1240, Burndy Y-35, Y750, PAT 750), Approved dies for the selected connector series

Supplies needed:

NSI aluminum compression lug or splice connector (AL, AL-N, AL-NT, or ASC-T), Appropriately sized aluminum conductor, Oxide-removal/clean conductor preparation materials if needed

  1. Select the correct connector

    Choose the proper lug or splice connector for the cable size being installed. Verify that the connector series and wire range match the conductor size shown in the chart, and confirm the connector color and strip length before starting.

  2. Strip the conductor to the required length

    Carefully strip the insulation from the conductor without nicking the strands. Strip only enough insulation so the conductor can be completely inserted into the connector barrel and fill it fully. Use the strip length specified for the selected wire size.

  3. Clean the conductor strands

    Wire brush the stripped portion of the conductor to remove oxide films. Ensure the stripped conductor is clean before insertion, because aluminum oxide can reduce connection quality.

  4. Insert the conductor fully into the barrel

    Insert the cleaned conductor completely into the connector barrel until it is fully seated. Verify that the stripped portion is fully inside the barrel and that no bare conductor is left exposed beyond the connector.

  5. Crimp the connector with the approved tool

    Crimp the connector using the approved tool and die set listed for the connector series. Follow the manufacturer’s suggested crimp locations on the barrel markings when using N12ID or N1240 tools, and apply the required number of crimps per side for splice connectors.

  6. Verify the finished connection

    Inspect the completed crimp to confirm the connector is properly compressed and the conductor remains fully seated. For 1000 MCM connectors, use 15-ton tools as required. Do not use unapproved tools or dies.

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