What should you do if the terminal clip is too large and the wire fits loosely?

Using a smaller terminal is an effective solution when the terminal clip is too large and does not hold the wire securely. A properly sized terminal ensures a good mechanical and electrical connection, reducing the risk of connection failure, intermittent contact, or electrical arcing.

Doubling over the end of the wire is another method that can provide a tighter fit, which may help in situations where an immediate replacement terminal is not available. This technique creates a larger surface area for the terminal clip to grip, though it is not a long-term solution.

Combining both approaches—switching to a smaller terminal and doubling over the wire—ensures a secure and reliable connection, which is critical in electrical systems to promote safety and efficiency. Therefore, utilizing both methods is a comprehensive strategy to address the issue of a loose fit with the terminal clip.