Harness Inspection Checklist
A structured pass over a finished (or incoming) connectorized harness, assembled from the guide's own checklists and trap lists: Selection Workflow §4, Practical Checklist §10, the 38999 mistakes table §7.9, and What People Forget.
This checklist tells you what to look at. It deliberately contains no acceptance values — no pull forces, crimp heights, torque numbers, or test voltages. What passing looks like comes from the workmanship/acceptance standard your program names (commonly IPC/WHMA-A-620, or the program/customer equivalent)1 and from the manufacturer's application specification for the exact contact system — never from this page. If you don't know which acceptance standard and application spec apply, that is finding #1.
1. Paperwork first
- The governing drawing / cable drawing is on hand, at the revision being built/inspected
- The ICD (or equivalent interface definition) is on hand, at revision
- The workmanship/acceptance standard and class the harness was built to is named on the drawing or work instruction (§4)
- The manufacturer application specs for each contact system used are identified
- Any deviations/waivers are recorded, not verbal
2. Crimp and contact evidence
Per the crimp design package §4 says the drawing should carry:
- The exact contact P/N used matches the drawing (not "equivalent-looking" — hobby crimping explains why families don't transfer)
- Wire gauge and insulation range match what the contact and wire seal were specified for — undersized wire in a wire seal defeats the seal (§7.9)
- The approved crimp tool / positioner / die was used and is in calibration (§4)
- Visual inspection performed per the named acceptance standard/class — remembering the trap: a crimp can pass visual and still fail in vibration (§7.9); the application spec's inspection/pull-test requirement decides, not appearance
- Pull-test or equivalent verification performed if and as the drawing/application spec requires, and recorded
3. Connector assembly
From the §7.9 mistakes table and What People Forget:
- Backshell present, correct P/N, assembled per its instructions — strain relief, rear seal, shield termination all depend on it
- Strain relief engaged on the cable, not on individual conductors
- Shield termination matches the drawing's stated strategy (360° / pigtail / isolated — as documented, not as improvised)
- Unused cavities carry sealing plugs where the drawing requires them
- Coupling / jam-nut torque applied per the documented torque procedure — finger-tight is not a sealed, engaged mate (What People Forget)
- Caps/covers present for connectors that ship or sit unmated (§7.9)
4. Mechanical checks
- Keying/clocking of each connector matches the ICD — same-key-different-pinout is an eventual mis-mate (§7.9)
- Contact gender vs. the mating half verified — gender is independent of plug/receptacle (§7.9)
- Bend radius and cable exit comply with the drawing (§10)
- Labels / identification present and matching the rev-controlled labeling scheme (§10)
- Overall length and breakout dimensions within drawing tolerance
5. Electrical verification
- Continuity / pinout verified against the ICD or wiring schedule — per the drawing's stated verification method (cable drawing template)
- Shield / drain continuity verified where the drawing requires it
- Insulation resistance / hipot performed only if and as the program/drawing requires — record the requirement source, parameters, and result; this checklist asserts no test values
6. The record
Echoing the evidence-fields convention used across the templates:
| Item | Entry |
|---|---|
| Harness / assembly P/N + rev | TBD |
| Drawing + ICD revision inspected against | TBD |
| Acceptance standard + class applied | TBD |
| Application spec(s) for contact systems | TBD |
| Inspector / date | TBD |
| Deviations, findings, dispositions | TBD |
This is a working template, not a standard. IPC/WHMA-A-620 (or the program/customer equivalent), the applicable contract and drawing notes, and the manufacturer's application specification for the exact connector/contact/tooling system always control.1