Wiring Harness Continuity and Hi-Pot Test Inspection

Inspection template for documenting continuity and insulation (hi-pot) testing of control wiring harnesses before installation in assembled equipment, to catch wiring faults early and verify electrical integrity.

Inspection Details

• Harness identification recorded
  Record harness part number, assembly number, revision, and serial or lot number.
• Work order and test traveler available
  Verify the correct work order, drawing, and test traveler are present and match the harness being inspected.
• Inspector and test date recorded
  Document the date/time of inspection and the person performing the test.

Pre-Test Conditions

• Harness is not installed in assembled gear
  Confirm the harness is being tested before installation into the final assembly.
• Test equipment calibrated and within due date
  Verify continuity tester and hi-pot/insulation test equipment calibration status is current.
• Test setup and safety controls verified
  Confirm leads, adapters, guarding, and safe work practices are in place before energizing test equipment.

Continuity Verification

• Point-to-point continuity matches wiring diagram
  Verify each conductor has continuity only to the intended termination points per the approved wiring diagram.
• No opens, shorts, or miswires detected
  Confirm there are no open circuits, unintended shorts, crossed conductors, or reversed terminations.
• Measured continuity resistance
  Record measured resistance for the continuity test.
• Continuity exceptions documented
  List any failed circuits, suspect terminations, or rework actions required.

Hi-Pot / Insulation Testing

• Hi-pot test performed to approved procedure
  Confirm the insulation test was performed using the approved voltage, dwell time, and test method for this harness.
• Applied test voltage recorded
  Record the applied hi-pot or insulation test voltage.
• Leakage current within acceptable limit
  Record measured leakage current and confirm it is within the approved limit for the harness.
• Insulation breakdown or flashover observed
  Confirm no insulation breakdown, arcing, flashover, or test failure occurred during hi-pot testing.

Acceptance and Closeout

• Harness released for installation
  Indicate whether the harness passed inspection and may be released for installation into assembled gear.
• Deficiencies and corrective actions documented
  Record any non-conformances, rework instructions, retest requirements, or disposition notes.
• Inspector signature
  Inspector signature confirming the test record is complete and accurate.