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Run: Wiring Harness Continuity and Hi-Pot Test Inspection

Use this inspection to verify control wiring harness continuity and insulation integrity before installation. It helps catch opens, shorts, miswires, and bre...

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Inspection Details

Harness identification recorded

Record harness part number, assembly number, revision, and serial or lot number.

Work order and test traveler available critical (required)

Verify the correct work order, drawing, and test traveler are present and match the harness being inspected.

Yes No N/A

Inspector and test date recorded critical (required)

Document the date/time of inspection and the person performing the test.

Pre-Test Conditions

Harness is not installed in assembled gear critical (required)

Confirm the harness is being tested before installation into the final assembly.

Yes No N/A

Test equipment calibrated and within due date critical (required)

Verify continuity tester and hi-pot/insulation test equipment calibration status is current.

Yes No N/A

Test setup and safety controls verified critical (required)

Confirm leads, adapters, guarding, and safe work practices are in place before energizing test equipment.

Yes No N/A

Continuity Verification

Point-to-point continuity matches wiring diagram critical (required)

Verify each conductor has continuity only to the intended termination points per the approved wiring diagram.

Yes No N/A

No opens, shorts, or miswires detected critical (required)

Confirm there are no open circuits, unintended shorts, crossed conductors, or reversed terminations.

Yes No N/A

Measured continuity resistance

Record measured resistance for the continuity test.

Note (optional)

Continuity exceptions documented

List any failed circuits, suspect terminations, or rework actions required.

Hi-Pot / Insulation Testing

Hi-pot test performed to approved procedure critical (required)

Confirm the insulation test was performed using the approved voltage, dwell time, and test method for this harness.

Yes No N/A

Applied test voltage recorded critical (required)

Record the applied hi-pot or insulation test voltage.

Leakage current within acceptable limit critical (required)

Record measured leakage current and confirm it is within the approved limit for the harness.

Insulation breakdown or flashover observed critical (required)

Confirm no insulation breakdown, arcing, flashover, or test failure occurred during hi-pot testing.

Yes No N/A

Acceptance and Closeout

Harness released for installation critical (required)

Indicate whether the harness passed inspection and may be released for installation into assembled gear.

Yes No N/A

Deficiencies and corrective actions documented

Record any non-conformances, rework instructions, retest requirements, or disposition notes.

Inspector signature critical (required)

Inspector signature confirming the test record is complete and accurate.

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