The lifeblood of any industrial robot lies in its Connection Cables and Internal Harnesses. Unlike external teach pendant leads, these heavy-duty cables carry high-voltage power to servo motors and sensitive feedback signals from encoders. Over years of high-speed articulation, even the most robust internal axis harnesses can suffer from torsional fatigue, leading to intermittent servo alarms (such as Fanuc SRVO-062 or ABB 39521).
This Robot Cable & Harness Guide is designed for maintenance engineers and system integrators. We cover everything from floor cables (connecting the controller to the robot base) to complex dress packs and internal wiring for 1st through 6th axes. Whether you are refurbishing a Fanuc R-2000iB, an ABB IRB 6640, or a KUKA KR QUANTEC, identifying the correct part numbers for motor power and signal harnesses is essential for long-term system reliability.
Robot Connection Cable Reference Table
| Robot Series | Cable Type | Common Part Number Prefixes | Standard Lengths |
|---|---|---|---|
| Fanuc R-2000i / M-710i | Power & Signal Set | A660-2003 / A660-8015 | 7M, 14M, 20M, 30M |
| ABB IRB 6600 / 6700 | Floor Cable / Harness | 3HAC16831 / 3HAC026787 | 5M, 7M, 15M, 20M |
| KUKA KR Series (KRC4) | Motor / Data Cables | 00-124-345 / 00-174-774 | 7M, 10M, 15M, 25M |
| Yaskawa DX100 / DX200 | Robot Connection | CBL-YRC061 / CBL-XRC001 | 8M, 12M, 20M |
Detailed Cable & Harness Listings
Controller-to-Robot Floor Cables
These external cables connect the robot base to the control cabinet. They are shielded to prevent EMI interference.
- Fanuc A660-8015-T5xx: Power Connection Cable for Fanuc R-2000iB Series
- ABB 3HAC16831-1: Complete Floor Cable Set for ABB IRB 6400/6600
- KUKA 00-182-465: 7M X20/X30 Power Cable for KUKA KRC4 Systems
Internal Axis Harnesses & Dress Packs
Internal cables are designed for extreme torsion and bending within the robot’s cast iron arms.
- 3HAC026787-001: Internal Harness Assembly for ABB IRB 6640 Axis 1-3
- A660-2003-Txxx: Custom Internal Signal Harness for Fanuc M-10iA/M-20iA
- 00-122-486: Internal Mechanical Wiring Kit for KUKA KR16/KR30
Encoder & Feedback Communication
- KUKA 00-174-774: Motor Encoder Signal Cable X21 for KRC4 Robot
- Fanuc A660-2004-Txxx: High-Speed Feedback Cable for Fanuc Alpha Servo Motors
Troubleshooting & Cable Maintenance
Q: How do I know if an error is caused by a cable or the motor itself?
A: A common technique is to "swap" cables between axes (if they are the same type). If the error follows the cable to the new axis, the harness is faulty. If the error stays on the same axis, the motor or drive module is likely the issue.
Q: Why are internal harnesses more expensive than external floor cables?
A: Internal harnesses are "High-Torsion" cables. They are built with specialized insulation and shielding that can withstand millions of twist-and-bend cycles. Using a standard floor cable inside a robot arm will lead to failure within weeks.
Q: Can I repair a broken internal wire, or must I replace the whole harness?
A: While soldering is possible for temporary fixes, we strongly recommend a full harness replacement. A repaired wire creates a "hard spot" in the cable, which will inevitably snap again due to the robot's high-speed motion.
Q: Do these cables come with the connectors pre-installed?
A: Yes, all our robot connection cables are shipped with OEM-standard heavy-duty connectors (HARTING, Intercontec, or military-style circular connectors) for plug-and-play installation.
Planning a robot refurbishment? Request a Quote for Bulk Harness Kits and ensure your fleet is ready for another decade of service.