ABB 3HAC025338-006 – OEM Robot Cable Assembly for IRC5/IRB Systems

The ABB 3HAC025338-006 is an original ABB cable assembly designed for IRB-series manipulators and IRC5-based installations. In many cases, it’s used to carry mixed power, brake, and feedback signals between the controller/cabinet and key points on the robot arm. From my experience, it’s the part maintenance teams reach for when they want a straight swap that restores motion and eliminates intermittent faults caused by tired harnesses.

• Genuine ABB fit and finish – Pre-terminated with OEM connectors for fast, tool-friendly replacement and consistent routing.

• High-flex jacket – Built for continuous flexing in multi-axis motion; typically PUR or equivalent abrasion-resistant compound.

• EMC-compliant shielding – Helps keep encoder/resolver and I/O lines clean in electrically noisy cells.

• Revision -006 compatibility – Matches the connector keying and pinout associated with this revision level in many IRB setups.

• Factory-tested – Continuity and insulation checks reduce troubleshooting time during commissioning.

• Service-friendly labeling – Clear identification at both ends shortens changeover and minimizes wiring errors.

• 
  

You’ll typically see this part in automotive welding cells, high-throughput material handling, machine tending, and palletizing lines where robots run multiple shifts. When a robot starts throwing sporadic encoder errors or axis brake faults, replacing the aging harness with ABB 3HAC025338-006 often stabilizes the system and brings the cycle back on spec.

“Swapped the harness on an IRB 6640 during a planned stop—plug-in, route, tie-down, back in production within an hour.” — Maintenance Supervisor, Tier-1 automotive supplier

• Reliability – OEM copper and shielding reduce signal drift and nuisance faults under continuous duty.

• Compatibility – Correct connector orientation and pinout for the -006 revision lowers integration risk.

• Maintenance efficiency – Pre-terminated ends cut replacement time; fewer wiring mistakes versus field-built cables.

• Total cost – Reduces downtime costs and avoids repeated troubleshooting on intermittent issues.

• Support – Easier to get ABB service alignment when using the specified spare part number.

• Environment – Route in accordance with ABB cabinet/robot guidelines; maintain ventilation and avoid sharp bend radii (use the minimum bend radius typically 7.5–10× cable OD unless otherwise stated).

• Wiring practice – De-energize the controller, relieve stored energy on brakes, and observe ESD precautions when handling connectors to feedback lines.

• Mechanical routing – Follow original clip points and strain relief; keep clear of pinch points and hot surfaces; avoid parallel runs tightly coupled to high-current weld cables.

• Commissioning – After installation, perform continuity checks if available and verify axis mastering/zeroing as required by your procedure.

• Routine care – Inspect connector shells and backshells during PM cycles; look for jacket wear at flex points; replace ties and grommets that have hardened or cracked.

• Manufactured to ABB quality standards; components typically comply with CE and RoHS directives for industrial machinery.

• Traceable ABB spare (3HAC025338-006 revision); documentation available upon request.

• Warranty: typically covered under ABB spare-parts warranty terms (often 12 months from commissioning or shipment—verify per contract).

• 
  

One thing I appreciate is that this part tends to “just fit” when matched to the robot’s serial-numbered parts list. If you’re unsure whether -006 is the correct revision for your unit, share the manipulator type and cabinet ID and we’ll cross-check before you commit.