Using the V5 Crimping Tool to Make Custom Length V5 Smart Cables – VEX Library

Assembling your own custom length V5 Smart Cables provides a great deal of flexibility for the location of sensors and/or motors, plus allows for efficient cable management.

Required supplies

The required supplies to assemble custom length V5 Smart Cables include:

V5 Smart Cable Crimping Tool piece.

V5 Smart Cable Crimping Tool (276-5773)

V5 Smart Cable Stock piece.

V5 Smart Cable Stock (276-5774)

V5 Smart Cable Connector pieces.

V5 Smart Cable Connectors (276-5775)

Cartoon icon of a marker.

A marker or other writing utensil used to mark the cutting location on the cable.

Note: Some string is useful but is not required.

Measuring and cutting the V5 Smart Cable

A string is being used to measure the distance between the two Smart Ports, as string is more easy to work with than the cable itself.

Layout the V5 Smart Cable between the Smart Port on the V5 Brain and a Smart Port on a device.

The cable may be stiff and difficult to lay out. If so, an option is to use a piece of string to measure the distance between the two Smart Ports.

A cut piece of string is placed next to a length of cable, and a marker has been used to transfer the string's measurement to the cable itself. About a half inch of space has been left on either side to leave room for the connectors.

Once the length of the cable is measured, leave a little extra space on each end for the connectors. Then, using the marker or other writing utensil, mark the location on the cable where it should be cut.

Another option is to cut a piece of string to the required length that the cable should be. Then, place the string next to the cable to measure the distance, leaving a little extra on each end for the connectors before marking the cut location.

V5 Smart Cable Crimping Tool is shown with its lock pin highlighted.

If your crimping tool is locked, squeeze the handles together or pull up on the lock pin.

V5 Cable is placed into the cutting section of the crimping tool up to the cable's marked length. Once the cable is in place, the handles can be squeezed to cut through the cable.

Insert the cable to the desired length into the cutter section of the tool and align the cable so the cut will be square across. Squeeze the handles together until the cable is cut all the way through.

Stripping the ends of the black casing from the V5 Smart Cable

Two images side by side. The left shows the stripper portion of the crimping tool, and an arrow highlights its location. The right shows one end of a cable placed into the stripper section of the crimping tool. Once the cable is in place, the handles can be squeezed to strip the end of the cable.

Insert one end of the cable into the stripper portion of the tool. Ensure you are inserting the cable on the correct side of the Crimping Tool.

Top down view of one end of a cable being stripped with the crimping tool to help visualize the setup. The end of the cable is flush with and touching the depth gauge on the back of the tool. A diagram indicates that the user should pay special attention to ensure that the cable is flush with the end of the depth gauge.

Two top down views of one end of a cable being stripped with the crimping tool. There is a checkmark on the left showing the cable flush with the end of the depth gauge, and not pushed all the way back. There is an X on the right showing the cable being pushed past the end of the depth gauge.

Align the cable so it is flush with the end of the depth gauge on the back of the tool.

Do not push the cable all the way back. Be sure to stop at the stopper, or you will strip off too much casing.

Once the cable is inserted and up against the stopper, squeeze the tool’s handles together.

It can be helpful to wiggle the cable around while the handles are pressed. This will help loosen the black casing.

Diagram shows a cable with its end almost fully stripped, and then an arrow indicating that the stripped casing can be pulled to remove it. The right shows a cable with one end properly stripped.

Gently work the outside black casing back and forth until it becomes loose and can be removed.

Be careful not to pull the inside wires out further when you remove the black casing.

Repeat the previous two steps for the other side of the cable.

Diagram showing that a correctly stripped cable will have colored wires of even length, and an incorrectly stripped cable will have uneven colored wires.

Once both sides of the cable have been cut, ensure that all colored wires are flush.

Proper alignment of the connectors

Close up of a cable connector attached to the end of a stripped cable. A diagram on the right shows that an incorrectly attached cable connector will have a gap between the colored wires and the end of the connector, while a correctly attached cable connector will have colored wires that are flush with the end of the connector.

Insert one end of the cable fully into the cable connector. Be sure all four wires (yellow, green, red, and black) extend to the end of the connector.

Cable with a cable connector on either end is placed on a table. The cable is laid straight and isn't twisted, and the cable connectors are shown to be facing opposite directions. A diagram below indicates that a correct cable will have cable connectors facing opposite each other, while an incorrect cable will have cable connectors facing the same direction.

Flip the cable over 180 degrees and fully insert the four wires on the other side of the cable into another cable connector.

Be sure the locking tabs are aligned so they are on opposite sides of the cable.

Close up of both ends of a cable to highlight that the cable connectors are oriented opposite each other.

By having the locking tabs aligned so they are on opposite sides of the cable, this will ensure the order of the colors of the wires will be the same from left to right on both ends.

Diagram shows a correctly stripped cable with part of its casing inserted into the cable connector. An incorrectly stripped cable is also shown with too much casing stripped off so none of its casing is inside of the cable connector.

Make sure that the black casing is inserted into the clear connector. The colored wires should not be exposed.

Crimping and checking connection

Top down view of a cable connector placed into the crimping section of the crimping tool.

Place the cable connector into the crimping section of the tool. Squeeze the handles together very firmly until they are no longer moving.

You should be able to feel the connector’s metal prongs seating into the wire. Now repeat with the connector on the other end of the cable.

Diagram of a correctly crimped cable connector with prongs that have been crimped to be flush. To the right is a diagram of an incorrectly crimped cable connector with prongs that aren't flush which will damage any connected Smart Port.

After crimping the connectors it is important to inspect the connector to make sure the prongs have been crimped down flush.

This is very important. If the prongs are not flush, your new Smart Cable will damage any Smart Port it is plugged into.

Cable connector is inserted into a V5 Smart Motor's Smart Port to connect it to a V5 Robot Brain. The Smart Port's indicator light is glowing red which indicates that the connection is successful.

Once you have finished crimping and inspecting your cable, check for a good connection.

Plug one side of your new custom length V5 Smart Cable into a V5 Robot Brain’s Smart Port and the other side into a V5 Smart Motor.

Turn on your V5 Robot Brain, if the V5 Smart Motor Smart Port lights up red the connection is good.

Once you are certain the new cable's connection is good, the cable may be used with any V5 Smart Motor or other V5 device.

For more information about proper cable management, view this article from the VEX Library.