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I called xerox and asked who last serviced the machine they would only give me the techs name. so i called mike at the LSU office and he said he had a contact number. so i called him and he said the code should be what ever the reading is the last 5 backwards then 0705 which is there account number with xerox. I am still working on it I found the processor intlk switch and it is working i traced all the other interlock switchs and they are functioning but in the diagnostics the exact name is "processor intlk sense" is red.

Don't worry about any references to tags.  This isn't your problem.  Ditto the IOT > finisher connection.  It sounds like you have everything properly connected between the IOT and finisher.  The finisher butts to the processor and there are two levers in the front to the left that cam down and lock the two pieces together.  There is no interlock there.  If the finisher is leveled to the two locator pins on the processor, then the finisher should just roll up against the IOT and dock.  You don't have to worry about this until you are ready to feed paper.

There are two parts to the interlock circuit, a 24V component and a 5V.  Both have to be present.  This CAN be a pain in the butt, broken wires, etc, but in your case, if the machine was working at LSU, then it is going to be something simple.

I would look carefully at all the interlock switches, there is one behind the fuser, at the back of the machine, below the fan.  Also check the relays on the back of the LVPS and on the folddown panel below the LVPS.  Check the fault list in diagnostics  (SCP) for any other fault codes.  The attached wiring diagram should help.


If you have other fault codes, let us know what they are.

As I remember the interlock sense circuit goes through a relay  (K104??) on the back of the LVPS.  The dust covers can be removed and the contacts cleaned with a thin strip of card stock.  It seems like there was also a switch on the back of the document handler, to the right standing at the back of the machine.  Take the back cover of the handler off, raise and lower the handler, and you'll see it actuated.  I haven't worked on 5090's in ten years, someone else can probably give you better advice at this point.

There are two diagnostic bypass switches, one on the processor and one on the finisher, covered by hinged caps, at the top.  You'll see them if you look for them.

I hate to put you threw this i have learned alot and still am the first one you set said the mirror in the prefuser is it at a 90 degree angle or do you know that would trigger it according to the tips sheet. P10-102 that won't clear. that might be the simple thing becasue the prefuser just swings back and forth there is no way to lock down just up.

ok, i cant really see anymore except rainbow wires. I have found two plugs that i cannot account for,  and i do not have the numbers in front of me. but going over the interlink and interlock wires and the trouble shooting information i am assuming AND ASSUMING that the two orange wires with the single connector, going to the interlock switches and some of the other connectors to some other things are so posed to be constant 24vdc one gets the power from the board and it relays back threw the switches and connectors and comes back to the board on the other wire just a closed loop. can you please clarify this for me. the other plug to the interlocks have a three wire connector they are a ground and two +5vdc i have traced all those and haven't found any problems with any of them or the actual switch the 5vdc seems to be working fine.

I need to clarify about the 24vdc and the orange wires, because they get voltage for about 3 seconds then loose it i can hear the relay cum on then go off.but more important I tested for continuity and it is a match with each other unplugged from the switch and more important it is a match with the chassis of the processor and finisher.

when it boots up, the screen is black then all 88888's on the readout then it gets 2 then all 000's on the read out then it goese from 000's  to 1 then 2 all the way to 14. i can hear the realy come on then 3 secounds or less the realy goese off. after fixing all the come lines and a few other things now the error is shutter not in position. when i goto to service meno goto the 330 24vdc has been disable'd because of the processor intlk sense is high/red. nothing has 24 power and anytime i try to test it says all outputs disabled. interlock open. i have checked all the white  switches  and the 4 black ones i have found and they all work and if i go into the menu they show hi and low when i open or close them. if one of the orange wires going to the plugs is ground out on the frame would this disable the relay if the door is open the lights at the bottom come on then get really dim then the relay clicks off and they lose power.
or am i grasping at straws with the orange wires. ??  the chart if i read it correctly says it should have 24 vdc all the time. unless a switch is open then the circuit is broken.

i will go take the back off and boot it up. be back in about 8 min. will pull the error log and look at the boards in the low foltage power supply.

And before I forget Again you said you might have parts, if you have the pwb dio 2 board the one connector that had the messed up cable looks kind of flacky  or the other boards, it seems that all the raps call for replacing them. i will check the number again in the morning. and any com cables I would like to get a price on that or  anything else that you think we will need. you have helpd us out so much the least i can do is buy whatever you can provide.

I'll dig up the raps for these faults.  I'll send the wiring diagram for the various LVPS boards,  (a little later this morning).   Focus on 6 and disconnect anything that board supports.  This will generate other fault codes, but you will keep your 24V.  You can then re-connect the various items until you isolate the one causing the problem.

Unfortunately, if it's a 5090 specific problem, my wirenets won't show the culprit.

Checkout the wiring behind the swing-out HVAC HVDC card cage at the rear bottom of the processor.  That's a common place for pinched wires.  If the chassis on the back of the handler was removed for shipping, check there too.  Visually inspect the area.

Disconnect the motor that raises and lowers the optics tub.

Dio 2 turns the LVPS on.  I have a ton of DIO's, you are welcome to a couple.  I'll send along a core just so you have it for trouble shooting purposes.  I suspect your comlines are not causing the problem at this point.  Something is drawing down the 24V, either a component (motor) that is stalled, or a wiring short.  Option one is more likely.

The P03 faults are a consequence of the missing 24V, not the cause of the problem.

12-285 is the tiltbed position, there is a 3 wire harness under the tiltbed that breaks.  The motor is an AC motor.


I don't have the 9-216 and 5-302 RAPs, these must be specific to the 5090. 
You may want to purchase the 5090 manual that Daryl Lessard has available.