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Symptoms of a Bad Fuser

Updated: 5 days ago

Top 5 Symptoms of a Bad Fuser


While every printer model is different and many show different problem, these are the most common symptoms of a bad fuser.


The fuser is a part of laser printers that bonds the toner and paper together using heat and pressure. Fusers need to be replaced every 75,000 - 300,000 pages depending on the printer model. The following are the 5 Top Symptoms of bad fusers.


1. Noise Coming From the Fuser Area


Humming Printer Noise - This occurs just prior to the gear being completely worn. As the drive gear starts to wear out, you will hear hum or drone. Remember: The hum comes before the grind.


Grinding Printer Noise- This can come from the printer's swing plate, main drive assembly or the fuser. Regardless of which one is causing it, they both should be replaced. Once either is compromised it will damage the other so its best to replace both.


Chirp or Squeaking Printer Noise- This occurs when a shaft or roller in the fuser rotates inside of a worn or damaged bushing. When it spins and hits that worn section of the bushing, it makes a noise. This is also can come from delivery rollers located in the printer fuser. Fusers made with inferior bushings can wear out in the critical areas. Older laser printers utilized hot rollers instead of fuser film sleeves which experience this same phenomenon.


Newer laser printers have diagnostic service modes that can run the fuser motor to help you isolate these noises.


---Fuser and Maintenance Kit Recommended Replacement Intervals


2. Image Defects

A lot of things can cause image defects however these are the top causes of fuser related image defects in office laser printers.

  • Darker gray (not black) vertical lines down the page can indicate a ripped or worn fuser film sleeve.

  • Repeated images / Ghosting may be due to wear found on the fuser film.

  • Toner rubbing off can be caused by a user not selecting the correct printer temperature setting to match the paper's weight or characteristics. If it is set to the correct temperature it may be times to change the fuser.

  • Poor quality toner with an inconsistent melting point can also cause toner to rub off pages.

Vertical lines down the page could mean ripped fuser film sleeve
Print defect example HP P3015 exhibiting vertical lines
Print defect example HP P3015 exhibiting crease down the middle of the page
Print defect example HP M608 exhibiting ghosting down the page due to worn fuser film sleeve
Print defect example HP M608 exhibiting ghosting down the page due to worn fuser film sleeve

3. Error codes

50 Service Error is the primary fuser failure code. The next character will specify the failure - For example 50.2 will be a fuser warm up failure as seen below.


50.WX.Y Fuser error To continue turn off then on


W = fuser error code, X = fuser mode, Y = previous printer sleep state

Recommended action

50.2 Fuser warm up failure


The 50.2 error codes is common with HP laser printers. You will see this error if your printer’s thermistors (which reads the fuser temperature as it warms up) fail to give an accurate reading of the fuser temperature in the expected time frame. The 50.2 error is indicative of a malfunctioning fuser or in less common cases, a bad DC controller/engine controller.

  1. Ensure the connection between the fuser and the DC controller/engine controller or power supply.

  2. Turn the product off. Remove the fuser and then reinstall it. If the error persists, replace the fuser.

  3. If the error persists, replace the low-voltage power supply.

---Shop for Printer Fusers


50.3 Low temperature thermistor 1

  1. Reinstall the fuser. Check/reconnect the connection between the fuser and the DC controller/engine controller or power supply. If it is damaged, replace the fuser.

  2. Replace the fuser.

  3. W = 2: Check/reconnect the connector on the low-voltage power supply PCA.

  4. If the error persists, replace the low-voltage power supply.

Fuser error 50.3 signals that your HP printer is overheating. Your fuser may overheat due to the type of paper you use. If you use thick paper for a prolonged printing session, overheating is likely to occur. Your printer would have to heat its fuser to a higher temperature to bond the toner to the thick paper. If your printer’s fuser runs at a higher temperature for a prolonged period, it may overheat.


50.4 High temperature thermistor 1

  1. Reinstall the fuser. Check/reconnect the connection between the fuser and the DC controller/engine controller or power supply. If it is damaged, replace the fuser.

  2. Replace the fuser.

  3. If the error persists, replace the low-voltage power supply.

50.6 Drive circuit fault

  1. Check the power source. Make sure the power source meets product requirements. NOTE: If the power source does not meet the power frequency requirement of 40 to 70Hz (in the USA), the fuser temperature control does not work properly and causes this error.

  2. Replace the DC controller/engine controller.

  3. If the error persists, replace the low-voltage power supply.

----HP Printer Error Codes


4. Paper Jam

The following are causes of paper jams that are a direct result of the fuser needing to be replaced.

  • Ripped or worn fuser film sleeve.

  • Worn or broken fuser sensor flags.

  • Worn or damaged fuser gears.

  • Ripped or worn lower pressure rollers.

5. Paper Jam Locations

  • Just before paper entry on the fuser.

  • Halfway through the fuser.

  • On fuser exit just as the paper is coming out of the fuser.

Can I still print?

Maybe, here are a couple workarounds you can try temporarily to get the printer up and running until you can replace the fuser.


  1. Turn printer off then wait 20 or 30 minutes the turn back on.

  2. Reseat the fuser and make sure the fuser is clicked in/locked in on both sides. Double check to make sure fuser lock levers are full engaged.


Metrofuser offers HP and Lexmark printer fusers in many different options. We offer same day and blind drop shipping.

Other Helpful Laser Printer Repair Resources

Metrofuser is a leading global innovator, manufacturer of printer parts, equipment, diagnostics, repair information and systems solutions for professional users performing critical tasks. Products and services include hp printer parts, printers and printer repair training. Parts include hp printer parts such as printer fusers, printer maintenance kits and other hp printer replacement parts. The company's customers include office equipment dealerships, online retailers, repair centers and MPS service providers nationwide. Metrofuser has been named to Inc. Magazine’s fastest growing companies five consecutive years. 

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