Solved: M401dne erroneous "Output Bin Full" error message - HP Support Community

MotoFred · ‎12-11-2022

My LaserJet Pro M401dne intermittently refuses to print and displays the "Output bin is full" and "Remove all paper from the output bin" alternating messages. This happens with no or very few pages in the bin. The model apparently does not use the "fingers" in the bin to sense paper height. I cannot find any reference in the available documentation showing what type of sensor it does use. On my printer it became so frequent I could not print more than a page or two then power off and power back on the printer and see if the message turned off.

The only possible solution I found is in this unnarrated 10+ minute video: (6) hp laserjet pro 400 m401d output bin is full remove all papers - YouTube

Most of the video is spent on disassembly and reassembly but the "fix" seems to happen at about 3:40. I performed the procedure and was amazed to see that it actually fixed the problem, for about two weeks. The printer is now failing intermittently again with the same symptoms.

I would appreciate any suggestions you can provide. Thank you.

Repairatrooper · ‎12-18-2022

As is typical in service manuals for lower end products, some "rare to fail" components are not shown at all. Based on this clip from the service manual you should look on the back right (if you are facing in the front of the printer) for the sensor.

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Repairatrooper · ‎12-11-2022

At 3:40 they are manipulating the fuser gears. On this model I believe that the sensor on the top of the fuser acts as the exit sensor. That sensor flag might be binding or simply failing.

If you find the information provided useful or solves your problems, help other users find the solution easier by marking my post as an accepted solution. Clicking "yes" on "was this reply helpful" also increases the chances that this solution will help others.
I am a volunteer, offering my knowledge to support fellow users, I do not work for HP nor speak for HP.

MotoFred · ‎12-18-2022

Thanks for your response. I believe you're correct that the sensor is binding or failing. I'm looking at the fuser but I cannot find the sensor to examine it. Can you tell me exactly where to locate the sensor and what it looks like?

Repairatrooper · ‎12-18-2022

As is typical in service manuals for lower end products, some "rare to fail" components are not shown at all. Based on this clip from the service manual you should look on the back right (if you are facing in the front of the printer) for the sensor.

If you find the information provided useful or solves your problems, help other users find the solution easier by marking my post as an accepted solution. Clicking "yes" on "was this reply helpful" also increases the chances that this solution will help others.
I am a volunteer, offering my knowledge to support fellow users, I do not work for HP nor speak for HP.

MotoFred · ‎01-03-2023

Thank you for the detailed and helpful information. I haven't disassembled the printer again yet because since I fiddled with the gears the problem is back to only occurring occasionally. When time permits, I will take the printer apart and re-examine the switch now that you have shown me where to look.

M401dne erroneous "Output Bin Full" error message

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