Envelopes pause in Deskjet 5940 and don't print

[Hazelg]

I have a Deskjet 5940 that I use only to print envelopes. I am running Mac OS 10.7.1, and it is connected bia USB to a powered hub. What happens is that the printer starts pulling the envelope as though everything were fine but then it pauses for a very very long time with the power light blinking, and when it finally comes out it has only a few light markings on it, nothing that's readable. I can hear that it has not printed because those characteristic sounds are gone.

I have tried all 5 solutions in hp's database, including deleting and re-adding the printer, resetting it, deleting jobs, disconnecting everything, etc.  I can't even remember them all and I just did them! At any rate, nothing has worked. The computer says that the blank ink cartridge is nearly full but the status of the color cartridge is unknown. I never use color per se with this printer because it has been dedicated to envelopes.

I checked the System Profile, and the printer is recognized there under USB. It does not appear to be the cable.

[PrintDoc]

Have you bypassed the USB hub and plugged directly into your Mac?  Try that.

Do you happen to have HP software in your Applications folder?

[Hazelg]

No, plugging the USB cable directly into the computer doesn't help. But the plot has thickened since I posted. In fiddling around with it more and more, the right cartridge light started to blink, obviously signifying that I need a new cartridge. However, I had replaced that black cartridge very recently and have hardly used it. I went to the supplies info area, and it says that the cartridge is either incompatible with the printer or damaged or incorrectly installed.

So I checked the correct number for this printer and did find the #96 cartridge, which I just put in. It does not go back as far as the color cartridge does, so it sticks out. I wondered about that but couldn't get it to go back further; it does seem to snap into place. So I thought it must be because the original color cartridge is #95, which is one of the smaller cartridges. So maybe I've got it narrowed down to a cartrdige problem--but what is the problem exactly? I appear to have the correct number. If it's a bigger cartridge, should  it not stick out more than the smaller one? 

[PrintDoc]

95 or 96 both work fine with the printer.  I still think its a software/connection issue.

How does it print on just plain paper?

[Hazelg]

Nope. Says "black catridge is faulty or incompatible with the printer." And the light still blinks.

[PrintDoc]

OK, it could be a bad cartridge.  Let's clean it and the printer to be sure:

Remove the cartridge and check the little electrical contacts on the front (a bunch of round bumps about 1/32" each).  Wipe them off with a wet, lint-free cloth.  The cloth will be ruined with ink.  Do the same with the mating part in the printer.

[Hazelg]

I cleaned the bumps on the cartridge but couldn't reached the ones on the white plate in the back on the printer where it would contact because of the wire that's in the way. No change. Light still blinking and still not printing.

This is an almost new cartridge in that I just installed it--but don't know exactly when I bought it since I buy a few at a time. This is the first time I've ever had a "bad" cartrdige. Wonder if hp would replace it.

[PrintDoc]

HP may replace it.  Do you have another to test with, even if empty?

[Hazelg]

By test, do you mean taking the cartridge out and putting in my OfficeJet 7310? If so, yes, I can try that. Called hp last night, though, and since I didn't by it directly through hp, they won't exchange it. I found an old Office Depot receipt that might be it but don't know if they will honor it. I threw away the box, so I don't know what its expiration date is. It's not on the cartridge itself, is it?

[PrintDoc]

I am going to move this thread to a board that can better serve your questions.  Sorry.