HP PC Hardware Diagnostics 4-IN-1 USB KEY

[RNR1995]

HP PC Hardware Diagnostics 4-IN-1 USB KEY 6500 Still does not boot up

Error is 

Attempting to boot from USB device
Loading FreeDos no KERNEL SYS

Solution is still here

https://h30434.www3.hp.com/t5/Notebook-Boot-and-Lockup/HP-PC-Hardware-Diagnostics-4-in-1-USB-Key-v6-...

Created a case with HP it has been over a year?

AM I the only one who uses this software?

Or am I doing something wrong?

[Raj_05]

Hi @RNR1995,

Welcome to HP Support Community.

Thank you for posting your query, I will be glad to help you.

It sounds like the HP PC Hardware Diagnostics 4-IN-1 USB Key (6500) isn't booting properly and is getting stuck at.

"Loading FreeDos no KERNEL SYS"

This usually happens when:

1. The USB drive is not properly created or is corrupted.
2. The system doesn’t recognize the boot files on the USB.
3. There's an issue with BIOS settings or boot order.

Possible Fixes:

Recreate the USB Drive

• Try re-downloading the HP PC Hardware Diagnostics software from HP's official site.
• Use Rufus (or HP's own tool) to create a fresh bootable USB.
• Make sure to format the USB as FAT32 before creating the boot disk.

Check Boot Order & Secure Boot

• Enter BIOS (F10 at startup).
• Go to Boot Options and make sure:
  • USB Boot is enabled.
  • Secure Boot is disabled (some systems require this).
• If using UEFI, try switching to Legacy Mode (some HP tools work better this way).

Test the USB on Another PC

• Try booting another HP system with the same USB to see if it works there.
• If it fails on multiple devices, the USB creation is likely faulty.

I hope this helps.

Take care and have a good day.

Please click “Accepted Solution” if you feel my post solved your issue, it will help others find the solution. Click the “Kudos/Thumbs Up" on the bottom right to say “Thanks” for helping!

Raj_05

HP Support 

[RNR1995]

Hello and thank you for your reply
However this is a softpaq that runs a batch file to create the USB disk (SP153574)
Kernel.sys is missing
Should be on root or in FDOS\Bin folder or both
Either way this has been an issue since version 5400
I would have thought by now someone else would have brought this to someones attention?
Download the softpaq and create the key to see for yourself
Thank you for your attention in this matter
Ron

[Max3Aj]

Hi @RNR1995, 

Thank you for your response. 

Since you've already tried the basic troubleshooting steps, here are some advanced troubleshooting steps to resolve the missing KERNEL.SYS issue with the HP PC Hardware Diagnostics 4-IN-1 USB Key (6500):

Manually Verify and Copy Missing Kernel.sys

• Once you've created the USB using SP153574, open it in File Explorer.
• Check for KERNEL.SYS in:
  • The root directory of the USB (X:\)
  • FDOS\BIN folder (X:\FDOS\BIN\)
• If missing, manually copy KERNEL.SYS from a working HP PC Hardware Diagnostics USB (if available) or download FreeDOS separately.

Manually Extract the Softpaq and Check Files

Extract Softpaq Without Running It

• Use 7-Zip or Universal Extractor to manually extract SP153574.exe.
• Look for KERNEL.SYS inside the extracted folders.
• If it's inside a compressed archive within the Softpaq, extract it and manually place it in FDOS\BIN and the root.

Manually Create the Bootable USB

• Format the USB as FAT32.
• Copy all necessary files from the extracted Softpaq.
• Run syslinux or FDOS sys to reinstall the bootloader.
• Use Rufus to set up FreeDOS manually and then copy the extracted Softpaq contents.

Force USB Boot Compatibility

Some HP systems with newer firmware may not recognize FreeDOS properly.

Try Booting with Legacy Mode:

• Enter BIOS (F10).
• Enable Legacy Support.
• Disable Secure Boot.
• Save and Exit.

[Max3Aj]

Try Different USB Ports

• Some HP systems have different controller chipsets for USB ports. Use a USB 2.0 port instead of USB 3.0.

Check for Softpaq Version Issues

• Since you mentioned the issue has existed since version 5400, consider using an older version of the HP PC Hardware Diagnostics Softpaq if available.

I hope this helps. 

Take care and have a good day. 

Please click “Accepted Solution” if you feel my post solved your issue, it will help others find the solution. Click the “Kudos/Thumbs Up" on the bottom right to say “Thanks” for helping! 

Max3Aj

HP Support 

[RNR1995]

OMG! it is like talking to a wall

This is why I do not post on these forums, such a waste of time

Dear all HP reps your software is flawed and I am asking you to resolve this issue

Obviously, no one must use it or someone would have verified this issue by now

See here

Solved: HP PC Hardware Diagnostics 4-in-1 USB Key v6.2.0.0 - HP Support Community - 8689077

Already been copying the software from older softpaqs

Really do know almost every trick to get USB to boot

This is for the poor soul whole downloads something from your website and expects it to work

Please try your own SP

Do not reply unless you try sp153574.exe

Then let me know what you find

Thank you

Ron

[Max3Aj]

Hi @RNR1995, Thank you for your response,  

I'm sending a private message to assist you with the next action. 

  

Please check your Private message icon on the upper right corner of your HP Community profile Next, to your profile Name, you should see a little blue envelope, please click on it or simply click on this link. 

  

I hope this helps! Keep me posted. 

  

Max3Aj

HP Support 

[Rob_Jaz]

Hello All,

For those struggling with this like me, i finally figured it out... After the EXE extracts and runs, just choose a drive letter that doesn't exist to abort.

Open a Command Prompt as Admin

Navigate to C:\SWSetup\sp157290 (or whatever revision yours is)

And copy/paste this into the prompt:

hpuf.exe "D:" -FBD -Y -VI -v:HP_TOOLS

             ^^^^^ change "D:" to whatever drive letter that your USB drive is plugged into

               ^^^^^^^^^ And don't use quotes! This forum keeps converting that to an emoji.

Let it run.

Then you should set the partition ACTIVE, since the tool doesn't do this:

diskpart

list disk

select disk x (where X= your USB drive)

list partition

select partition 1 (unless you have others...)

active

exit

/win

Although FYI, this diag tool did not offer me any advanced BIOS/Firmware tools, it was only hardware testing.

[RNR1995]

Almost like the line in the makekey.bat file

:CREATE_USB
echo.
attrib -r .\field\*.* /d /s >nul
hpuf.exe %drvletter% -Y -VI -v:HP_TOOLS
if ERRORLEVEL 1 goto ERROR

Unfortunately the sp153574.exe (v6500) is missing a whole lot of data in the "field" folder
Most importantly the FDOS (freeDOS) folder
Check out this one to compare sp139757.exe (v5400)
You can download from the ftp site
https://ftp.hp.com/pub/softpaq/sp139501-140000/sp139757.exe
This tool is supposed to create a bootable USB device that does have advanced BIOS tools etc.
The readme.txt will give you a list of switches to create a customized version of the tool
Cannot figure out how to get HP to resolve this issue
Was actually even told by level 2 support that the tool is not bootable?
Sad and lame
See here
https://h30434.www3.hp.com/t5/Notebook-Boot-and-Lockup/HP-PC-Hardware-Diagnostics-4-in-1-USB-Key-v6-...
RNR