Hi DRG,

If you do a web search for 'illegal media size pcl xl error', you'll see many many HP users reporting similar problems to yours. The sad fact is that HP has a poor record at producing drivers that work with updated systems. This is especially so where OS updates are involved. If Word 2010 (which talks to the printer driver through the OS) breaks an HP driver, that just goes to show how non-compliant the driver is.

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Cheers,
Paul Edstein
[Fmr MS MVP - Word]