Hi Chris,
Thanks for your input, i have provided some additional info below:
The PCL XL Error is all that is printed on a single page for each print job. Even if the same document is reprinted by the same user the error is exactly the same, nothing changes.
I am not surpised that for something of this age that HP doesn't provide full function discrete drivers. The print server is currently using a driver that has been pulled through windows update and is the suggested/recommended driver.
The full error is 'PCL EX error subsystem kernel error illegal operator sequence. operator end session position 4104
Thanks