Several models of HP LaserJet printer are known to crash or hang when certain documents are printed from 10.5/Leopard machines. The culprit may be a bad or corrupted font, in particular, version 6 of the Papyrus font. In short: replace the font file with one from a 10.4 installation to stop the printer crashes.
The longer version: I have a Color Laserjet 3800n and also a 2430dtn that crash any time a document that uses the Papyrus font is printed from a machine running Mac OS 10.5.x. They display an Error 49.4 C02 code and the printer must be powered cycled to clear the problem. HP lists this code as ‘A critical firmware error has occurred;’ not particularly useful or informative. The same problem did not occur when printing from 10.4.x machines.
This all led me to look at the font itself. The file always passes the verification tests in Font Book; there is nothing overtly wrong with it. But, it clearly does not get along well with these HP Laserjet printers. The version of the font installed on a 10.5 system is is 6.0d6e1. It contains both Regular and Condensed versions of the font.
I went hunting for a different version of the Papyrus.dfont file and found one on a 10.4.11 machine. It is version 4.0d1e1 and contains only Regular, not Condensed. Replacing the newer font with the older one in the /Library/Fonts folder allowed me to successfully print documents using the Papyrus font. This has fixed the printer crashing problem for me.
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