Unable to Generate Printed Documentation in PDF Format

This past week I started having a consistent error when attempting to generate a Printed Documentation layout. This error reads "Internal error encountered,  Failed to generate Printed Documentation."  Prior Printed Documentation builds on this same project completed fine. Nothing was done to the Help project between the times when this worked and when it no longer was able to create Printed Documentation.
I receive this error even if I generate an entirely new "blank project" build, and then attempt to create a Printed Documentation build from this new blank project.  Researching this error, I see this has been a reoccuring problem with this product for some time. The few threads that list the problem as having been "fixed" provide resolution steps that have not worked in my case. Right now I am waiting for our IT Helpdesk people to re-install the Suite. Hopefully this will resolve this problem.
Additional information on this problem - PDF Printed Documentation is failing - the HTML build works fine. If I select just a .DOC Printed Documentation output, this also works correctly. The resulting Word document looks good, although hyperlinks do not work within this Word document. I have reloaded Office 2003 as a troubleshooting effort, but this has nbot resulted in any change in symptoms.
The entire error text is enclosed below, although several other people have also done this in past entries. The few lines that read "Warning, and then report a style issue is NOT the problem here. As stated earlier, when I do this same Printed Documentation build on an entirely new "blank project" it does not work, and the Output text in that case does not contain any such "Warnings" about Styles.
Error text below:
Starting to build Printed Documentation...
Printed Documentation processor 8.0.1.204
Building C:\Documents and Settings\tcleary\My Documents\My RoboHelp Projects\Adobe RoboHelp 8\10515-0366-5004_7800v-hh rsp\!SSL!\Printed_Documentation.doc ...
Preparing to create Printed Documentation...
Clearing output folder...
Preparing files for Print Document...
Copying files...
Updating files...
Finished preparing in 2 seconds.
Preparing environment...
Printed Document Generator Environment: Word 11.0.8313,  OS 5.1.2600, RAM 2048 M Bytes
Building Printed Documentation 'Printed Documentation'...
Building Single Document 'Printed_Documentation.doc'...
Building 'RF-7800V-HH About this Help'...
Building 'Table of Contents'...
Preparing to build chapters...
Building 'RF-7800V-HH Help and Support'...
Processing 'RF-7800V-HH Welcome'...
Building 'RF-7800V-HH RSP Help'...
Processing 'RF-7800V-HH Station Information'...
Building 'RF-7800V-HH Features'...
Processing 'RF-7800V-HH Features'...
Processing 'RF-7800V-HH Anc. Connector Mode'...
Processing 'RF-7800V-HH No-Sync Beeps'...
Processing 'RF-7800V-HH Power Management'...
Processing 'RF-7800V-HH Retransmit'...
Processing 'RF-7800V-HH USB Mode'...
Processing 'RF-7800V-HH Broadcast Gateway'...
Processing 'RF-7800V-HH IP Routing'...
Processing 'RF-7800V-HH Voice Settings'...
Processing 'RF-7800V-HH Time and Date Settings'...
Processing 'RF-7800V-HH Position Reporting'...
Processing 'RF-7800V-HH User Interfaces'...
Processing 'RF-7800V-HH Net Switches'...
Processing 'RF-7800V-HH Ethernet Interface'...
Building 'RF-7800V-HH Global Settings'...
Processing 'RF-7800V-HH Global Settings'...
Processing 'RF-7800V-HH Radio Passwords'...
Processing 'RF-7800V-HH GPS'...
Processing 'RF-7800V-HH Locksets'...
Building 'RF-7800V-HH Network Types'...
Processing 'RF-7800V-HH Network Types'...
Building 'RF-7800V-HH Fixed Frequency LOS'...
Processing 'General Information - Fixed Frequency LOS'...
Processing 'RF-7800V-HH FF Network Information'...
Processing 'RF-7800V-HH FF Preset'...
Processing 'RF-7800V-HH FF General'...
Processing 'RF-7800V-HH FF Comsec'...
Processing 'RF-7800V-HH FF Data-Voice'...
Processing 'RF-7800V-HH FF Squelch'...
Processing 'RF-7800V-HH FF Advanced'...
Warning: style (p.Heading7) is not defined and will be mapped to 'Normal'.
Building 'RF-7800V-HH Quicklook'...
Processing 'General Information - Quicklook'...
Processing 'Hopset Creation - Quicklook'...
Processing 'RF-7800V-HH QL Network Information'...
Processing 'RF-7800V-HH QL Preset'...
Processing 'RF-7800V-HH QL General'...
Processing 'RF-7800V-HH QL Comsec'...
Processing 'RF-7800V-HH QL Data-Voice'...
Processing 'RF-7800V-HH QL Advanced'...
Building 'RF-7800V-HH Sample Plans'...
Processing 'General Information - Sample Plans'...
Processing 'Simple Fixed and Quicklook Nets'...
Processing 'Single Fixed and Quicklook Nets'...
Processing 'RF-7800V-HH Manage Keys'...
Processing 'RF-7800V-HH Program Radio'...
Building 'RF-7800V-HH Tech Support'...
Processing 'RF-7800V-HH Technical Support'...
Processing 'RF-7800V-HH Radio Firmware Compatibility'...
Building 'FAQs'...
Processing 'RF-7800V-HH FAQ Index'...
Processing 'FAQ 01'...
Warning: style (span.strong) is not defined and will be removed.
Warning: style (p.para) is not defined and will be mapped to 'Normal'.
Processing 'FAQ 02'...
Processing 'FAQ 03'...
Processing 'FAQ 04'...
Processing 'FAQ 05'...
Processing 'RF-7800V-HH Glossary'...
Warning: style (p.FM_CellRowHead) is not defined and will be mapped to 'Normal'.
Warning: style (span.Glossary) is not defined and will be removed.
Warning: style (p.FM_CellBodyLeft) is not defined and will be mapped to 'Normal'.
Warning: style (p.FM_GLOSSARY) is not defined and will be mapped to 'Normal'.
Warning: style (p.FM_Para) is not defined and will be mapped to 'Normal'.
Completed building chapters...
Building 'Index'...
Updating list paragraphs...
Updating images...
Updating page numbers...
Updating page headers...
Updating Table of Contents...
Updating Index...
Saving 'Printed_Documentation.doc'...
Generating 'Printed_Documentation.pdf'...
Failed the generate PDF file 'C:\Documents and Settings\tcleary\My Documents\My RoboHelp Projects\Adobe RoboHelp 8\10515-0366-5004_7800v-hh rsp\!SSL!\Printed_Documentation.pdf'...
Failed to save 'Printed_Documentation.doc'...
Cleaning up temporary files...
I am pretty sure nobody will have any fix suggestions that work to solve this problem, but I am making this entry for historical purposes. I will add an entry stating whether the Suite reload resolves this issue.
Thanks,
Tim C @ Harris

If I select ONLY the Word DOC Output format in the Printed Documentation
setup, the output is created without an error (output text below).  Links do work within
this Word document (a symptom change since installing patch 8.0.2).
When I use this Word document to create a PDF (using the Adobe PDF
printer driver) a PDF is successfully created, however no bookmarks are
created in the bookmarks panel and none of the links in this PDF work
(although they are created looking like they will work, i.e., blue
underlined text).
Regards,
Tim
------------- Output Text --------------------------
Starting to build Printed Documentation...
Printed Documentation processor 8.0.1.204
Building C:\Documents and Settings\tcleary\My Documents\My RoboHelp Projects\Adobe RoboHelp 8\10515-0366-5004_7800v-hh rsp\!SSL!\Printed_Documentation.doc ...
Preparing to create Printed Documentation...
Clearing output folder...
Preparing files for Print Document...
Copying files...
Updating files...
Finished preparing in 3 seconds.
Preparing environment...
Printed Document Generator Environment: Word 11.0.8313,  OS 5.1.2600, RAM 2048 M Bytes
Building Printed Documentation 'Printed Documentation'...
Building Single Document 'Printed_Documentation.doc'...
Building 'RF-7800V-HH About this Help'...
Building 'Table of Contents'...
Preparing to build chapters...
Building 'RF-7800V-HH Help and Support'...
Processing 'RF-7800V-HH Welcome'...
Building 'RF-7800V-HH RSP Help'...
Processing 'RF-7800V-HH Station Information'...
Building 'RF-7800V-HH Features'...
Processing 'RF-7800V-HH Features'...
Processing 'RF-7800V-HH Anc. Connector Mode'...
Processing 'RF-7800V-HH No-Sync Beeps'...
Processing 'RF-7800V-HH Power Management'...
Processing 'RF-7800V-HH Retransmit'...
Processing 'RF-7800V-HH USB Mode'...
Processing 'RF-7800V-HH Broadcast Gateway'...
Processing 'RF-7800V-HH IP Routing'...
Processing 'RF-7800V-HH Voice Settings'...
Processing 'RF-7800V-HH Time and Date Settings'...
Processing 'RF-7800V-HH Position Reporting'...
Processing 'RF-7800V-HH User Interfaces'...
Processing 'RF-7800V-HH Net Switches'...
Processing 'RF-7800V-HH Ethernet Interface'...
Building 'RF-7800V-HH Global Settings'...
Processing 'RF-7800V-HH Global Settings'...
Processing 'RF-7800V-HH Radio Passwords'...
Processing 'RF-7800V-HH GPS'...
Processing 'RF-7800V-HH Locksets'...
Building 'RF-7800V-HH Network Types'...
Processing 'RF-7800V-HH Network Types'...
Building 'RF-7800V-HH Fixed Frequency LOS'...
Processing 'General Information - Fixed Frequency LOS'...
Processing 'RF-7800V-HH FF Network Information'...
Processing 'RF-7800V-HH FF Preset'...
Processing 'RF-7800V-HH FF General'...
Processing 'RF-7800V-HH FF Comsec'...
Processing 'RF-7800V-HH FF Data-Voice'...
Processing 'RF-7800V-HH FF Squelch'...
Processing 'RF-7800V-HH FF Advanced'...
Warning: style (p.Heading7) is not defined and will be mapped to 'Normal'.
Building 'RF-7800V-HH Quicklook'...
Processing 'General Information - Quicklook'...
Processing 'Hopset Creation - Quicklook'...
Processing 'RF-7800V-HH QL Network Information'...
Processing 'RF-7800V-HH QL Preset'...
Processing 'RF-7800V-HH QL General'...
Processing 'RF-7800V-HH QL Comsec'...
Processing 'RF-7800V-HH QL Data-Voice'...
Processing 'RF-7800V-HH QL Advanced'...
Building 'RF-7800V-HH Sample Plans'...
Processing 'General Information - Sample Plans'...
Processing 'Simple Fixed and Quicklook Nets'...
Processing 'Single Fixed and Quicklook Nets'...
Processing 'RF-7800V-HH Manage Keys'...
Processing 'RF-7800V-HH Program Radio'...
Building 'RF-7800V-HH Tech Support'...
Processing 'RF-7800V-HH Technical Support'...
Processing 'RF-7800V-HH Radio Firmware Compatibility'...
Building 'FAQs'...
Processing 'RF-7800V-HH FAQ Index'...
Processing 'FAQ 01'...
Warning: style (span.strong) is not defined and will be removed.
Warning: style (p.para) is not defined and will be mapped to 'Normal'.
Processing 'FAQ 02'...
Processing 'FAQ 03'...
Processing 'FAQ 04'...
Processing 'FAQ 05'...
Building 'RF-7800V-HH Glossary'...
Warning: style (p.FM_CellRowHead) is not defined and will be mapped to 'Normal'.
Warning: style (span.Glossary) is not defined and will be removed.
Warning: style (p.FM_CellBodyLeft) is not defined and will be mapped to 'Normal'.
Warning: style (p.FM_GLOSSARY) is not defined and will be mapped to 'Normal'.
Warning: style (p.FM_Para) is not defined and will be mapped to 'Normal'.
Completed building chapters...
Building 'Index'...
Updating list paragraphs...
Updating images...
Updating page numbers...
Updating page headers...
Updating Table of Contents...
Updating Index...
Saving 'Printed_Documentation.doc'...
Completed building Printed Documentation...
Preparing output directory...
Cleaning up temporary files...
Finished Printed Documentation generation in 5 minutes 36 seconds.
Building Printed Documentation complete.

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