Large format printing to PDF errors

Question

Hi -
I'm creating 36" x 90" posters in Illustrator CS4 on Windows 7 and suddenly cannot print full-size to PDF.   I simply get the big red X that says, "Can't print Illustration".   Not exactly a helpful error message.
I've done it in the past, so losing the capability with no apparent explaination is frustrating.   After some reinstalling and trial/error, I've discovered that the max width (or height) is now 72".  Interestingly enough, older files the same size ALSO cannot now print to PDF.  (I can SAVE to PDF, I can't PRINT to PDF.  Printing brings a smaller file size I can email to my printer...)     
Interestingly enough, saving the file as a Postscript and opening it in Photoshop also exhibits the same problem.
I have also isolated the problem to this particular setup/computer because it works like a champ at home (which is how I solved the problem this time) with the same OS/CS versions.
Is there something I'm missing?  Some setting that was inadvertently changed?
TIA

Answer 1

The size of the PDf can be directly related to it's content. ie: A PDF file containing only black text may be 100k, where as if you add an 8-bit tiff file, it may jump to 3 Mgs.
When you create your PDF (if size does matter!), you can adjust many areas by Optimizing it. (You can also do this with Distiller and the PS or EPS route). Use the "Advanced" menu, and use PDF optimizer to lower quality of the file. ie: turn on Jpg compression and adjust the compression ratio to your desired level. You can also downsample rasterized art (not vector!) by turning on downsampling. I'm not sure if there is an action you can create to do this or not. Never tried batching in Acrobat.
P.S. After optimizing it, DO NOT resave. The Optimized file will already be saved. Saving it again, removes much of the optimizing you just did.
Also, Acrobat 7 files tend to be a little larger than 6!