Illustrator :: CS5 Suite - Can't Print This Illustration

I've had this 'Can't Print the illustration' window - brand new CS5 suite, brand new computer - 4 days old (Dell, 36bit - would prefer a Mac but there you go).
 
History - large format packaging file - 600mm x 1200mm. Line drawings. Black and one spot (Pantone) color only. Job needed original English version converted to Chinese language. This had to be done on an older 'chinese' PC in Illustrator 4 with correct Chinese fonts. But after the translator did her job, I needed to return it to CS5 on the Dell to make alterations. Chinese fonts converted to outlines for transfer. Once alterations done, tried to print and got the silly can't print message.
 
prints fine from Dell in PDF format.
prints fine from Dell in jpeg format.
prints fine form old 'chinese' PC in Illustrator 4 format with either outlined fonts or fonts.
 
havent had any problems printing anything else in CS5, just this one job.
 
The only thing I can think of is that there was a problem when converting the Chinese font to outlines there were too many points created and either Illustrator or the printer cracked the irrites.
 
Although I have been using Macs/PC's and all Adobe programs for over 25 years I HATE trying to figure out this stuff and prefer to just be an end user without trying to figure out why a perfectly reasonable request goes odd.