Printed Documentation won't generate

I am working with RoboHelp 7 and Word 2003 on an XP machine.  I started a new RoboHelp for Word project from scratch, including a tutorial with a lot of screen captures.  The RTF file was about 72 MB in size, and the HLP would not compile; the error message simply said "Failed to generate", and the error wizard was empty.  Adobe Technical Support has had the case for 4 weeks, and has not helped.  I asked if the size of the file mattered, and was told "no", but when I removed some JPGs from the file, the HLP finally compiled.  This small success encouraged me to try tagging the rest of the images as excluded from the HLP.  The HLP now compiles (although it takes a very long time), but printed still gives the "Failed to generate" error mesasge with nothing in the error wizard.  Although it's possible to manually format the printed document, this isn't satisfactory over the long run as I anticipate several rounds of edits in the near future.  Has anyone run into this apparent "size matters" issue before?