chuckl,
Maximum Data Line Length will happen if some lines in your data exceed the value specified in the "Maximum data line length" parameter of your form under Compilation options. (we are talking about the data as it is put in the postscript file sent to the printer, not necessarely how you see it in the emulation, so you may have some lines actually longer than what you see in the emulation...) If 256 fails, do NOT decrease it, or it will still fail, you must raise it. The maximum is 65535, which should work, and you should try it first. If it works, you can then try to lower it, as it's best to have it lower performance-wise.
65535 should work, if you say it doesn't, well, I'm a little surprised... Are you using Workflow? And if so, are you sure you've properly resent your form to Workflow after changing it to 65535? If Workflow was actively running, you might want to do a Refresh to make sure the document was updated properly. (right-click on the .ptk in the list of documents, and do Refresh)
Alternatively, you could switch the run mode to Optimized PostScript instead of Printer Centric. This error should not happen in Optimized PostScript.
Hope that helps!
Regards,
Raphaël Lalonde Lefebvre