Jen - Have the cc person forward the email to you and the person with the failed PDF. Check them both on your system. I've noticed Acrobat issues in the past and it could be as simple as a bug in acrobat. Sometimes other PDF readers work fine (like Nitro).

Thanks for the suggestion John. I downloaded Nitro, and I tried opening both PDF's and the one that was from the recipient in the "TO" field failed. The one from the person in the "CC" opened. I still think it has something to do with the file size being bigger - like Sage is shoving extra info into the PDF for just the "To" recipient.

I'm out of easy troubleshooting. My pdfing code used the crystal report engine to generate the PDFs in ReportEngine.DLL. I actually modified it to pass a flag to make Crystal do the PDFing. That always seemed to work fine. I'm not sure what Sage is doing but I bet Joe or someone else there could trace the code. You might see if there is a known bug on the Crystal site for this problem assuming they do it the same way. MAS 100/200 used to use AMYUNI to do the PDFing so it's possible MAS 500 is doing the same though I doubt it.

John, Document Transmittal is simply using the Report Engine to create the attachment it needs for the email. As you point out, it is using Crystal Reports to do this and save the file. Once it has a file, it then uses the Sage 500 EmailUtils.DLL to create the email and attach the PDF to it.

Now this issue about PDF's being corrupted has come up before and was discussed on some older posts. However, they dealt with SMTP set ups. (Example: Document Transmittal - Clients get unreadable Invoice). If using Exchange for email it may have something to do with that as Exchange handles the attachment where as SMTP is using CDO to create the email.

Lou - Do you know if a copy of the PDF is stored on the system so Jen can get at it? Do you know if it creates 2 PDFs. Maybe she can check if one of them is bad. She should probably get Sage involved.

The PDF is stored temporarily on the system until the email is created and sent. There is only one copy. Looking at the code for both Exchange and SMTP, all the addresses (To, CC, etc.) are added to the single email transaction at creation as well as the attachment. One thing I noticed in the thread is that the type of email (SMTP or Exchange) was not mentioned.

As I posted before, if SMTP is being used there is an issue with trying to send PDF attachments because of how Sage is implementing CDO (Collaboration Data Objects), which it uses to create the email. I'm not sure if Sage is going to address the issue or not, but the thread "Document Transmittal - Clients get unreadable Invoice" discusses the issue and talks about possible code changes to correct the problem.

Thank you both! They are using SMTP. Lou, I'll check out the other thread too.
I really appreciate the feedback.