I regularly get emails with medium length PDF files (2-10 pages). I recently got an email with a 112 page PDF file attached. When I downloaded the file, the Blackberry indicated that I wouldn't be able to view the file. While I was able to confirm that the file was on the memory card, I was not able to open it. Other than the length, I am not aware of any other differences between the PDF files I have been able to open and the one I couldn't.
The BB has a maximum file size it can manipulate. I forget how big that is on the Tour, but check the size difference between the files you usually work with and the big file.
Posted from my CrackBerry at wapforums.crackberry.com