Yeah my guess is your /var directory is full. The printer creates a text file, usually in /var/spool/lpd, and if that's full, ,I can see why you'd have problems. Here's two things to try that may work (I haven't tried it myself):
The -s switch (lpr -s document) will print files directly to the printer. No spool file is created. So you can see why that may work for you.
Could also edit your /etc/printcap file, in particular the :sd (spool directory) setting. Try changing that to another partition other than the default /var/spool/
Let us know if it works.
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