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strange ClassCastException on init?

I have some code that's been running perfectly for a few months now.  Suddenly we ran into a document (I think) that causes it to crash when I'm trying to load it into a PdfReader!  Never seen this before, and the code has been used on thousands of documents -- 99% of which are created in the same manner.
 
My java code at the specified line is simple:
 
PdfReader reader = new PdfReader(fileList[f]);
 
The thrown (uncaught) exception is:
 
java.lang.ClassCastException
 at com.lowagie.text.pdf.PdfReader$PageRefs.iteratePages(Unknown Source)
 at com.lowagie.text.pdf.PdfReader$PageRefs.iteratePages(Unknown Source)
 at com.lowagie.text.pdf.PdfReader$PageRefs.readPages(Unknown Source)
 at com.lowagie.text.pdf.PdfReader$PageRefs.<init>(Unknown Source)
 at com.lowagie.text.pdf.PdfReader$PageRefs.<init>(Unknown Source)
 at com.lowagie.text.pdf.PdfReader.readPages(Unknown Source)
 at com.lowagie.text.pdf.PdfReader.readPdf(Unknown Source)
 at com.lowagie.text.pdf.PdfReader.<init>(Unknown Source)
 at com.lowagie.text.pdf.PdfReader.<init>(Unknown Source)
 at com.documentum.ajw.PDF.PDFconcat.concatPDFs(PDFconcat.java:64)
 
This is using the 1.4 version of iText.
 
Anyone have any ideas why this would happen?  I can open the PDF in Acrobat Standard 6.0 just fine...don't see anything obviously "wrong" with the file.
 
Thanks in advance,
AJ