Are you using SQL express? There is a size limit on the database in the express edition, 2008 = 10gb, 2005 = 4 gb if i remember correct. Are you using the express edition
And how large is the database? Is the database stored on a disk with the 180gb free space?
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If it's approaching the 4Gb mark, and complaing about getting full, it sounds like you're got the 2005 version of SQL express. It's not disk space it's complaing about, it's the SQL database size.
There are a couple of options to solve this:
1) Upgrade/migrate the database to a SQL 2008 express database
2) Migrate the database to a full blow SQL server (on a separate SQL server box).
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I think I found the solution. The SQL Server 2008 express has also a 4GB database limit.
Since SQL Server 2008 R2 express it was increased to 10GB.
the answer is to use a database which can support the amount of data you need to handle.
Though if you need something more then these limits I would first check if there is data which
should be purged. If you do not need history data its better to be removed.
On the other side if you have so much live data, looking into a dedicated SQL server might make sense.
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