Hrmm, same problem. First game it gave me the error after saving it normally. It was my first fortress anyway so I decided to restart. Now the second game is crashing and giving me this error.
It crashes at approx late summer in my third year (several times) and I'm not sure if it is the time of year or something I do at that time that causes it. The first few times it crashed the file was fine and I loaded it and redid all the stuff I did before. Now the save is borked and I tried loading from the beginning of summer - ran fine until late summer and crashed again. Now I'm running it again but not doing some of the tasks I set up the previous time... Hopefully it won't crash again. I'm not sure what else to do.
Don't think it's the caverns like the OP, I've got NO CAVERNS yet, still digging and looking for the top one. It's not on 13 through 25, which i think? is odd, I get the impression that I should have found one by now. But that's not related, uhh.
I'm running vista, btw.