First let me thank the 11 people that responded so quickly, some of those should have not responded at all, you know who you are. Of course, there were the few out-of-office responses in addition.
All the good responses said pretty much the same, add a second boot to the boot.ini file to switch to 3GB. Getting a 64 bit machine is not an option since this one is only 5 months old.
Francois Klinkenberg of the Herstalgroup (wherever that is) was the first responder and had the best information. The only difference was that Dell has 2 partitions already on the HD so you have to change the partition number to 2 or you'll get an error that it cannot find a certain .dll file which is located on partition 2, not 1.
The issue is that XP can not manage a process bigger than 1.3 Gb. If Pro/E occupies more than that when the assembly is opened, XP can not follow.
There is an XP option which allows it to manage bigger process.
Open the boot.ini file in your C:\ drive (it's a hidden file) and change the existing line (or copy it and add it under) to incorporate the /3Gb parameter).
Here is an example after you set it ip :
multi(0)disk(0)rdisk(0)partition(1)\WINDOWS="Microsoft Windows XP Pro 3GB"
/3GB /fastdetect /NoExecute=OptIn
This will allow XP to manage a process of 2.59 Gb in RAM.
If you copied it, you have to select it during the OS boot
Thanks to all again.
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