The trick to solving this is to figure out what is the difference between the one that works and the one that doesn't work.

Make sure you are using the same workstation and same install of Adagio for testing the database that works against the one that doesn't work.

If that still fails then trying taking the data to your office and print the reports there. Still fails then it's the data. Doesn't fail then something is going on at your clients site.

If it's the data and you recently converted it from DOS then they may be left over dead temp files that need to be cleaned up (though I doubt they would be causing the problems you describe).