Thank you for taking the time to answer each question.

Two more, have you tried opening sample data (SOFTRAK\ICWIN\Samdata folder) and printing both of the reports? Do the reports (a) print or (b) give you the same progress bar and screen flash?

6/26 Good call. Both of the I/C reports in question run just fine with the sample data and with any selected variable. This should confirm that the software (or workstations) are not at fault.
Knowing this, we've gone back and tried to compare as many options as we could find or think of for the two data sets.

We've been able to run the Item Status Reports from the main data when either "Total quantities" or "Quantities by location" were selected. The report will not run if both options are selected.

Also, I don't believe your DIC errors are related. They are more probably related to the uom being changed on an item and that item having been sold previously using an old uom that is sitting in history.
06/26 thanks we'll keep checking