Are you using "Page N of M" or "Total Pages" in your report? If so, take it out and see whether that will help.
Also, Crystal can be very memory intensive and it will swap out to disk if it runs out of RAM. So, you need to look at how much RAM and disk space is available while the report is processing. Also, Crystal is not good about cleaning up its temp files when a report fails. So, you'll need to go to C:\Users\<your user ID>\AppData\Local\Temp and delete all files with the following file name format: "~*.tmp" or "~*.rpt". Skip any files that are in use (Windows will ask if you want to skip them.) NOTE: This is a "hidden" folder, so you'll need to set Explorer to view hidden folders in order to get to it.
Having said all of that, your only other option that I can think of would be to limit the number of records that the report reads using one or more parameters and then use multiple exports to get "all" of the data.
-Dell