I don't know if it still exists, but there used to be a zone crash (or maybe client crash) from casting spells while using armor with focus effects with spell IDs that did not exist. I recall this issue happening on servers that had updated their items table with newer items that had focus effects that the Titanium spell file can not support. You might try searching your items table for any focus effects that are above spell ID 9999, since that is the Titanium spell file cut-off.
Also, if it is only the client that is crashing and not the zone, you should get the client version from the people experiencing the issue (I am guessing they are all on Titanium). I would also recommend that you try moving the characters to one of your accounts so you can test casting spells with their characters on different clients to see if it crashes for you as well.
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