Does anybody know how to solve this?
"The operation has timed out (emailCrystalReport)"
It has only started happening on a large report. The report worked fine for 1 year.

That message usually means that the e-mail server that Logicity is attempting to use for SMTP was inaccessible, was responding too slowly, or closed the connection because it didn't like something about the e-mail. I would check your e-mail server to see if something in the logs provides any hints to what is going on. Also possibly try a smaller report to see if it goes through alright (it could be the attachment size that is the problem).