When user tries to save as flat file a data grid that has over 1,000+ columns (not rows), an access violation is generated in 8.6.1 and 184.108.40.206.
"Access violation at address 00405E10 in module 'TOAD.exe'. Read of address 000013F0"
Toad 220.127.116.11 does not get an access violation, but Toad will hang at the Save Grid Content Window when the OK button is clicked.
Try reducing the number of columns your are trying to save as flat file.
Issue fixed in version 9.5. The latest version of Toad for Oracle can be downloaded at here.