If you do the dump using 9.1's pg_dump without --binary-upgrade, and then load that dump file into a new empty 9.1 server, then does it crash if you take a dump against *that* server?
I'll give it a try.
If so, would you be allowed to post that dump file?
I will not be able to provide the dump file but i will try to isolate the contents causing the issue and hopefully be able to provide a minimal dump file that doesn't contain any proprietary data yet still reproduces the crash. It's a fair amount of data, 45+G, so if i can reproduce it in a new database, isolating it may take some time.
Thanks