Well I found a way do this and decided to post it in case someone else comes
across this same issue.

I think the arreload was not able to update the cache because storing the
640,000+ records before performing the update to the user_cache table was
using up all of the servers resources so it didn’t have enough RAM left for
the update process. But I cannot confirm that was the issue because ARERR 92
is a rather generic error.

The upside to the arreload was that it did flush the user_cache table.

So after adding an administrator account using the arcache utility (as the
user_cache was empty so I was unable to login), I created an escalation that
updated a NULL character field on the user form to 1. The field was the core
field "assigned to" which on our user records is never used. All the users
had a null value. This field is also a varchar field so any value could be
put in it.

The escalation took somewhere between 4 to 6 hours to complete (not sure
exactly because we let it run over night as it was taking too long). Since
it was using a set fields action and not a sql update it updated the user
cache for us and unlike the arreload it updated the records as it ran. Even
if it got interrupted for whatever reason the work that was done in the time
it was running would remain. Arreload seems to lose all progress if you run
even a simple search command on the sql database. This may not be the best
way to solve this issue but it did work and right now that is all that
matters.


josepht wrote:
> 
> I ran this twice so far and both times got the same results. I think this
> might be too many records for the arreload to handle at one time. Is there
> another way to get the desired results without running arreload? Or do I
> need to do something differently to get arreload to work as desired?
> 

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