Looks like one of your character is wearing a piece of gear that is not in your Item.Sdata, thats the common problem that comes with the "Character load error".
Also one thing that pops in my mind: If you probably tried to add/edit some of your Armor/Weapon files, you probably imported them wrong. To import edited .dds or .3do files you have to import them manually 1 by 1 using Lilprohackers Data file Tool that you can find on the Forums.