Hello kledor,
Try to generate a very basic catalog:
Use "remove books" to delete any "empty" catalog files that have been created. Right-click the Library icon and select "Library Maintenance" > "Check Library" to make sure the library database hasn't been corrupted.
In create catalog, click the "e-book options" tab and select only Authors and Titles. Skip "prefixes" and "other options" for now.
Try to generate a catalog in EPUB format first. If it works, then try AZW3.
Holler back with

or

.
Marty