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60KB is absurdly small,
I read a lot on my Astak, and it is really (RMSDK) fussy, except for image rich pages, <260K has worked out well (although, I do tend to split on chapters if I tune the book)
I suspect something else is really wrong, you could even have a bit of RAM (where the working book file is being processed) going bad.
Validate both the book HTML AND CSS
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