This bug is tricky as hell :).
Here are my observations:
1) No separate tile causes broken index. This only happens when all (or at least unknown combination of) tiles are compiled together.
2) After many hours of testing I've selected 2 particular tiles. When I remove them from my compilation, index starts working again.
3) Those 2 tiles - 6600435 and 6600436 cover border parts of Ukraine. I suppose Ukrainian transliterated names cause problems. My guess would be cities like: Volia-Baraniets'Ka or Ostrozhiets' (note apostrophe at the end)
4) I uploaded my splitted map here:
https://mega.co.nz/#!8l1jCLSR!x9FhsFVzLa6T7OfvYb-jYglP6voK04BcVwWHeeu7Hhwhere are generated boundaries:
https://mega.co.nz/#!R5k1iZqS!2UDuibgP1BAXNbh5FMMp3yt_5U5dyJBrh5hvObMVl0oIf you try to compile this map, please use particular config file, as I may be crucial for replication of this bug:
verbose
max-jobs
country-name=Polska
name-tag-list=name:pl,name
generate-sea
location-autofill=is_in,nearest
tdbfile
index
add-pois-to-areas
link-pois-to-ways
remove-short-arcs
preserve-element-order
country-abbr=POL
route
net
gmapsupp
nsis
check-styles
process-exits
process-destination
housenumbers
overview-mapnumber=66007001
overview-levels=6:16,7:15
best regards
Michal Rogala