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You haven't said whether you tried deleting the CPD?
Also you haven't said where the project is located, network or local.
See if this thread helps and post back.
See www.grainge.org for RoboHelp and Authoring tips
The project is local.
I just now tried the "delete the CPD" trick, and tried to reopen from the HHP. RoboHelp rebuilt the CPD and XPJ files, then seemed to stall out trying to open the project. The project did eventually open (yay!) but was missing all its previous tables of contents (boo!), so I'll have to see if those can be quickly/easily reconstructed.