To create a new category, first open the dialog box by clicking on the "New category" menu item. The "New category" menu item is located in the Category menu on the right side of the main menu bar. The dialog box should like something like this:
NOTE: If the name at the top of your dialog box or the look of the dialog box is a bit different than in the example it is not cause for alarm. Different versions of TaskCoach have looks to them.
You can also create a new category from within the "Task Dialog Box" (see image below) by selecting the "Categories" tab then clicking the "New category" menu item located on its task bar.
To create a new sub-category you follow the same steps as you do when making a Top Level Category just click the "New sub-category" menu item instead. You can makes sub-categories within sub-categories within sub-categories as many times as needed.
With the Category Dialog Box open you can type in a description to each Category / Sub-Category that you have created. The description that you have entered there will show up when you hover over the Category itself; it will not show up when you hover over Task that it is assigned to (the description of the task will show up).
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To put tasks and notes in a specific category, edit the task or note, and select the categories tab in the Categories tab, like this: (note that you can select more than one categories)
If you want to synchronize with Outlook, create a category Appointments as well (see Sync with Outlook Events).
Documentation: manual
Documentation: sync-with-outlook-events