>Using non-standard cache size 61490 (bonus 4095Mb, adjustment 0)

That line above indicates that the Reserved Memory option in Hijack must have been non-zero at the time. The 61490 is the number of 64KB buffers the player is trying to allocate, which is obviously WAY more than what your player has..

What does the serial log show after setting it to zero in Hijack, and then rebooting the machine?

-ml