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Is there any reason why my player (3a10) would keep doing this every sync?

Most likely, as you've said, you need to manually FSCK the disks.

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trying to get the reservecache setting into my config.ini file, but it does the check and emplode usually crashes...

This usually ends up happening (config.ini changes don't take) because you've got a piece of third-party software auto-starting at bootup which is locking the /drive0 filesystem.
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Tony Fabris