From: "Daniel Heise" <dh at dhml dot de>

> I've a big problem. Last week my m0n0wall crashed and wasn't able to 
> reboot. For me it seemed like the cf card was
> damaged. So bought a new one to replace the broken card. Now, six days 
> later I've got the following error message on the top of each page:

> Warning: filemtime(): Stat failed for /conf/config.xml (errno=6 - Device 
> not configured) in /etc/inc/config.inc on line 127

> And when I try to download my current configuration the following error 
> messages appear:

> Warning: filemtime(): Stat failed for /conf/config.xml (errno=6 - Device 
> not configured) in /etc/inc/config.inc on line 127 Warning: filesize(): 
> Stat failed for /conf/config.xml (errno=6 - Device not configured) in 
> /usr/local/www/diag_backup.php on line 54 Warning: Cannot modify header 
> information - headers already sent by (output started at 
> /etc/inc/config.inc:127) in /usr/local/www/diag_backup.php on line 55 
> Warning: Cannot modify header information - headers already sent by 
> (output started at /etc/inc/config.inc:127) in 
> /usr/local/www/diag_backup.php on line 56 Warning: Cannot modify header 
> information - headers already sent by (output started at 
> /etc/inc/config.inc:127) in /usr/local/www/diag_backup.php on line 57 
> Warning: readfile(/conf/config.xml): failed to open stream: Device not 
> configured in /usr/local/www/diag_backup.php on line 58

Your file system is failing.  And since your file system is in memory, it is 
most likely your memory that is failing.  Boot some kind of mem-test.  For 
example, write the Ultimate Boot CD onto your flash, and boot it.  Bet you 
find it is flaky hardware.

                        Lee