Man this stuff is dangerous!
After editing the config.ini, my player wouldn't boot up. Perhaps the larger reservecache + a 22,000 track playlist was too much for the player to get going. It was caught on "Loading Music Databases" and "Building Database". I could not ftp into the player, but a serial connection was working. The "rebuilding" one confuses me a bit. I never let it finish rebuilding, but that was never a problem.
TeraTerm Pro does not receive files (or if it does, doing a search on my computer for "config.ini" showed nothing after doing a "sz config.ini" on it). So, I had to go back to Hyperterminal, send the config.ini to my PC, edit out the reservecache line and send it back to the player. Typed "exit" and player booted up fine!
It didn't even ask me to do a database rebuild.
Thank you Tony for the FAQ. It had been a while since I had used zmodem to send fijles. Doing the needed ro, rom, rw, rwm and chmod went great too.
Guess I need one of those RAM cards now!