I'm also seeing this error message but in different conditions:

on a grub-pc installed in a USB-device where i with a menuentry i want
to boot an iso. 

Strange is that this happens on ainstallation on a 150GB USB-HD  but not
on 20GB USB-HD !

Choosing the last menu entry,  works on the tiny HD but not with
the big one!!

There throws the message: 
error: you need to load the kernel first

other message also seen is 
error: out of disk



20GB USB-HD installation:  All grub entries Work fine

Package: grub-pc
Version: 1.98~20091210-1

-- Package-specific info:

*********************** BEGIN /proc/mounts
/dev/disk/by-uuid/78e9c4d0-07fc-4846-bd24-d82afd0ca2be / ext4
rw,noatime,errors=remount-ro,barrier=0,data=ordered 0 0 
/dev/sda2 /media/disk1part2 ntfs
ro,nosuid,nodev,noexec,relatime,uid=0,gid=0,fmask=0133,dmask=022,nls=utf8,errors=continue,mft_zone_multiplier=1
0 0 
/dev/sda3 /media/disk1part3 ext3
rw,nosuid,nodev,noatime,errors=continue,data=writeback 0 0
*********************** END /proc/mounts

*********************** BEGIN /boot/grub/device.map
(hd0)   /dev/sda
(hd1)   /dev/sdb
*********************** END /boot/grub/device.map
*********************** BEGIN /boot/grub/grub.cfg
#
# DO NOT EDIT THIS FILE
#
# It is automatically generated by /usr/sbin/grub-mkconfig using
templates # from /etc/grub.d and settings from /etc/default/grub
#

### BEGIN /etc/grub.d/00_header ###
set default=0
insmod ext2
set root=(hd1,1)
search --no-floppy --fs-uuid --set 78e9c4d0-07fc-4846-bd24-d82afd0ca2be
if loadfont /usr/share/grub/unicode.pf2 ; then
  set gfxmode=640x480
  insmod gfxterm
  insmod vbe
  if terminal_output gfxterm ; then true ; else
    # For backward compatibility with versions of terminal.mod that
don't # understand terminal_output
    terminal gfxterm
  fi
fi
set locale_dir=/boot/grub/locale
set lang=de
insmod gettext
set timeout=5
### END /etc/grub.d/00_header ###

### BEGIN /etc/grub.d/05_debian_theme ###
set menu_color_normal=cyan/blue
set menu_color_highlight=white/blue
### END /etc/grub.d/05_debian_theme ###

### BEGIN /etc/grub.d/10_linux ###
menuentry "Debian GNU/Linux, with Linux 2.6.32-2.slh.1-sidux-686" {
        insmod ext2
        set root=(hd1,1)
        search --no-floppy --fs-uuid --set
78e9c4d0-07fc-4846-bd24-d82afd0ca2be
linux   /boot/vmlinuz-2.6.32-2.slh.1-sidux-686
root=UUID=78e9c4d0-07fc-4846-bd24-d82afd0ca2be ro vga=791 quiet
initrd  /boot/initrd.img-2.6.32-2.slh.1-sidux-686 } menuentry "Debian
GNU/Linux, with Linux 2.6.32-2.slh.1-sidux-686(recovery mode)" { 
        insmod ext2
        set root=(hd1,1)
        search --no-floppy --fs-uuid --set
78e9c4d0-07fc-4846-bd24-d82afd0ca2be
linux   /boot/vmlinuz-2.6.32-2.slh.1-sidux-686
root=UUID=78e9c4d0-07fc-4846-bd24-d82afd0ca2be ro single vga=791 initrd  
/boot/initrd.img-2.6.32-2.slh.1-sidux-686 } 
### END /etc/grub.d/10_linux ###

### BEGIN /etc/grub.d/20_memtest86+ ###
menuentry "Memory test (memtest86+)" {
        insmod ext2
        set root=(hd1,1)
        search --no-floppy --fs-uuid --set
78e9c4d0-07fc-4846-bd24-d82afd0ca2be 
        linux16 /boot/memtest86+.bin
}
menuentry "Memory test (memtest86+, serial console 115200)" {
        insmod ext2
        set root=(hd1,1)
        search --no-floppy --fs-uuid --set
78e9c4d0-07fc-4846-bd24-d82afd0ca2be linux16 /boot/memtest86+.bin
console=ttyS0,115200n8 } 
### END /etc/grub.d/20_memtest86+ ###

### BEGIN /etc/grub.d/30_os-prober ###
menuentry "Microsoft Windows XP Professional (on /dev/sda1)" {
        insmod ntfs
        set root=(hd0,1)
        search --no-floppy --fs-uuid --set a61820aa18207b85
        drivemap -s (hd0) ${root}
        chainloader +1
}
### END /etc/grub.d/30_os-prober ###

### BEGIN /etc/grub.d/40_custom ###
# This file provides an easy way to add custom menu entries.  Simply
type the # menu entries you want to add after this comment.  Be careful
not to change # the 'exec tail' line above.
### END /etc/grub.d/40_custom ###

### BEGIN /etc/grub.d/60_fll-fromiso ###
menuentry "sidux-xfce (2.6.31-6.slh.2-sidux-686)" {
        insmod ext2
        set root=(hd1,1)
        search --no-floppy --fs-uuid --set
78e9c4d0-07fc-4846-bd24-d82afd0ca2be 
        loopback loop /opt/Isos/sidux-xfce.iso 
        linux (loop)/boot/vmlinuz-2.6.31-6.slh.2-sidux-686
fromhd=UUID=78e9c4d0-07fc-4846-bd24-d82afd0ca2be 
fromiso=/opt/Isos/sidux-xfce.iso boot=fll lang=de_DE TZ=UTC    vga=791 quiet 
noeject nointro
        initrd (loop)/boot/initrd.img-2.6.31-6.slh.2-sidux-686 } 
### END /etc/grub.d/60_fll-fromiso 
### *********************** END /boot/grub/grub.cfg

-- System Information:
Debian Release: squeeze/sid
  APT prefers unstable
  APT policy: (500, 'unstable')
Architecture: i386 (i686)

Kernel: Linux 2.6.32-2.slh.1-sidux-686 (SMP w/2 CPU cores; PREEMPT)
Locale: LANG=de_DE.utf8, LC_CTYPE=de_DE.utf8 (charmap=UTF-8)
Shell: /bin/sh linked to /bin/dash

Versions of packages grub-pc depends on:
ii  debconf [debconf-2.0]       1.5.28          Debian
configuration management sy 
ii  grub-common                 1.98~20091210-1 GRand Unified
Bootloader, version 
ii  libc6                               2.10.2-2        GNU C
Library: Shared libraries 
ii ucf                                  3.0025  Update
Configuration File: preserv

grub-pc recommends no packages.

Versions of packages grub-pc suggests:
pn  desktop-base                  <none>     (no description available)
-- debconf information:
  grub2/kfreebsd_cmdline:
  grub2/linux_cmdline:
  grub-pc/chainload_from_menu.lst: true
  grub-pc/kopt_extracted: false
  grub-pc/install_devices:
  grub-pc/postrm_purge_boot_grub: false
  grub2/kfreebsd_cmdline_default: quiet
  grub2/linux_cmdline_default: quiet
#-------------------------------------------------------------------------





150GB USB-HD installation all menu entries except the last one work fine

-- Package-specific info:

*********************** BEGIN /proc/mounts
/dev/disk/by-uuid/2f46ee2d-3ac0-46f8-af61-311252327898 / ext4
rw,noatime,errors=remount-ro,barrier=0,data=ordered 0 0 
/dev/sda2 /media/disk1part2 ntfs
ro,nosuid,nodev,noexec,relatime,uid=0,gid=0,fmask=0133,dmask=022,nls=utf8,errors=continue,mft_zone_multiplier=10
 0 
/dev/sda3 /media/disk1part3 ext3
rw,nosuid,nodev,noatime,errors=continue,data=writeback 0 0
*********************** END /proc/mounts

*********************** BEGIN /boot/grub/device.map
(hd0)   /dev/sda
(hd1)   /dev/sdb
*********************** END /boot/grub/device.map

*********************** BEGIN /boot/grub/grub.cfg
#
# DO NOT EDIT THIS FILE
#
# It is automatically generated by /usr/sbin/grub-mkconfig using
templates # from /etc/grub.d and settings from /etc/default/grub
#

### BEGIN /etc/grub.d/00_header ###
set default=0
insmod ext2
set root=(hd1,1)
search --no-floppy --fs-uuid --set 2f46ee2d-3ac0-46f8-af61-311252327898
if loadfont /usr/share/grub/unicode.pf2 ; then
  set gfxmode=640x480
  insmod gfxterm
  insmod vbe
  if terminal_output gfxterm ; then true ; else
    # For backward compatibility with versions of terminal.mod that
don't # understand terminal_output
    terminal gfxterm
  fi
fi
set locale_dir=/boot/grub/locale
set lang=de
insmod gettext
set timeout=5
### END /etc/grub.d/00_header ###

### BEGIN /etc/grub.d/05_debian_theme ###
set menu_color_normal=cyan/blue
set menu_color_highlight=white/blue
### END /etc/grub.d/05_debian_theme ###

### BEGIN /etc/grub.d/10_linux ###
menuentry "Debian GNU/Linux, with Linux 2.6.32-2.slh.1-sidux-686" {
        insmod ext2
        set root=(hd1,1)
        search --no-floppy --fs-uuid --set
2f46ee2d-3ac0-46f8-af61-311252327898
linux   /boot/vmlinuz-2.6.32-2.slh.1-sidux-686
root=UUID=2f46ee2d-3ac0-46f8-af61-311252327898 ro vga=791 quiet initrd  
/boot/initrd.img-2.6.32-2.slh.1-sidux-686 
} 
menuentry "Debian GNU/Linux, with Linux
2.6.32-2.slh.1-sidux-686(recovery mode)" { 
        insmod ext2 set root=(hd1,1)
        search --no-floppy --fs-uuid --set
2f46ee2d-3ac0-46f8-af61-311252327898
linux   /boot/vmlinuz-2.6.32-2.slh.1-sidux-686 
root=UUID=2f46ee2d-3ac0-46f8-af61-311252327898 ro single vga=791 
        initrd  /boot/initrd.img-2.6.32-2.slh.1-sidux-686 
} 
### END /etc/grub.d/10_linux ###

### BEGIN /etc/grub.d/20_memtest86+ ###
menuentry "Memory test (memtest86+)"  {
        insmod ext2
        set root=(hd1,1)
        search --no-floppy --fs-uuid --set
2f46ee2d-3ac0-46f8-af61-311252327898 
        linux16 /boot/memtest86+.bin
}
menuentry "Memory test (memtest86+, serial console 115200)" {
        insmod ext2
        set root=(hd1,1)
        search --no-floppy --fs-uuid --set
2f46ee2d-3ac0-46f8-af61-311252327898 
        linux16 /boot/memtest86+.bin console=ttyS0,115200n8 
}
### END /etc/grub.d/20_memtest86+ ###

### BEGIN /etc/grub.d/30_os-prober ###
menuentry "Microsoft Windows XP Professional (on /dev/sda1)" {
        insmod ntfs
        set root=(hd0,1)
        search --no-floppy --fs-uuid --set a61820aa18207b85
        drivemap -s (hd0) ${root}
        chainloader +1
}
### END /etc/grub.d/30_os-prober ###

### BEGIN /etc/grub.d/40_custom ###
# This file provides an easy way to add custom menu entries.  Simply
type the # menu entries you want to add after this comment.  Be careful
not to change # the 'exec tail' line above.
### END /etc/grub.d/40_custom ###

### BEGIN /etc/grub.d/60_fll-fromiso ###
menuentry "sidux-xfce (2.6.31-6.slh.2-sidux-686)" {
        insmod ext2
        set root=(hd1,1)
        search --no-floppy --fs-uuid --set
2f46ee2d-3ac0-46f8-af61-311252327898 
        loopback loop /opt/Isos/sidux-xfce.iso 
        linux (loop)/boot/vmlinuz-2.6.31-6.slh.2-sidux-686
fromhd=UUID=2f46ee2d-3ac0-46f8-af61-311252327898 
fromiso=/opt/Isos/sidux-xfce.iso boot=fll lang=en_EN TZ=UTC vga=791 quiet 
noeject nointro 
        initrd (loop)/boot/initrd.img-2.6.31-6.slh.2-sidux-686 
} 
### END /etc/grub.d/60_fll-fromiso 
### ***********************END /boot/grub/grub.cfg

-- System Information:
Debian Release: squeeze/sid
  APT prefers unstable
  APT policy: (500, 'unstable')
Architecture: i386 (i686)

Kernel: Linux 2.6.32-2.slh.1-sidux-686 (SMP w/2 CPU cores; PREEMPT)
Locale: LANG=de_DE.utf8, LC_CTYPE=de_DE.utf8 (charmap=UTF-8)
Shell: /bin/sh linked to /bin/dash

Versions of packages grub-pc depends on:
ii  debconf [debconf-2.0]       1.5.28          Debian configuration management 
sy 
ii  grub-common 1.98~20091210-1 GRand Unified Bootloader,version 
ii  libc6                       2.10.2-2        GNU C Library: Shared libraries 
ii ucf                  3.0025 Update Configuration File: preserv


grub-pc recommends no packages.

Versions of packages grub-pc suggests:
pn  desktop-base                  <none>     (no description available)

-- debconf information:
  grub2/kfreebsd_cmdline:
  grub2/linux_cmdline:
  grub-pc/chainload_from_menu.lst: true
  grub-pc/kopt_extracted: false
  grub-pc/install_devices:
  grub-pc/postrm_purge_boot_grub: false
  grub2/kfreebsd_cmdline_default: quiet
  grub2/linux_cmdline_default: quiet




If you need more information feel free to ask for

Joaquim

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