cisco router loses configuration on reload even after saving it
Solution 1:
It sounds like you have a configuration register at the wrong setting. For instance, setting: confreg 0x2142 at an rommon will boot the router to a fresh/default mode. Trying entering config-register 0x2102 from an enable prompt to got back to booting from your configuration
Solution 2:
Rommon is probably set to ignore the startup-config.
Do a 'show version' and see if the configuration register is 0x2142. If it is you will have to change this to 0x2102.
Edit: Points to Andy he posted first.
Someone got half way through a password reset and gave up. http://www.cisco.com/en/US/products/hw/routers/ps274/products_password_recovery09186a0080094774.shtml