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I've had the same problem several times. I think it's due to floating point rounding errors. You can check that the current joint values are a bit off the limit specified in the URDF. Often moving the joints a little bit usually helps.

We usually save "safe" poses using the pr2_control_gui an we load them at startup. Please let me know if you need help with using the gui (which is at the moment undocumented but quite straightforward to use).