Hi,

the help file says 
merge-lines
< ... >
        At the moment this option causes routing errors. Use only if routing 
        is not needed in your map. 

Maybe I found the reason for the routing errors:
If the segments of a road are merged, it might happen that the 
LineSplitterFilter has to split it because it has more than 250 points.
The current implementation of LineSplitterFilter does this:
The first part of a road is added as a road, all remaining parts are added
as lines.
With a simple change all parts are added as roads:
Index: LineSplitterFilter.java
===================================================================
--- LineSplitterFilter.java     (revision 2581)
+++ LineSplitterFilter.java     (working copy)
@@ -84,7 +84,7 @@
                                        log.debug("saving next part");
                                l.setPoints(coords);
                                next.doFilter(l);
-                               l = new MapLine(line);
+                               l = line.copy();
 
                                count = 0;
                                first = false;



The interesting part for me is that the following routines seem to expect
exactly this, but parts of the code was never executed. 
See also 
http://gis.19327.n5.nabble.com/PATCH-v1-highwayCount-tp5748554p5748864.html

I also wonder if it really makes sense to limit the check "Non-routable way
with routable type ..." to resolution 24. I'll try to find out more
tomorrow.

Gerd



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