fix: high severity memory leaks and bugs

- Add warningTimer to AgentContext and clean it up in cleanupAgent
- Clear all state in subagent-watcher stop() for clean restart
- Add cleanupStaleAgents() to remove completed agents older than 24h
- Delete pendingToolCalls entries after lookup to prevent memory leak
- Add FSWatcher error handlers to prevent unhandled exceptions
- Bump version to 0.1382

Co-Authored-By: Claude Opus 4.5 <noreply@anthropic.com>

CLAUDE.md

@@ -21,7 +21,7 @@ When user says "COM": 1) Increment version in BOTH `package.json` AND `CLAUDE.md
 
 Claudeman is a Claude Code session manager with a web interface and autonomous Ralph Loop. It spawns Claude CLI processes via PTY, streams output in real-time via SSE, and supports scheduled/timed runs.
 
-**Version**: 0.1381 (must match `package.json`)
+**Version**: 0.1382 (must match `package.json`)
 
 **Tech Stack**: TypeScript (ES2022/NodeNext, strict mode), Node.js, Fastify, Server-Sent Events, node-pty
 

package.json

@@ -1,6 +1,6 @@
 {
   "name": "claudeman",
-  "version": "0.1381",
+  "version": "0.1382",
   "description": "The missing control plane for Claude Code - run 20 autonomous agents with real-time monitoring and session persistence",
   "type": "module",
   "main": "dist/index.js",

src/spawn-orchestrator.ts

@@ -545,6 +545,7 @@ export class SpawnOrchestrator extends EventEmitter {
       parentSessionId: task.parentSessionId,
       depth: task.depth,
       timeoutTimer: null,
+      warningTimer: null,
       progressTimer: null,
       status: 'initializing',
       startedAt: null,
@@ -688,9 +689,9 @@ export class SpawnOrchestrator extends EventEmitter {
   private setupTimeout(agent: AgentContext): void {
     const timeoutMs = agent.task.spec.timeoutMinutes * 60 * 1000;
 
-    // Warning at 90%
+    // Warning at 90% - store timer for cleanup
     const warningMs = timeoutMs * 0.9;
-    setTimeout(() => {
+    agent.warningTimer = setTimeout(() => {
       if (agent.status === 'running' && this._sessionCreator && agent.sessionId) {
         this._sessionCreator.writeToSession(
           agent.sessionId,
@@ -818,6 +819,10 @@ export class SpawnOrchestrator extends EventEmitter {
       clearTimeout(agent.timeoutTimer);
       agent.timeoutTimer = null;
     }
+    if (agent.warningTimer) {
+      clearTimeout(agent.warningTimer);
+      agent.warningTimer = null;
+    }
     if (agent.progressTimer) {
       clearInterval(agent.progressTimer);
       agent.progressTimer = null;

src/spawn-types.ts

@@ -259,6 +259,8 @@ export interface AgentContext {
   depth: number;
   /** Timeout timer handle */
   timeoutTimer: NodeJS.Timeout | null;
+  /** Warning timer handle (fires at 90% of timeout) */
+  warningTimer: NodeJS.Timeout | null;
   /** Progress poll timer handle */
   progressTimer: NodeJS.Timeout | null;
   /** Current status */

src/subagent-watcher.ts

@@ -272,6 +272,39 @@ export class SubagentWatcher extends EventEmitter {
     this.pendingToolCalls.clear();
   }
 
+  /**
+   * Clean up stale completed agents to prevent unbounded memory growth
+   * Removes agents that have been completed for longer than STALE_AGENT_MAX_AGE_MS
+   */
+  private cleanupStaleAgents(): void {
+    const now = Date.now();
+    const agentsToDelete: string[] = [];
+
+    for (const [agentId, info] of this.agentInfo) {
+      if (info.status === 'completed') {
+        const lastActivity = new Date(info.lastActivityAt).getTime();
+        if (now - lastActivity > STALE_AGENT_MAX_AGE_MS) {
+          agentsToDelete.push(agentId);
+        }
+      }
+    }
+
+    for (const agentId of agentsToDelete) {
+      const info = this.agentInfo.get(agentId);
+      if (info) {
+        // Clean up all associated resources
+        this.agentInfo.delete(agentId);
+        this.pendingToolCalls.delete(agentId);
+        this.filePositions.delete(info.filePath);
+        const watcher = this.fileWatchers.get(info.filePath);
+        if (watcher) {
+          watcher.close();
+          this.fileWatchers.delete(info.filePath);
+        }
+      }
+    }
+  }
+
   /**
    * Get all known subagents
    */
@@ -744,6 +777,13 @@ export class SubagentWatcher extends EventEmitter {
         }
       });
 
+      // Handle watcher errors to prevent unhandled exceptions
+      watcher.on('error', (error) => {
+        this.emit('subagent:error', error instanceof Error ? error : new Error(String(error)));
+        this.dirWatchers.delete(dir);
+        this.knownSubagentDirs.delete(dir);
+      });
+
       this.dirWatchers.set(dir, watcher);
     } catch {
       // Watch failed
@@ -836,6 +876,12 @@ export class SubagentWatcher extends EventEmitter {
         }
       });
 
+      // Handle watcher errors to prevent unhandled exceptions
+      watcher.on('error', (error) => {
+        this.emit('subagent:error', error instanceof Error ? error : new Error(String(error)), agentId);
+        this.fileWatchers.delete(filePath);
+      });
+
       this.fileWatchers.set(filePath, watcher);
       this.resetIdleTimer(agentId);
     } catch {
@@ -997,7 +1043,10 @@ export class SubagentWatcher extends EventEmitter {
           } else if (content.type === 'tool_result' && content.tool_use_id) {
             // Extract tool result
             const resultContent = this.extractToolResultContent(content.content);
-            const toolName = this.pendingToolCalls.get(agentId)?.get(content.tool_use_id);
+            const agentPendingCalls = this.pendingToolCalls.get(agentId);
+            const toolName = agentPendingCalls?.get(content.tool_use_id);
+            // Delete after lookup to prevent memory leak
+            agentPendingCalls?.delete(content.tool_use_id);
 
             const toolResult: SubagentToolResult = {
               agentId,
@@ -1044,7 +1093,10 @@ export class SubagentWatcher extends EventEmitter {
         for (const content of entry.message.content) {
           if (content.type === 'tool_result' && content.tool_use_id) {
             const resultContent = this.extractToolResultContent(content.content);
-            const toolName = this.pendingToolCalls.get(agentId)?.get(content.tool_use_id);
+            const agentPendingCalls = this.pendingToolCalls.get(agentId);
+            const toolName = agentPendingCalls?.get(content.tool_use_id);
+            // Delete after lookup to prevent memory leak
+            agentPendingCalls?.delete(content.tool_use_id);
 
             const toolResult: SubagentToolResult = {
               agentId,