Sendmail message size issue

[mlewis54]

I have an odd problem with sendmail. I have a php program that emails the results of a search to a user at their request. The result is an html formatted email. When the size gets to approximately 185,000 characters in size the message is queued (essentially forever) in the /var/spool/clientmqueue directory. Anything less than this goes through fine. These are the lines from the maillog file when the email is successully sent:

Mar 14 10:02:10 xxxx sendmail[22907]: r2EF27IE022907: from=daemon, size=249420, class=0, nrcpts=1, msgid=<201303141502.r2EF27IE022907ATxxxxx.net>, relay=daemon at localhost
Mar 14 10:02:19 xxxx sendmail[22909]: r2EF2DGL022909: from=<daemonATxxxxDOTnet>, size=249606, class=0, nrcpts=1, msgid=<201303141502.r2EF27IE022907 xxxxDOTnet>, proto=ESMTP, daemon=MTA, relay=localhost.localdomain [127.0.0.1]
Mar 14 10:02:40 xxxx sendmail[22907]: r2EF27IE022907: to=USERNAME <userATsomedomain.com>, ctladdr=daemon (2/2), delay=00:00:33, xdelay=00:00:27, mailer=relay, pri=279420, relay=[127.0.0.1] [127.0.0.1], dsn=2.0.0, stat=Sent (r2EF2DGL022909 Message accepted for delivery)

These are the lines that are in the log file when the message gets stuck in the queue:

Mar 14 10:03:10 xxxx sendmail[22927]: r2EF336W022927: from=daemon, size=250092, class=0, nrcpts=1, msgid=<201303141503.r2EF336W022927ATxxxx.net>, relay=daemonATlocalhost
Mar 14 10:03:10 xelent sendmail[22927]: r2EF336W022927: to=USERNAME <userATsomedomain.com>, delay=00:00:07, mailer=relay, pri=280092, stat=queued

The interesting this is the size. The 185,000 characters I referenced above is the size of the message delivered to my mail function. It does not include headers and other overhead. I am assuming based on the message sizes above that 250,000 characters is the message size limit.

Checking my sendmail.cf file, the maximum message size parameter is:

#O MaxMessageSize=0

Which I believe has always defaulted to no max message size. Is this correct? If so, what could be causing the problem? It's not the receiving system since I can force the messages from the queue by manually placing them in the mqueue directory and running sendmail -q and the mail is sent and is received normally.

Because I don't have 15 posts I had to convert all the 'AT signs' to AT and remove the URLs.

[Segfault]

#O MaxMessageSize=0

This is commented out, remove #.

[mlewis54]

This is commented out, remove #.

That has already been commented out and set to a value of 10,000,000. According to the documentation that I found if it is not specified it will default to no size restriction.