Scott,

> Amavisd version is :  amavisd-new-2.3.0

Consider upgrading to 2.3.3.

> About every 4-5 days, email will stop sending/receiving, and I get the
> following error in my amavisd log file.

> Oct  1 16:14:41 ns1 /usr/local/sbin/amavisd[16241]: (16241-03) ESMTP>
> 451 4.5.0 Error in processing, id=16241-03, mime_decode-1 FAILED:
> run_command (open pipe):
> Can't fork at /usr/lib/perl5/5.8.3/i586-linux-thread-multi/IO/File.pm
> line 176. at /usr/local/sbin/amavisd line 1783.

Like Gary said, check for resource depletion, like swap space full.
On some OS a tmpfs maps into swap. 

> After rebooting, amavisd will fail (kicked off via rc.local) with the
> following error:

> Oct  1 16:28:34 ns1 /usr/local/sbin/amavisd[1015]: SpamControl:
> initializing Mail::SpamAssassin
> Oct  1 16:28:34 ns1 /usr/local/sbin/amavisd[1015]:
> TROUBLE in pre_loop_hook: Error creating a DNS resolver socket:
>   Network is unreachable
> at /usr/lib/perl5/site_perl/5.8.3/Mail/SpamAssassin/DnsResolver.pm line 202.

The code there does:
    $sock = IO::Socket::INET->new(%args);
    $errno = $!;
    die "Error creating a DNS resolver socket: $errno";

It appears the IO::Socket::INET->new fails to connect
to resolver socket because "Network is unreachable"
(assuming you are not using IPv6 network addresses
to access local resolver)

If you are using remote resolver in /etc/resolve.conf,
consider having a locally running 'named' as a caching-only DNS server.

> After this, if I manually run /usr/local/sbin/amavisd it will start
> successfully.

Seems like the network is not fully up by the time amavisd
is being started. Perhaps you need to reorder startup sequence.

> The second part only started after I did the most recent update of
> SpamAssassin (SA version 3.1.0)

SA 3.1 does DNS resolver setup differently in order to be able
to work around Net::DNS problems that were affecting SA 3.0.x.

  Mark


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