File too large error unpacking War during app deploy - RHEL &WLS 10.3.5

I'm stumped and I'm hoping someone can help out here. Does anyone have any insights into the cause of my problem below, or tips on how to diagnose the cause?
scenario
We ran into an open files limit issue on our RH Linux servers, and had the SA boost the our open files limit fro 1024 to 3096. This seems to have solved the open files limit issue, once we restarted the node managers and the managed servers (our WLS startup script sets the soft limit to the hard limit).
But now we've got a new issue, right after this change. The admin server is now no longer able to deploy and war/ear, as when I click on "Activate" after the install I get
Message icon - Error An error occurred during activation of changes, please see the log for details.
Message icon - Error Failed to load webapp: 'TemplateManagerAdmin-1.0-SNAPSHOT.war'
Message icon - Error File too large
on the console, and see the stack trace below in the Admin server log (nothing in the managed server logs) - indicating it's getting the error in exploding the war.
I've tried both default deployment mode, and the mode "will make the deployment available in the following location" where the war is manually copied to the same location on each box, available to each server - all with the same result. I've also tried restarting the admin server, but no luck.
The files are not overly large (<=34 MByte) and we had no trouble with them before today. I'm able to log in as the WebLogic user and copye files, etc. with no problem.
There is no disk space issue - plenty of space left on all of our filesystems. There is, as far as I can tell, no OS or user file size limit issue:
 -bash-3.2$ ulimit -a
 core file size (blocks, -c) 0
 data seg size (kbytes, -d) unlimited
 scheduling priority (-e) 0
 file size (blocks, -f) unlimited
 pending signals (-i) 73728
 max locked memory (kbytes, -l) 32
 max memory size (kbytes, -m) unlimited
 open files (-n) 3096
 pipe size (512 bytes, -p) 8
 POSIX message queues (bytes, -q) 819200
 real-time priority (-r) 0
 stack size (kbytes, -s) 10240
 cpu time (seconds, -t) unlimited
 max user processes (-u) unlimited
 virtual memory (kbytes, -v) unlimited
 file locks (-x) unlimited
environment
WLS 10.3.5 64-bit
Linux 64-bit RHEL 5.6
Sun Hotspot 1.6.0_29 (64--bit)
stack trace
####<Mar 6, 2013 4:09:33 PM EST> <Error> <Console> <nj09mhm5111> <prp_appsvcs_admin> <[ACTIVE] ExecuteThread: '3' for queue: 'weblogic.kernel.Default (self-tuning)'> <steven_elkind> <> <> <1362604173724> <BEA-240003> <Console encountered the following error weblogic.application.ModuleException: Failed to load webapp: 'TemplateManagerAdmin-1.0-SNAPSHOT.war'
at weblogic.servlet.internal.WebAppModule.prepare(WebAppModule.java:393)
at weblogic.application.internal.flow.ScopedModuleDriver.prepare(ScopedModuleDriver.java:176)
at weblogic.application.internal.flow.ModuleListenerInvoker.prepare(ModuleListenerInvoker.java:199)
at weblogic.application.internal.flow.DeploymentCallbackFlow$1.next(DeploymentCallbackFlow.java:517)
at weblogic.application.utils.StateMachineDriver.nextState(StateMachineDriver.java:52)
at weblogic.application.internal.flow.DeploymentCallbackFlow.prepare(DeploymentCallbackFlow.java:159)
at weblogic.application.internal.flow.DeploymentCallbackFlow.prepare(DeploymentCallbackFlow.java:45)
at weblogic.application.internal.BaseDeployment$1.next(BaseDeployment.java:613)
at weblogic.application.utils.StateMachineDriver.nextState(StateMachineDriver.java:52)
at weblogic.application.internal.BaseDeployment.prepare(BaseDeployment.java:184)
at weblogic.application.internal.SingleModuleDeployment.prepare(SingleModuleDeployment.java:43)
at weblogic.application.internal.DeploymentStateChecker.prepare(DeploymentStateChecker.java:154)
at weblogic.deploy.internal.targetserver.AppContainerInvoker.prepare(AppContainerInvoker.java:60)
at weblogic.deploy.internal.targetserver.operations.ActivateOperation.createAndPrepareContainer(ActivateOperation.java:207)
at weblogic.deploy.internal.targetserver.operations.ActivateOperation.doPrepare(ActivateOperation.java:98)
at weblogic.deploy.internal.targetserver.operations.AbstractOperation.prepare(AbstractOperation.java:217)
at weblogic.deploy.internal.targetserver.DeploymentManager.handleDeploymentPrepare(DeploymentManager.java:747)
at weblogic.deploy.internal.targetserver.DeploymentManager.prepareDeploymentList(DeploymentManager.java:1216)
at weblogic.deploy.internal.targetserver.DeploymentManager.handlePrepare(DeploymentManager.java:250)
at weblogic.deploy.internal.targetserver.DeploymentServiceDispatcher.prepare(DeploymentServiceDispatcher.java:159)
at weblogic.deploy.service.internal.targetserver.DeploymentReceiverCallbackDeliverer.doPrepareCallback(DeploymentReceiverCallbackDeliverer.java:171)
at weblogic.deploy.service.internal.targetserver.DeploymentReceiverCallbackDeliverer.access$000(DeploymentReceiverCallbackDeliverer.java:13)
at weblogic.deploy.service.internal.targetserver.DeploymentReceiverCallbackDeliverer$1.run(DeploymentReceiverCallbackDeliverer.java:46)
at weblogic.work.SelfTuningWorkManagerImpl$WorkAdapterImpl.run(SelfTuningWorkManagerImpl.java:528)
at weblogic.work.ExecuteThread.execute(ExecuteThread.java:209)
at weblogic.work.ExecuteThread.run(ExecuteThread.java:178)
Caused by: java.io.IOException: File too large
at java.io.FileOutputStream.writeBytes(Native Method)
at java.io.FileOutputStream.write(FileOutputStream.java:282)
at weblogic.utils.io.StreamUtils.writeTo(StreamUtils.java:19)
at weblogic.utils.FileUtils.writeToFile(FileUtils.java:117)
at weblogic.utils.jars.JarFileUtils.extract(JarFileUtils.java:285)
at weblogic.servlet.internal.ArchivedWar.expandWarFileIntoDirectory(ArchivedWar.java:139)
at weblogic.servlet.internal.ArchivedWar.extractWarFile(ArchivedWar.java:108)
at weblogic.servlet.internal.ArchivedWar.<init>(ArchivedWar.java:57)
at weblogic.servlet.internal.War.makeExplodedJar(War.java:1093)
at weblogic.servlet.internal.War.<init>(War.java:186)
at weblogic.servlet.internal.WebAppServletContext.processDocroot(WebAppServletContext.java:2789)
at weblogic.servlet.internal.WebAppServletContext.setDocroot(WebAppServletContext.java:2666)
at weblogic.servlet.internal.WebAppServletContext.<init>(WebAppServletContext.java:413)
at weblogic.servlet.internal.WebAppServletContext.<init>(WebAppServletContext.java:493)
at weblogic.servlet.internal.HttpServer.loadWebApp(HttpServer.java:418)
at weblogic.servlet.internal.WebAppModule.registerWebApp(WebAppModule.java:972)
at weblogic.servlet.internal.WebAppModule.prepare(WebAppModule.java:382)

In the end, the problem was not in the Admin server where the log entry is, but in one of the managed servers where there was no such log entry.
Somehow, and we have no idea how, the NodeManager process had the soft limit for max file size set to 2k blocks. Thus, the managed server inherited that. We restarted the Node Manager, then the managed server, and the problem went away.
The diagnostic that turned the trick:
cat /proc/<pid>/limits
for the managed server showed the bad limit setting, then diagnosis proceeded from there. The admin server, of course, had "unlimited" since it was not the source of the problem.

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tar: Alex - External HD.apvault/Library/2003.approject/2007-03-24 @ 08\:17\:52 PM - 1.apimportgroup/IMG0187/Thumbnails/IMG0187.jpg: Read error at byte 0, reading 3840 bytes: Result too large
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tar: Alex - External HD.apvault/Library/Vacation Croatia 2006.approject/2007-03-25 @ 09\:47\:17 PM - 1.apimportgroup/IMG0490/IMG0490.jpg.apfile: Read error at byte 0, reading 1224 bytes: Result too large
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####<Nov 8, 2012 10:28:51 PM PST> <Notice> <WebLogicServer> <edrpoc10.ftb.ca.gov> <AdminServer> <main> <<WLS Kernel>> <> <> <1352442531304> <BEA-000365> <Server state changed to STARTING>
####<Nov 8, 2012 10:28:54 PM PST> <Warning> <oracle.as.jmx.framework.MessageLocalizationHelper> <edrpoc10.ftb.ca.gov> <AdminServer> <JMX FRAMEWORK Domain Runtime MBeanServer pooling thread> <<anonymous>> <> <0000JfZqpLg4ykJLQm5Eid1GbAAX000001> <1352442534039> <J2EE JMX-46041> <The resource for bundle "oracle.jrf.i18n.MBeanMessageBundle" with key "oracle.jrf.JRFServiceMBean.checkIfJRFAppliedOnMutipleTargets" cannot be found.>
####<Nov 8, 2012 10:28:57 PM PST> <Error> <Deployer> <edrpoc10.ftb.ca.gov> <AdminServer> <[ACTIVE] ExecuteThread: '0' for queue: 'weblogic.kernel.Default (self-tuning)'> <<WLS Kernel>> <> <> <1352442537493> <BEA-149205> <Failed to initialize the application 'adf.oracle.domain [LibSpecVersion=1.0,LibImplVersion=11.1.1.2.0]' due to error weblogic.application.library.LibraryDeploymentException: [J2EE:160141]Could not initialize the library Extension-Name: adf.oracle.domain, Specification-Version: 1, Implementation-Version: 11.1.1.2.0. Please ensure the deployment unit is a valid library type (war, ejb, ear, plain jar). weblogic.application.library.LibraryProcessingException: java.io.IOException: File too large
 at weblogic.application.internal.library.EarLibraryDefinition.init(EarLibraryDefinition.java:93)
 at weblogic.application.utils.LibraryLoggingUtils.initLibraryDefinition(LibraryLoggingUtils.java:277)
 at weblogic.application.internal.library.LibraryDeployment.prepare(LibraryDeployment.java:44)
 at weblogic.application.internal.DeploymentStateChecker.prepare(DeploymentStateChecker.java:154)
 at weblogic.deploy.internal.targetserver.AppContainerInvoker.prepare(AppContainerInvoker.java:60)
 at weblogic.deploy.internal.targetserver.AppDeployment.prepare(AppDeployment.java:141)
 at weblogic.management.deploy.internal.DeploymentAdapter$1.doPrepare(DeploymentAdapter.java:39)
 at weblogic.management.deploy.internal.DeploymentAdapter.prepare(DeploymentAdapter.java:191)
 at weblogic.management.deploy.internal.AppTransition$1.transitionApp(AppTransition.java:21)
 at weblogic.management.deploy.internal.ConfiguredDeployments.transitionApps(ConfiguredDeployments.java:240)
 at weblogic.management.deploy.internal.ConfiguredDeployments.prepare(ConfiguredDeployments.java:165)
 at weblogic.management.deploy.internal.ConfiguredDeployments.deploy(ConfiguredDeployments.java:122)
 at weblogic.management.deploy.internal.DeploymentServerService.resume(DeploymentServerService.java:180)
 at weblogic.management.deploy.internal.DeploymentServerService.start(DeploymentServerService.java:96)
 at weblogic.t3.srvr.SubsystemRequest.run(SubsystemRequest.java:64)
 at weblogic.work.ExecuteThread.execute(ExecuteThread.java:209)
 at weblogic.work.ExecuteThread.run(ExecuteThread.java:178)
Caused by: java.io.IOException: File too large
 at java.io.FileOutputStream.writeBytes(Native Method)
 at java.io.FileOutputStream.write(FileOutputStream.java:282)
 at weblogic.utils.io.StreamUtils.writeTo(StreamUtils.java:19)
 at weblogic.utils.FileUtils.writeToFile(FileUtils.java:117)
 at weblogic.utils.jars.JarFileUtils.extract(JarFileUtils.java:285)
 at weblogic.utils.jars.JarFileUtils.extract(JarFileUtils.java:246)
 at weblogic.application.io.ExplodedJar.extractJarFile(ExplodedJar.java:301)
 at weblogic.application.io.ExplodedJar.<init>(ExplodedJar.java:54)
 at weblogic.application.io.Ear.<init>(Ear.java:47)
 at weblogic.application.internal.library.EarLibraryDefinition.init(EarLibraryDefinition.java:81)
 ... 16 more
####<Nov 8, 2012 10:28:59 PM PST> <Error> <Deployer> <edrpoc10.ftb.ca.gov> <AdminServer> <[ACTIVE] ExecuteThread: '0' for queue: 'weblogic.kernel.Default (self-tuning)'> <<WLS Kernel>> <> <> <1352442539037> <BEA-149205> <Failed to initialize the application 'emai' due to error weblogic.application.library.LibraryDeploymentException: [J2EE:160141]Could not initialize the library Extension-Name: emai. Please ensure the deployment unit is a valid library type (war, ejb, ear, plain jar). weblogic.application.library.LibraryProcessingException: java.io.IOException: File too large
Any pointers on resolving the issue?
Regards,
Sunny
Edited by: ajmerasunny on Nov 9, 2012 10:23 AM

Hi Sunny,
The issue is because in your OS AIX,You dont have the support for largefile .
How do you enable largefile support in AIX?
On file /etc/security/limits , change the value of "fsize" to -1 . "-1" denotes unlimited. Log-off and login , stop & start applications to make largefiles work.
Ref: http://unixfoo.blogspot.in/2008/11/aix-filesystem-tips.html

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