flexfax: Faxmail error? HELP!!!

[Patrick Gardella <patrick@cre8tivegroup.com>]

I am running Hylafax 4.0pl1 on FreeBSD 2.2.1 on a Pentium 200 with 128 Megs
RAM.  Sendmail is 8.8.5.  Modems are seven Multitech Multimodems 2834ZDX on a Cy
clades8Yo multiport serial card. I'm sending this to both the HylaFAX and 
FreeBSD lists to get input from both parties. 

I've got a high volume email to fax server set up that processes up to 2500 
faxes a day.  (1500 is typical.)  It takes a while, but works through them.  
No other major apps are running on the system besides sending faxes.

I got a number of the following messages today.

   ----- The following addresses had permanent fatal errors -----
"|/usr/local/bin/faxmail -d -n joe@202-224-6079"
    (expanded from: <joe@dc.numbersusa.com>)

   ----- Transcript of session follows -----
Cannot fork
554 "|/usr/local/bin/faxmail -d -n joe@202-224-6079"... unknown mailer
error 2

All of them had the error code 2 that says "Cannot fork"

I've included some stats on the system to provide some clues to what
might be happening.

/etc/sendmail.cf had MaxDaemonChild and ConnectionRateThrottle commented
out, so they are not limiting the number of fork children sendmail has.

The kernel is compiled with  "maxusers" as 40 giving me 656 processes.

SO.  What is happening?  Which is it that cannot fork?  faxmail?  or sendmail?
What you see here is the limit of my knowledge in this area!

Can anyone suggest a fix?

Patrick

#df
Filesystem  1K-blocks     Used    Avail Capacity  Mounted on
/dev/wd0a       63567    30929    27553    53%    /
/dev/wd0s2f   3984516   515008  3150747    14%    /usr
/dev/wd0s2e     29727     4483    22866    16%    /var
procfs              4        4        0   100%    /proc
#top
last pid: 22278;  load averages:  0.55,  0.74,  0.87                 08:45:55
42 processes:  2 running, 39 sleeping, 1 zombie
CPU states: 40.1% user,  0.0% nice, 59.9% system,  0.0% interrupt,  0.0% idle
Mem: 64M Active, 5508K Inact, 23M Wired, 68K Cache, 3177K Buf, 32M Free
Swap: 264M Total, 64K Used, 264M Free

  PID USERNAME PRI NICE SIZE    RES STATE    TIME   WCPU    CPU COMMAND
  156 root     57   0  2032K  2372K RUN    716:07 39.25% 39.25% faxq
  169 root      2   0   540K   728K select 183:03  0.23%  0.23% ppp
22276 root     28   0   304K   856K RUN      0:00  0.21%  0.15% top
22278 root      3   0   556K  1376K cydtr    0:00  0.63%  0.11% faxsend
20139 root     18   0   640K   960K pause    0:00  0.00%  0.00% tcsh
  142 root     18   0   500K   812K pause    3:59  0.00%  0.00% httpd
  102 root     18   0   332K   448K pause    0:16  0.00%  0.00% cron
   22 root     18   0   200K    80K pause    0:00  0.00%  0.00% adjkerntz
    1 root     10   0   456K   164K wait     0:05  0.00%  0.00% init
22254 root      3   0   600K  1456K ttyin    0:00  0.00%  0.00% faxsend
22200 root      3   0   576K  1420K ttyin    0:00  0.00%  0.00% faxsend
22277 root      3   0   576K  1420K ttyin    0:00  0.00%  0.00% faxsend
22258 root      3   0   576K  1420K ttyin    0:00  0.00%  0.00% faxsend
  214 root      3   0   164K   488K ttyin    0:00  0.00%  0.00% getty
  213 root      3   0   164K   488K ttyin    0:00  0.00%  0.00% getty
  974 root      3   0   164K   416K ttyin    0:00  0.00%  0.00% getty
  210 root      2   0   572K   984K select   0:38  0.00%  0.00% faxgetty