Oh, does this sound familiar.  I used to run into PermGen exhaustion
all the time.  The only thing to do was to kill -KILL Tomcat, raise
MaxPermSize, restart, and watch it with e.g. LambdaProbe to see if we
were getting into trouble again.  I eventually settled on the same
number you did:  MaxPermSize=128M.

The state that it can get out of with patience sounds to me like you
are short of heap, as you apparently suspect.  My guess is that it's
spending much time in the garbage collector but is gleaning enough
memory to make a very little progress before it has to GC again.  You
should find it helpful to sample the VM's memory management stat.s
repeatedly and see how close to your limits you are running.

If I thought that GC was being triggered by memory starvation more
than a few times a day, I'd raise the heap maximum until the periodic
GC is able to maintain sufficient free memory for all but the most
demanding usage spikes.  More than that probably just makes GC cycles
more noticeable without any benefit.

-- 
Mark H. Wood, Lead System Programmer   [email protected]
Balance your desire for bells and whistles with the reality that only a 
little more than 2 percent of world population has broadband.
        -- Ledford and Tyler, _Google Analytics 2.0_

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