I split with: max-nodes=1300000
but also lower max-nodes will not help here...
Data is South-America from geofabrik.de

without --index everything runs fine. with --index all maps are created, but no tdb/basemap and 0kb mdr.img
South America is the only country extract where I found this error (does not happen in any european country, Asia, Australia-Oceania)

I ran mkgmap with the following options:
start /low /b /wait java -enableassertions -jar -Xmx2800M mkgmap.jar --index --max-jobs=3 --latin1 --delete-tags-file=deletetags --adjust-turn-headings --ignore-maxspeeds --ignore-turn-restrictions --remove-short-arcs=4 --location-autofill=1 --description=openmtbmap_%abr%_%date% --route --country-abbr=%abr% --style-file=new2 --country-name=%country% --mapname=%mapid%0000 --family-id=%mapid% --product-id=1 --series-name=openmtbmap_%abr%_%date% --family-name=mtbmap_%abr%_%date% --tdbfile --overview-mapname=mapset %mapid%0*.osm.gz

I have never seen this error mentioned so I though I will just send it in. It happens on mdr.img creation. without --index it works fine.

SCHWERWIEGEND (RouteArc): Way RP4 (id 26633902) contains an arc whose length is too big to be encoded so the road will not be routable
SCHWERWIEGEND (RouteArc): Way RP4 (id 26633902) contains an arc whose length is too big to be encoded so the road will not be routable
SCHWERWIEGEND (RouteArc): Way RP5 (id 37687380) contains an arc whose length is too big to be encoded so the road will not be routable
SCHWERWIEGEND (RouteArc): Way RP5 (id 37687380) contains an arc whose length is too big to be encoded so the road will not be routable
SCHWERWIEGEND (RoadNetwork): Road ruas (OSM id 39368817) contains zero length arc
SCHWERWIEGEND (RoadNetwork):   http://www.openstreetmap.org/?lat=-22.12247&lon=-51.40677&zoom=17
SCHWERWIEGEND (RoadNetwork): Road ruas (OSM id 39368817) contains zero length arc
SCHWERWIEGEND (RoadNetwork):   http://www.openstreetmap.org/?lat=-22.12245&lon=-51.40677&zoom=17
SCHWERWIEGEND (RoadNetwork): Road ruas (OSM id 39368877) contains zero length arc
SCHWERWIEGEND (RoadNetwork):   http://www.openstreetmap.org/?lat=-22.12247&lon=-51.40677&zoom=17
SCHWERWIEGEND (RoadNetwork): Road ruas (OSM id 39368877) contains zero length arc
SCHWERWIEGEND (RoadNetwork):   http://www.openstreetmap.org/?lat=-22.12245&lon=-51.40677&zoom=17
SCHWERWIEGEND (RouteArc): Way ♠MS-320 (id 31572666) contains an arc whose length is too big to be encoded so the road will not be routable
SCHWERWIEGEND (RouteArc): Way ♠MS-320 (id 31572666) contains an arc whose length is too big to be encoded so the road will not be routable
SCHWERWIEGEND (RouteArc): Way null (id 28294020) contains an arc whose length is too big to be encoded so the road will not be routable
SCHWERWIEGEND (RouteArc): Way null (id 28294020) contains an arc whose length is too big to be encoded so the road will not be routable
SCHWERWIEGEND (RoadNetwork): Road avenida ParaŻba (OSM id 23726122) contains zero length arc
SCHWERWIEGEND (RoadNetwork):   http://www.openstreetmap.org/?lat=-14.85369&lon=-40.85925&zoom=17
SCHWERWIEGEND (RouteArc): Way ♠BR-364 (id 23655710) contains an arc whose length is too big to be encoded so the road will not be routable
SCHWERWIEGEND (RouteArc): Way ♠BR-364 (id 23655710) contains an arc whose length is too big to be encoded so the road will not be routable
SCHWERWIEGEND (RouteArc): Way ♠BR-163 (id 31239020) contains an arc whose length is too big to be encoded so the road will not be routable
SCHWERWIEGEND (RouteArc): Way ♠BR-163 (id 31239020) contains an arc whose length is too big to be encoded so the road will not be routable
SCHWERWIEGEND (RouteArc): Way ♠BR-174 (id 28957743) contains an arc whose length is too big to be encoded so the road will not be routable
SCHWERWIEGEND (RouteArc): Way ♠BR-174 (id 28957743) contains an arc whose length is too big to be encoded so the road will not be routable
Regions for map:
Exception in thread "main" java.lang.AssertionError: Invalid label offset found 2460949
        at uk.me.parabola.imgfmt.app.lbl.LBLFileReader.fetchLabel(LBLFileReader.java:83)
        at uk.me.parabola.imgfmt.app.lbl.LBLFileReader.readPoiInfo(LBLFileReader.java:348)
        at uk.me.parabola.imgfmt.app.lbl.LBLFileReader.<init>(LBLFileReader.java:71)
        at uk.me.parabola.imgfmt.app.map.MapReader.<init>(MapReader.java:80)
        at uk.me.parabola.mkgmap.combiners.MdrBuilder.onMapEnd(MdrBuilder.java:108)
        at uk.me.parabola.mkgmap.main.Main.endOptions(Main.java:361)
        at uk.me.parabola.mkgmap.CommandArgsReader.readArgs(CommandArgsReader.java:124)
        at uk.me.parabola.mkgmap.main.Main.main(Main.java:122)