We normally only enable the DEBUG log level when we're actively testing or trying to diagnose a problem in a node. Is there any reason that you need to have the log level for actionlib set to DEBUG? Can you try setting it to INFO instead to see if that solves your load/logfile problems. If it doesn't, please let us know as that's a bug for the ROS logging system.

Ken can correct me if I'm wrong, but I believe in Python all logging statements get written to the log file even if they're not printed to the console.

Josh