diff --git a/cylc/uiserver/resolvers.py b/cylc/uiserver/resolvers.py
index ca0c778d..2ce7f493 100644
--- a/cylc/uiserver/resolvers.py
+++ b/cylc/uiserver/resolvers.py
@@ -22,6 +22,7 @@
 import errno
 from getpass import getuser
 import os
+import re
 import signal
 from subprocess import (
     DEVNULL,
@@ -53,6 +54,8 @@
 from cylc.flow.scripts.clean import CleanOptions, run
 from cylc.flow.util import natural_sort_key
 
+from cylc.uiserver.utils import cast_non_null
+
 if TYPE_CHECKING:
     from concurrent.futures import Executor
     from logging import Logger
@@ -357,9 +360,17 @@ async def play(
         return cls._return('Workflow(s) started')
 
     @staticmethod
-    async def enqueue(stream, queue):
-        async for line in stream:
-            await queue.put(line.decode())
+    async def enqueue(
+        stream: asyncio.StreamReader, queue: asyncio.Queue[str | Exception]
+    ):
+        try:
+            async for line in stream:
+                await queue.put(line.decode())
+        except Exception as exc:
+            if re.match(r'Separator .+ chunk .+ limit', str(exc)):
+                await queue.put(ValueError('line too long'))
+            else:
+                await queue.put(exc)
 
     @classmethod
     async def cat_log(cls, id_: Tokens, app: 'CylcUIServer', info, file=None):
@@ -382,15 +393,18 @@ async def cat_log(cls, id_: Tokens, app: 'CylcUIServer', info, file=None):
         # For info, below subprocess is safe (uses shell=false by default)
         proc = await asyncio.subprocess.create_subprocess_exec(
             *cmd,
+            limit=200 * 1024,  # increase line limit to 200 kiB
             stdout=asyncio.subprocess.PIPE,
             stderr=asyncio.subprocess.PIPE,
         )
         buffer: List[str] = []
-        queue: asyncio.Queue = asyncio.Queue()
+        queue: asyncio.Queue[str | Exception] = asyncio.Queue()
         # Farm out reading from stdout stream to a background task
         # This is to get around problem where stream is not EOF until
         # subprocess ends
-        enqueue_task = asyncio.create_task(cls.enqueue(proc.stdout, queue))
+        enqueue_task = asyncio.create_task(
+            cls.enqueue(cast_non_null(proc.stdout), queue)
+        )
 
         # GraphQL operation ID
         op_id = info.root_value
@@ -445,18 +459,25 @@ async def cat_log(cls, id_: Tokens, app: 'CylcUIServer', info, file=None):
                         }
                         break
 
-                    elif line_count == 0:
+                    line = await queue.get()
+
+                    if isinstance(line, Exception):
+                        yield {'lines': buffer}
+                        yield {'error': f"Error reading file: {line}"}
+                        app.log.warning(line)
+                        break
+
+                    if line_count == 0:
                         # this is the first line
                         # (this is a special line contains the file path)
                         line_count += 1
                         yield {
                             'connected': True,
-                            'path': (await queue.get())[2:].strip(),
+                            'path': line[2:].strip(),
                         }
                         continue
 
                     # read in the log lines and add them to the buffer
-                    line = await queue.get()
                     line_count += 1
                     buffer.append(line)
                     if len(buffer) >= 75:
diff --git a/cylc/uiserver/utils.py b/cylc/uiserver/utils.py
index 98f9cb66..5364aaae 100644
--- a/cylc/uiserver/utils.py
+++ b/cylc/uiserver/utils.py
@@ -14,16 +14,33 @@
 # along with this program.  If not, see <http://www.gnu.org/licenses/>.
 
 
-from typing import TYPE_CHECKING
+from typing import (
+    TYPE_CHECKING,
+    TypeVar,
+    cast,
+)
 
 from jupyter_server.auth.identity import PasswordIdentityProvider
 
+
 if TYPE_CHECKING:
-    from cylc.uiserver.handlers import CylcAppHandler
     from jupyter_server.auth.identity import (
         IdentityProvider as JPSIdentityProvider,
     )
 
+    from cylc.uiserver.handlers import CylcAppHandler
+
+
+_T = TypeVar('_T')
+
+
+def cast_non_null(var: _T | None) -> _T:
+    """Type cast an "Optional" variable to its non-None type.
+
+    Does not perform any runtime checks.
+    """
+    return cast('_T', var)
+
 
 def is_bearer_token_authenticated(handler: 'CylcAppHandler') -> bool:
     """Returns True if this request is bearer token authenticated.