High Intercooler level

[Grizzly]

I like following Ranger, You ask all the correct Questions my friend.
Mark.
You obviously given your series of questions have lost control of your system.
Here is a guess.
Your surge drum control has been lost due say to a malfunctioning level control?
Your liquid makeup line solenoid valve to the inter cooler is Passing.
Which in itself would not always be an issue, but if the level in the surge drum was artificially high the system charge would look for a new home!
It's just possible that your liquid could then migrate to the inter cooler.
To identify one problem is hard, when you have 2 or more then you have to go back to basics and start at the beginning.

OH! by the way if you do have an actual high inter cooler high level on start-up?
Then that could be the reason why you pump is cavitating.

A classic case of the charge gone walk about!

I have seen many systems loose control, simply because the oil in the system is in the wrong place.
When was the last time you oil drained, does the oil separator have a bleed line back to the level column?
What is the oil level in the oil separator?
There are loads of questions, rather than trying to control an efficient piece of kit like the comp / oil pump.

Step back and try and confirm where you are actually loosing control.
Ask where is the difference in settings / levels from the norm.
Most of all let us know how you get on, so we all can learn from this!
good luck Grizzly.