So trying to make sense out of this issue...and we are doing it MY way this time.

Ordered a headmaster and I'll be going back and replacing it. Its the only thing that makes sense.
Noise tends to happen right at 235psi which is right at the valve's modulating point and if the head pressure rises above to the point where the valve shouldnt be doing anything, the noise is gone.

Maybe the "jose" at the Manitowoc factory got the factory headmaster too hot when it was brazed in and now the rubber diaphragm inside is making that noise.

Thanks for all the feedback and help guys, I'll let you know how it turns out.
Gotta pull the charge....AGAIN..haha

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