OK, time to start recreating my work in an older version of the project.
1. The PicCache was on D, not on C as I was told.
2. The size was set in the configuration file as 500 MB. The file on the disk was bigger than that. (How?) I changed the size to 1500.
3. I unfroze all the frozen VIs.
4. I deleted Dim Pro, in case that was the issue.
The project will play about one third of the way through before it stops and Sonar locks up.