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I have to disagree with this. I've have run into problems on systems before where the return dumped into the top of the tank. You can create bubbles in the fluid when the return fluid free falls into the fluid in the sump. It's ok to run the return into the side of the tank but it needs to be...

I think we've found most of the problem. Until you get the oil to quit foaming, the setup will never work right. With how you had the gauge installed, even if everything is working like it should, the gauge should read near zero.

I'm pretty sure it's a cavatatation issue in the latest vid. Look inside the tank and see if you see a bunch of bubbles. Where was the gauge connected?

Flow restriction won't limit your line pull (and work as a shear pin). You'll still have full system pressure, just at a reduced flow. A pressure relief valve is what prevents hyd overload. All a restrictor will do is slow it down. You could add a adjustable flow control valve and tune the...

That may be your problem. You're trying to push 5 gpm into a 3.5 gpm winch. It just depends what they are calling a "restrictor". If it's just a restriction in the system, it will cause you problems trying to push 5 gpm into it. If it's some other valve that will just divert anything above 3.5...

What is the GPM of the pump? What is the GPM of the winch? It would also help if your suction and return lines were as far away from one another as possible. Another solution that may help would be to just install a "tee" in the bottom of the tank and have the suction and return hoses tied...