Western DEFENDER User manual

October 15, 2019
Lit. No. 72451, Rev. 03
This manual supersedes all editions with an earlier date.
DEFENDER™ Compact Plow
Owner's Manual
Original Instructions
A DIVISION OF DOUGLAS DYNAMICS, LLC
CAUTION
Read this document before operating or
servicing snowplow.
Western Products, PO Box 245038, Milwaukee, WI 53224‑9538 • www.westernplows.com

Lit. No. 72451, Rev. 03 3 October 15, 2019
OWNER INFORMATION
Register your snowplow online at www.westernplows.com
Owner Name: ______________________________________________________________________________
Date Purchased: ____________________________________________________________________________
Dealer Name: ______________________________________________ Phone: _________________________
Dealer Address:_____________________________________________________________________________
Vehicle Model/Year: _________________________________________________________________________
Snowplow Model/Year: _______________________________________________________________________
Snowplow Type/Size: ______________________________________________ Weight: ______________ lb/kg
Ballast: No ___ Yes ___ Amount: ___________lb/kg
Hydraulic Unit Serial Number: __________________________________________________________________
Blade Serial Number: ________________________________________________________________________

Lit. No. 72451, Rev. 03 4 October 15, 2019

Lit. No. 72451, Rev. 03 5 October 15, 2019
TABLE OF CONTENTS
PREFACE................................................................... 6
SAFETY ..................................................................... 7
Safety Denitions.................................................. 7
Warning/Caution and Instruction Labels .............. 7
Safety Precautions................................................ 8
Hydraulic Safety.................................................... 8
Fuses .................................................................... 8
Personal Safety..................................................... 9
Fire and Explosion ................................................ 9
Cell Phones........................................................... 9
Ventilation ............................................................. 9
Battery Safety ....................................................... 9
Noise..................................................................... 9
Vibration................................................................ 9
Snowplow Weight ................................................. 9
VEHICLE APPLICATION INFORMATION ........... 10
GETTING TO KNOW YOUR SNOWPLOW .......... 11
Snowplow Components ...................................... 11
Vehicle Mount Kit ................................................ 11
Snowplow Headlamps ........................................ 11
Hydraulic Unit...................................................... 12
System Capacity .......................................... 12
Cab Controls....................................................... 12
MOUNTING SNOWPLOW TO VEHICLE.............. 13
OPERATING YOUR SNOWPLOW ........................ 14
Hand-Held Control.............................................. 14
Joystick Control................................................... 15
SECURITY GUARD™ System ........................... 17
Smooth Stop ....................................................... 19
One-Touch Float ................................................. 19
Blade Positions ................................................... 20
Snowplow Headlamp Check............................... 20
Blade Drop Speed Adjustment ........................... 21
Transporting the Snowplow ................................ 21
Driving and Plowing on Snow and Ice ................22
Plowing Snow .....................................................22
Parking with Snowplow Attached ....................... 24
Towing a Disabled or Stuck Vehicle.................... 24
Checking Hydraulic Fluid Level........................... 24
DETACHING SNOWPLOW FROM VEHICLE ...... 25
MAINTENANCE ...................................................... 26
Maintenance Videos ........................................... 26
Preseason Check................................................ 26
In-Season Maintenance...................................... 26
Postseason Maintenance.................................... 26
Storage ...............................................................26
Aiming Headlamp Beams ................................... 27
Changing Plow-Edge Illumination Mode............. 28
Hydraulic System ................................................29
Annual Fluid Change.................................... 29
Hose or Fitting Replacement........................30
Procedure for Installing Fittings and Hoses ..30
Fuse Replacement.............................................. 31
Snowplow Vehicle Battery Best Practices .......... 31
Vehicle ................................................................ 31
Recycle ............................................................... 31
Emergency Parts/Tools ...................................... 31

Lit. No. 72451, Rev. 03 6 October 15, 2019
This manual has been prepared to acquaint you with
the safety information, operation, and maintenance of
your new snowplow. Please read this manual carefully
and follow all recommendations.
Before installing a snowplow, make sure that your
vehicle is equipped with our recommended options
for plowing snow. This will help ensure trouble-free
operation of your snowplow. Keep this manual
accessible. It is a handy reference in case minor
service is required.
PREFACE
When service is necessary, bring your snowplow to
your local outlet. They know your snowplow best and
are interested in your complete satisfaction.
The illustrations found in this manual represent
typical components. They may not match your exact
installation.

Lit. No. 72451, Rev. 03 7 October 15, 2019
SAFETY
Instruction Label
SAFETY DEFINITIONS
NOTE: Indicates a situation or action that can
lead to damage to your snowplow and vehicle or
other property. Other useful information can also
be described.
CAUTION
Indicates a potentially hazardous situation
that, if not avoided, may result in minor or
moderate injury. It may also be used to alert
against unsafe practices.
WARNING/CAUTION AND
INSTRUCTION LABELS
Become familiar with and inform users about the
warning/caution, serial number, and instruction labels
on the back of the blade.
NOTE: If labels are missing or cannot be read, see
your sales outlet.
WARNING
Indicates a potentially hazardous situation
that, if not avoided, could result in death or
serious personal injury.
Warning/Caution Label
Serial Number Label
Serial No.
Code Denition
YY 2-Digit Year
MM 2-Digit Month
DD 2-Digit Day
LL 2-Digit Location Code
XXXX 4-Digit Sequential Number
ZZZZZZ 5- to 7-Digit Blade Assembly PN
YYMMDDLLXXXXZZZZZ
ZZZZZ
zzzzz YYMMDDLLXXXXZZZZZ

Lit. No. 72451, Rev. 03 8 October 15, 2019
SAFETY
HYDRAULIC SAFETY
• Always inspect hydraulic components and hoses
before using. Replace any damaged or worn parts
immediately.
• If you suspect a hose leak, DO NOT use your hand
to locate it. Use a piece of cardboard or wood.
FUSES
The electrical and hydraulic systems contain several
automotive-style fuses. If a problem should occur
and fuse replacement is necessary, the replacement
fuse must be of the same type and amperage rating
as the original. Installing a fuse with a higher rating
can damage the system and could start a re.
Fuse Replacement, including fuse ratings and
locations, is located in the Maintenance section of
this Owner's Manual.
SAFETY PRECAUTIONS
Follow all safety and operating instructions in
your vehicle owner's manual.
Improper installation and operation could cause
personal injury, and/or equipment and property damage.
Read and understand labels and this Owner's Manual
before installing, operating, or making adjustments.
WARNING
Lower the blade when the vehicle is parked.
Temperature changes could change
hydraulic pressure, causing the blade to
drop unexpectedly or damaging hydraulic
components. Failure to do this could result in
serious personal injury.
WARNING
Remove blade assembly before placing
vehicle on hoist.
WARNING
The driver shall keep bystanders clear of the
blade when it is being raised, lowered, or
angled. Do not stand between the vehicle and
the blade or within 8 feet of a moving blade. A
moving or falling blade could cause personal
injury.
WARNING
To prevent accidental movement of the blade,
always turn the control OFF whenever the
snowplow is not in use. The power indicator
light will turn OFF.
WARNING
Keep hands and feet clear of the blade and
A‑frame when mounting or removing the
snowplow. Moving or falling assemblies could
cause personal injury.
WARNING
Hydraulic uid under pressure can
cause skin injection injury. If you are
injured by hydraulic uid, get medical
attention immediately.
WARNING
Do not exceed GVWR, GAWR, or
maximum vehicle load capacity,
including the blade and ballast.

Lit. No. 72451, Rev. 03 9 October 15, 2019
VENTILATION
BATTERY SAFETY
NOISE
Airborne noise emission during use is below 70 dB(A)
for the snowplow operator.
VIBRATION
Operating snowplow vibration does not exceed 2.5 m/s2
to the hand-arm or 0.5 m/s2to the whole body.
SNOWPLOW WEIGHT
Size Blade Assembly Wt (lb) Wt (kg)
6'8" DEFENDER™ Compact Plow 290 132
7'2" DEFENDER Compact Plow 297 135
PERSONAL SAFETY
• Remove the ignition key and put the vehicle in
PARK or in gear to prevent others from starting
the vehicle during installation or service.
• Wear only snug-tting clothing while working on
your vehicle or snowplow.
• Do not wear jewelry or a necktie, and secure
long hair.
• Wear safety goggles to protect your eyes from
battery acid, gasoline, dirt, and dust.
• Wear hearing protection such as earmu󰀨s or
earplugs as appropriate or required.
• Avoid touching hot surfaces such as the engine,
radiator, hoses, and exhaust pipes.
• Always have a re extinguisher rated BC handy for
ammable liquids and electrical res.
FIRE AND EXPLOSION
Be careful when using gasoline. Do not use gasoline
to clean parts. Store only in approved containers away
from sources of heat or ame.
CELL PHONES
A driver's rst responsibility is the safe operation of the
vehicle. The most important thing you can do to prevent
a crash is to avoid distractions and pay attention to
the surroundings. Wait until it is safe to operate Mobile
Communication Equipment such as cell phones,
text messaging devices, pagers, or two-way radios.
SAFETY
CAUTION
Batteries normally produce explosive gases
which can cause personal injury. Therefore,
do not allow ames, sparks, or lit tobacco
to come near the battery. When charging or
working near a battery, always cover your
face and protect your eyes, and also provide
ventilation.
• Batteries contain sulfuric acid, which burns
skin, eyes, and clothing.
• Disconnect the battery before removing or
replacing any electrical components.
WARNING
Vehicle exhaust contains lethal fumes. Breathing
these fumes, even in low concentrations,
can cause death. Never operate a vehicle in
an enclosed area without venting exhaust to
the outside.
WARNING
Gasoline is highly ammable, and gasoline
vapor is explosive. Never smoke while
working on vehicle. Keep all open ames
away from gasoline tank and lines. Wipe up
any spilled gasoline immediately.

Lit. No. 72451, Rev. 03 10 October 15, 2019
Vehicle application recommendations are based on
the following:
• The vehicle with the snowplow installed must
comply with applicable Federal Motor Vehicle
Safety Standards (FMVSS).
• The vehicle with the snowplow installed must
comply with the vehicle manufacturer's stated
gross vehicle and axle weight ratings (found on
the driver-side door cornerpost of the vehicle) and
the front and rear weight distribution ratio. In some
cases, rear ballast may be required to comply with
these requirements. See "Ballast Requirements"
later in this section.
• The WESTERN Quick Match selection system is
based on available vehicle capacity for snowplow
equipment on a representative vehicle equipped
with options commonly used for plowing and with
300 lb of front seat occupant weight.
• Weights of front seat occupants can be adjusted
above 300 lb, but vehicle with snowplow must not
exceed vehicle GVWR or GAWR.
• In some cases there may be additional limitations
and requirements.
• Installation, modication, and addition of
accessories must comply with published
WESTERN recommendations and instructions.
Available capacity decreases as the vehicle is
loaded with cargo or other truck equipment, or
snowplow accessories are installed.
• If there is uncertainty as to whether available
capacity exists, the actual vehicle as congured
must be weighed.
BALLAST REQUIREMENTS
Ballast (additional weight) is an important part of
qualifying vehicles for snowplow eligibility. Rear
ballast must be used when necessary to remain in
compliance with axle ratings and ratios as specied
by the vehicle manufacturer. If ballast is required, it is
important that it be secured properly behind the rear
axle. A ballast retainer kit (PN 62849) is available from
your WESTERN outlet.
NOTE: The ballast retainer kit is for snowplow
vehicles requiring ballast. See your WESTERN
outlet for the correct amount of ballast required.
Include the weight of the retainer as part of the
ballast requirement. Sand bags are recommended
for use as ballast.
NOTE: Ballast recommended and its weight
calculations assume the entire width of the bed is
lled as close to tailgate as possible.
CAUTION
See your WESTERN®outlet/website for
specic vehicle application recommendations
before installation. The Quick Match selection
system has specic vehicle and snowplow
requirements.
Position
and secure ballast
as close to the tailgate
as possible.
VEHICLE APPLICATION INFORMATION