Western DEFENDER User manual

DEFENDER™ Compact Plow
Blade Assembly 85270/85275
O󰀨‑Truck Kit 85260/85260‑3
Installation Instructions
Western Products, PO Box 245038, Milwaukee, WI 53224‑9538 • www.westernplows.com
July 15, 2020
Lit. No. 85308, Rev. 04
A DIVISION OF DOUGLAS DYNAMICS, LLC
CAUTION
Read this document before installing the
snowplow.
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.

Lit. No. 85308, Rev. 04 2 July 15, 2020
SAFETY
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.
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
Warning/Caution Label
Instruction Label

Lit. No. 85308, Rev. 04 3 July 15, 2020
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 the Owner's
Manual.
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.
• 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.
SAFETY
WARNING
Hydraulic uid under pressure can cause skin
injection injury. If you are injured by hydraulic
uid, get medical attention immediately.
SAFETY PRECAUTIONS
Improper installation and operation could cause
personal injury and/or equipment and property damage.
Read and understand labels and the Owner's Manual
before installing, operating, or making adjustments.
WARNING
Lower the blade when 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
Do not exceed GVWR, GAWR, or maximum
vehicle load capacity, including the blade and
ballast.
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.
CAUTION
Refer to the current online selection system
for minimum vehicle recommendations and
ballast requirements.

Lit. No. 85308, Rev. 04 4 July 15, 2020
SAFETY
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 road. Wait until it is safe to operate
Mobile Communication Equipment such as cell
phones, text messaging devices, pagers, or two‑way
radios.
VENTILATION
BATTERY SAFETY
NOISE
Airborne noise emission during use is 70 dB(A) for the
snowplow operator.
VIBR ATION
Operating snowplow vibration does not exceed
2.5 m/s2to the hand‑arm or 0.5 m/s2to the whole
body.
TORQUE CHART
1/4-20 10
91
54
1/4-28 12
11
71
5/16-1
81
50 212
5/16-2
41
70 240
3/8-16 269 376
3/8-24 29
74
20
7/16-1442
96
06
7/16-20
9/16-12
9/16-18
5/8-11
5/8-18
3/4-10
3/4-16
7/8-9
7/8-14 47
46
69
64
49
091-8
1-12 70
49
95
1/2-13
1/2-20
11.9
13.7
24.6
27.3
43.6
26.9
53.3
93
148
49.4
69.8
77.9
106.4
120.0
8.4
9.7
17.4
19.2
30.8
35.0
49.4
55.2
75.3
85.0
M6 x 1.00
M12 x 1.75
M8 x 1.25
M14 x 2.00
M10 x 1.50
M27 x 3.00
M22 x 2.50
M30 x 3.50
M24 x 3.00
M20 x 2.5011.1
19.5
38.5
67
107
7.7
613
778
1139
1545
450
428
562
796
1117
M33 x 3.50
M36 x 4.00
2101
2701
1468
1952
325
M16 x 2.00 231167
M18 x 2.50 318222
Recommended Fastener Torque Chart
Size Size
Torque (ft-lb)
Grade
5
Grade
8
Metric Fasteners Class 8.8 and 10.9
These torque values apply to fasteners
except those noted in the instructions.
Torque (ft-lb)
Grade
5
Grade
8
Size Size
Torque (ft-lb)
Class
8.8
Class
10.9
Torque (ft-lb)
Class
8.8
Class
10.9
Inch Fasteners Grade 5 and Grade 8
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.
CAUTION
Read instructions before assembling.
Fasteners should be nger tight until
instructed to tighten according to torque
chart. Use standard methods and practices
when attaching snowplow, including proper
personal protective safety equipment.
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. 85308, Rev. 04 5 July 15, 2020
INSTALLATION INSTRUCTIONS
UNPACKING
1. Set aside the blade guides, parts bag, and
headlamp bag.
2. Remove the receivers by pulling out the hitch pin
and rotating the hitch pin to lock into the notch on
the receiver.
3. Remove the cable ties that hold the blade
assembly to the pallet.
4. Remove the fasteners and strapping that secure
the A‑frame to the pallet.
A‑FRAME TO BLADE ASSEMBLY
1. Insert the nose of the A‑frame into the quadrant
and align the pivot bolt hole on the A‑frame with
the pivot bolt hole on the quadrant. Loosen and
remove both trip springs and tip the blade forward.
Insert the pivot tube through the quadrant into the
A-frame, tapered end rst.
2. Install a trip bumper to each end of the pivot tube
and under the blade stop as shown below. The
round boss on the bumper will t into the pivot
tube, and the long bumper leg will butt up against
the upward bend of the quadrant.
Trip Bumper
Trip
Bumper
1/2" x 3-11/16"
Clevis Pin
5/16" x 5"
Cap Screw
5/16" Locknut
Pivot
Tube
5/16" Washer
5/16" Washer
1/2" x 3-11/16"
Clevis Pin
Cotter
PinCotter
Pin
Receivers
Hitch
Pin
Hitch
Pin

Lit. No. 85308, Rev. 04 6 July 15, 2020
INSTALLATION INSTRUCTIONS
3. Install the rubber bumpers using 5/16" x 5" cap
screws, 5/16" at washers, and 5/16" locknuts, as
shown on facing page. Tighten the fasteners until
the bumpers begin to dimple.
4. Move the blade back to upright position.
5. Reinstall the trip springs.
6. Adjust the trip springs by tightening the top nuts
until the coils of the springs begin to separate
(a piece of paper, such as this instruction sheet,
should pass between the second and third coils).
7. Remove the protective packaging from the angle
rams. Align the holes in the rod end of the angle
ram with the corresponding holes on the back of
the quadrant.
8. Install a 1/2" x 3‑11/16" clevis pin from the top
down to attach each rod. Secure the clevis pins
with cotter pins from the parts bag.
9. Install the blade guides.
10. With the A‑frame parallel to the ground, secure
the stand by pulling the stand lock pin out and
letting the stand drop to the ground. Release the
stand lock pin and verify that the stand is secure
by pulling up on the stand.
11. Finish securing the cutting edge with two carriage
bolts and locknuts (included in the parts bag).
12. Install the receivers into the truck mount pockets
using the pins provided in the receivers.
St
and
Lock
Pin
Stand
Cl
amp
Blade
Guide
Flag
S-Hook
5/16" Hex
Locknuts
5/16" x 1"
Cap Screws

Lit. No. 85308, Rev. 04 7 July 15, 2020
INSTALLATION INSTRUCTIONS
HEADLAMPS
Headlamps, hardware, and instructions are found in
the headlamp box.
1. Install the vehicle wiring according to the
instructions provided.
2. Set the headlamp channel on the lift frame, label
to the front, with the holes aligned.
3. With the correct headlamp on the correct side, set
each headlamp and swivel into place as shown.
4. Secure the headlamps with the correct hardware
for the application as shown below. Inner and
outer posts require di󰀨erent hardware. On LED
headlamps, a rubber washer must be installed
under the slotted holes. Hand tighten.
5. Connect the headlamp wires to the headlamps.
6. Aim the headlamps according to the Snowplow
Headlamp Beam Aiming Instructions
(Lit. No. 27769). Tighten LED headlamp fasteners
to 22 ft‑lb (30 N·m). Tighten halogen headlamp
fasteners to 50 ft‑lb (68 N·m).
7. From inside the headlamp channel, insert the
cable tie anchors into the holes as shown. The
anchor locking tabs should be horizontal.
8. For halogen headlamps only, install a split rubber
grommet on each headlamp wire 3" from the
headlamp. Insert the grommet and wire into the
slot on the rear of the channel.
9. Route the wires under the channel and down the
back of the driver‑side vertical support. Secure the
wires to the anchors and the vertical support with
cable ties.
WARNING
Your vehicle must be equipped with snowplow
headlamps and directional lights.
Cable Tie
Anchors
Cable
Ties
Grommet
Run harnes
s
underneath
channel
Halogen Headlamp
sL
ED Headlamps
Headlamp
Swivel
Headlamp
Channel
1/2" Flat
Washers
1/2" Lock
Washers
1/2" Hex Nuts
Slotted
Hole
1/2" Ru
bber
Washer
Lift Frame

Lit. No. 85308, Rev. 04 8 July 15, 2020
INSTALLATION INSTRUCTIONS
3. Turn the control ON and raise and lower the
snowplow several times. With the snowplow in
the raised position, fully angle the plow from right
to left several times. Activate the control FLOAT
function and make sure the blade is lowered
completely to the ground. Turn the control OFF.
4. Remove the breather and check the uid level.
The uid level should be 1-1/2"–2" below
the ll hole. If additional uid is needed, add
WESTERN® High Performance Hydraulic Fluid
rated to –40°F (–40°C), or other uid conforming
to Military Specication MIL-H-5606 A, such as
Mobil Aero HFA or Shell AeroShell® Fluid.
NOTE: Loosen the breather slowly to relieve any
pressure in the reservoir.
NOTE: Add uid only when the blade is resting
fully on the ground.
5. Replace and tighten the breather.
HYDRAULIC UNIT
The hydraulic unit comes from the factory
pre-assembled, partially lled, and fully tested.
1. Attach the snowplow to the vehicle according to
the instructions on the back of the blade.
2. Remove the cover from the hydraulic unit. Remove
and discard the factory‑installed pipe plug from
the top of the reservoir and install the breather.
CAUTION
Do not mix di󰀨erent types of hydraulic uid.
Some uids are not compatible and may
cause performance problems and product
damage.
WARNING
Keep 8' clear of the blade when it is being
raised, lowered, or angled. Do not stand
between vehicle and blade or directly in front
of the blade. If the blade hits or drops on you,
you could be seriously injured.
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.
AeroShell®is a registered trademark (®) of Shell Oil Company.
Breather/Fill Plug
Reservoir
Drain Plug

Lit. No. 85308, Rev. 04 9 July 15, 2020
INSTALLATION INSTRUCTIONS
BLADE DROP SPEED ADJUSTMENT
The quill in the valve manifold adjusts blade drop speed.
NOTE: The blade will not drop when quill is fully
tightened (clockwise). Turn OFF the plow control,
turn the quill 1/8 turn outward (counterclockwise),
then proceed with blade drop speed adjustment.
1. Lower the blade to the ground before making any
adjustment.
2. Remove the hydraulic unit cover.
WARNING
Keep 8' clear of the blade when it is being
raised, lowered, or angled. Do not stand
between vehicle and blade or directly in front
of the blade. If the blade hits or drops on you,
you could be seriously injured.
Quill
3. Turn the quill IN (clockwise) to decrease drop
speed. Turn the quill OUT (counterclockwise) to
increase drop speed.
4. Stand 8 feet clear of the blade when checking
adjustment.
5. Replace the cover.

Lit. No. 85308, Rev. 04 10 July 15, 2020
FINAL INSPECTION AND ADJUSTMENT
1. Fully angle the blade in both directions in raised
and lowered positions. Adjust hose ttings, wraps,
and clamps so that the hoses do not contact
the vehicle bumper, have no sharp bends, are
wrapped at contact points, and do not become
pinched between the headgear and A‑frame.
2. Add grease to the two hitch pins.
OPERATIONAL TEST AND FINAL ADJUSTMENTS
Use good quality
multipurpose grease
WARNING
Keep 8' clear of the blade when it is being
raised, lowered, or angled. Do not stand
between vehicle and blade or directly in front
of the blade. If the blade hits or drops on you,
you could be seriously injured.
PLUG COVERS
When the snowplow is removed from the vehicle,
install plug covers on the vehicle battery cable. Insert
the snowplow battery cable into the cable boot on the
snowplow.
OWNER'S MANUAL PACKET
If the completed snowplow will be delivered
immediately, the Owner's Manual should be reviewed
with and given to the purchaser.
If the snowplow is completed prior to delivery to the
purchaser, attach the Owner's Manual packet to the
electrical cable of the cab control for safekeeping.
CAUTION
Plug covers shall be used whenever
snowplow is disconnected. Vehicle battery
cable is 12V unfused source.

Lit. No. 85308, Rev. 04 11 July 15, 2020
OPERATIONAL TEST AND FINAL ADJUSTMENTS

Lit. No. 85308, Rev. 04 12 July 15, 2020
Western Products reserves the right under its product improvement policy to change construction or design details and furnish equipment when
so altered without reference to illustrations or specications used. Western Products or the vehicle manufacturer may require or recommend
optional equipment for snow removal. Do not exceed vehicle ratings with a snowplow. Western Products o󰀨ers a limited warranty for all
snowplows and accessories. See separately printed page for this important information. The following are registered (®) or unregistered (™)
trademarks of Douglas Dynamics, LLC: DEFENDER™, WESTERN®.
Printed in U.S.A.
A DIVISION OF DOUGLAS DYNAMICS, LLC
Western Products
PO Box 245038
Milwaukee, WI 53224‑9538
www.westernplows.com