Armored Fitness Equipment XPO SLED User manual

XPO SLED OWNER’S MANUAL
The latest, full-color version of this document, as well as instructional videos for
assembly, use and workouts, can be viewed online at www.ArmoredFitness.com.
The online version will contain the very latest updates and photos.
Armored Fitness Equipment, LLC | 6300 Douglas St. | Plano, TX 75093 |469-547-SLED
www.armoredfitness.com | [e-mail]

© 2013 Armored Fitness Equipment, LLC Page 2
Thank you for your purchase of the XPO Sled trainer from Armored Fitness Equipment. We will do all we
can to make your ownership experience as pleasant as possible for years to come.
It is VERY IMPORTANT THAT YOU READ THIS MANUAL before operating your new XPO Sled.
MEDICAL DISCLAIMER:
Before beginning any exercise program, always discuss the program with your physician and
follow your physician’s advice. This information is not intended to replace a physician’s
independent judgment about the appropriateness or risks of engaging in this or any exercise
program.
Exercise is not without its risks, and using this or any other exercise equipment may result in
injury. They include but are not limited to: risk of injury, aggravation of a pre-existing
condition, or adverse effect of over-exertion such as muscle strain, abnormal blood pressure,
fainting, disorders of heartbeat, and in very rare instances, heart attack. To reduce the risk of
any injury and /or illness, before beginning use of this or any exercise equipment or program,
please seek medical advice for guidance regarding appropriate exercise levels and precautions.
It is particularly important to seek such advice if you suffer from an ongoing medical condition
which may be affected by exercise. The exercise instruction and advice presented is for
information purposes only and is in no way intended as a substitute for medical consultation.
Armored Fitness Equipment, LLC accepts no liability from or in connection with the use of this
equipment. As with any exercise program, if at any point during your workout you begin to
feel faint, dizzy, or have physical discomfort, you should stop immediately and consult a
suitably qualified health professional.

© 2013 Armored Fitness Equipment, LLC Page 3
IMPORTANT SAFETY INSTRUCTIONS:
SAFETY WARNING: The safety of the product can be maintained only if it is examined regularly for
damage and wear. See Preventive Maintenance section for details.
•Do not overinflate the tires! Maximum pressure for the rear tires is 20 PSI; the maximum
pressure for the front tire is 40 PSI.
•Pay special attention to parts that are subject to wear as outlined in the Preventive
Maintenance Schedule.
•Keep small children away from the XPO Sled. There are pinch points and other areas that can
cause harm.
•Keep all loose clothing, hair, and shoelaces away from moving parts.
•Do not attempt to use the XPO Sled for any purpose other than that for which it is intended.
•Wear shoes with rubber or high-traction soles. High heels, dress shoes, sandals or bare feet are
not suitable for use with the XPO Sled.
•Never carelessly drop the front wheel down when turning the XPO Sled around. Set the front
wheel down carefully -- especially with weight plates on the center post and/or pulling
attachment post.
•Never place more than 100 pounds of weight on the weight plate post; or place more than 180
pounds total weight on the XPO Sled
•Never drop weight plates onto the XPO Sled. Violently dropping the plates will damage the
front wheel components over time.
•Never expose the XPO Sled to rain.
•Never use the XPO Sled in wet or slippery conditions.
•Never push the XPO Sled while wearing a tow harness attached to the front.
•Never allow multiple athletes to push or pull the XPO Sled at the same time.
•Never step on the chain guard.
•Do not stand or ride on the XPO Sled.

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UNPACKING AND ASSEMBLING YOUR XPO SLED:
You may notice some small scratches at the attachment points on the powder coating finish of your
new XPO Sled. This is not an indication your XPO Sled has been used or refurbished in any way. As part
of our thorough quality control process, every XPO Sled is inspected, assembled, and adjusted at the
factory to insure proper fit and alignment of the front wheel.
We highly recommend that you watch the XPO Sled Assembly Demo video posted on our website, prior
to assembling your XPO Sled. You can find this and more video demonstrations at
www.ArmoredFitness.com. Once there, click on the Support menu.
UNPACKING PARTS:
Carefully remove all parts from carton and
inspect for damaged or missing parts.
If damaged parts are found or parts are
missing, contact Armored Fitness
Equipment immediately.
Your carton should contain:
Front wheel/fork assembly
Rear axle assembly, including two
bolts, two nuts, and four washers
Weight plate post
Long handles (two)
ASSEMBLY:
1. After unpacking and checking all parts,
you’ll need the following tools for
assembly (not included):
Two crescent/adjustable
wrenches or the appropriate sized
non-adjustable wrenches
2. Important note if you purchased or
own multiple XPO Sleds: Each XPO
Sled is unique. The Rear axle
assembly and Front wheel/fork
assembly are not interchangeable
between units. If you have more than
one unit, ensure that the parts are not
mixed up. Your serial number is
located underneath the motor on the
Front wheel/fork assembly. We
suggest writing the serial number on
the Rear axle assembly as well. A
Sharpee works well.

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3. Locate and remove the two bolts,
nuts, and washers, pre-inserted in the
rear axle tabs.
4. Join the rear axle assembly and the
front wheel/fork assembly by inserting
the forks between the rear axle tabs,
lining up the bolt holes as shown.
The motor and the handle stubs
should be facing up.
If necessary, use a rubber mallet or
block of wood to gently tap the
forks/front wheel assembly into
alignment. Use care not to use a
hammer or other object that could
chip or damage the powder coat
finish.
5. Insert one washer over each bolt and
insert the bolts in the holes, putting
them through the rear axle tabs and
the fork assembly. Be sure to insert
the bolts completely through the
holes, lightly tapping as necessary to
fully insert the bolt.
Place another washer over the end of
the bolt, followed by a nut. The nut is
rounded off on one side. The flat side
of the nut should be placed against
the washer, and the rounded side
should face outward.
Tighten firmly. Do not over-tighten.

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6. Place the weight plate post over the
stub located on the center of the fork
assembly.
7. Place the long handles over the handle
stubs on the rear axle assembly.

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8. When assembly is completed, the following test and adjustment needs to be performed before
regular use. Before completing this test, we highly recommend that you view the General Use
videos posted at www.ArmoredFitness.com. Once there, click on the Support menu.
Locate an area where you can push the XPO Sled straight for at least 10 yards. Load the weight
plate post with at least one 45# weight plate.
Aggressively push the XPO Sled to the end of your 10 yard (or more) area, put your foot on the
kick tape, turn the sled around, and push it back. Repeat this aggressive relay push 10 times.
Re-tighten the rear axle tab bolts.
Congratulations! Your XPO Sled is now ready for use. If you notice that your XPO Sled does not roll
straight, please see the section later in this manual on ALIGNING THE FRONT WHEEL AND ADJUSTING
CHAIN TENSION. It is a good idea to read this section now to understand how to perform maintenance
that may be required on your XPO Sled in the future.

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OPTIONAL EQUIPMENT:
INSTALLING THE PULLING ATTACHMENT:
1. Place at least one 45 lb. weight plate
on the weight plate post on the XPO
Sled.
2. Insert the rear upright of the Pulling
Attachment into the weight plate post
on the XPO Sled.
3. Lower it until the front tabs fully seat
between the fork tubes.
4. Place at least one 45 lb. weight plate
on the weight plate post on the Pulling
Attachment.
Please remember, never place more than 100
pounds of weight on either weight plate post;
or place more than 180 pounds total weight
on the XPO Sled.

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USING THE XPO SLED:
Your XPO Sled can be pushed at this stage of assembly, or it can be pulled with the optional Pulling
Attachment.
Proper use of weight plates on the XPO Sled:
Unlike older style sleds, the weight on the XPO
Sled does not create or influence the
resistance. Resistance is provided by the
resistance motor driven by the front wheel.
The only purpose for weight plates on the XPO
Sled is to provide traction for the front wheel.
On indoor high traction surfaces, such as stall
mats, there is no need for more than a single
45 pound plate. Outdoor or slicker surfaces,
such as concrete, may require more weight to
maintain traction. If the front tire begins to slip
(usually can be heard) or leaves a skid mark,
you should add weight plates to the XPO Sled
to prevent unnecessary wear on the front tire.
It is a common mistake to push or lift up on the handles while trying to push forward. This will cause
the back tires to lift off the ground as the XPO Sled begins to move. Apply force directly forward
instead of lifting up to keep all tires on the ground.
Pushing the XPO Sled:
Long Handles:
Begin pushing the XPO Sled by holding the
handles, leaning forward, and beginning to
walk or run. In general, slower walking
movements will involve higher hand positions.
Experiment to find what works best for you.
Changing Direction/Turning the XPO Sled:
Small changes in direction can be accomplished
by applying greater force to one handle to
“steer” the XPO Sled.
Larger changes in direction can be made
quickly while still under load, by squeezing the
handles toward each other, lifting the rear
wheels off the ground slightly, while continuing
to push, and steering in the direction needed.

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Pulling the XPO Sled:
Prior to installing the optional pulling
attachment, load the weight plate post with at
least one 45 pound plate, then install the
pulling attachment as per the instructions in
this manual. Now load the pulling attachment
weight plate post with at least one 45 pound
plate. (Do not exceed the XPO Sled 180 pound
total weight limit)
Connect any harness or rope of your choice to
the pulling attachment loading ring.
In general, the longer the rope or harness
strap, the better. If the pulling attachment lifts
up and down when being pulled, add additional
weight plates to the pulling attachment weight
plate post and/or use a longer rope or harness
strap. This is even more important if pulling
the XPO Sled from a high position, such as over
the shoulder.
The XPO Sled may be pulled by walking or
running, forward or backward.
The XPO Sled will track behind the athlete and
follow very small changes in direction. If the
XPO Sled is consistently pulling the athlete to
one side or the other, see the section in this
manual on ALIGNING THE FRONT WHEEL AND
ADJUSTING CHAIN TENSION.
Re-Positioning the XPO Sled:
The XPO Sled will easily roll backward with little
resistance. It may also be pushed even more
easily by placing a foot on the black kick tape
located at the center of the rear axle assembly,
pulling back on the handles, and lifting the
front wheel off the ground. Once the front
wheel is off the ground, the XPO Sled handles
similarly to a two-wheel furniture dolly and can
be pushed or pulled freely.

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Warm Ups:
The XPO Sled is an excellent full-body warm up when pushed at lower levels of intensity. A 200-400
meter push at a brisk walking pace, using multiple hand positions, will thoroughly warm up most major
joints and muscle groups.
Workouts:
An XPO Sled push or pull is an excellent
substitution for the running or rowing portion
of workouts that you may already be familiar
with. As a general guideline, try substituting
half the distance of the run or row with an XPO
Sled push or pull. Combine it with a barbell, a
kettlebell, or a medicine ball and the options
are endless. Don’t let the weather stop you,
the XPO Sled can be used indoors or outdoors.
Some of our favorite workout combinations are
listed below, and videos can be found on our
website at www.ArmoredFitness.com.
XPO Sled Benchmark 1:
Set up two barbells 50 meters apart. Load one
for deadlift and one for front squat.
Recommended weights are 275# or 315# for
deadlift and 155# or 185# for front squat for
men. Scale and select your weights as
appropriate. Begin with the XPO Sled beside
your front squat barbell.
For Time:
50m XPO Sled Push
5 Deadlift
50m XPO Sled Push
5 Front Squat
50m XPO Sled Push
4 Deadlift
50m XPO Sled Push
4 Front Squat
50m XPO Sled Push
3 Deadlift
50m XPO Sled Push
3 Front Squat
50m XPO Sled Push
2 Deadlift
50m XPO Sled Push
2 Front Squat
50m XPO Sled Push
1 Deadlift
50m XPO Sled Push
1 Front Squat
XPO Sled Benchmark 2:
For Time:
400m XPO Sled Push
Front tire must remain on the ground at all
times.
XPO Sled Benchmark 3:
For Time:
100m XPO Sled Push or Pull
500m row

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XPO Sled Benchmark 4:
For Time:
15 Burpees
150m XPO Sled Push
15 Burpees
*This is a great workout to turn into a team
relay race.
XPO Sled Benchmark 5:
5x50m XPO Sled Push or Pull
1:1 work to rest
XPO Sled Benchmark 6:
For Time:
21 Thrusters
30m XPO Sled Push
15 Thrusters
30m XPO Sled Push
9 Thrusters
30m XPO Sled Push
XPO Sled Benchmark 7:
For Time:
100 Double Unders
100m XPO Sled Push
80 Double Unders
80m XPO Sled Push
60 Double Unders
60 XPO Sled Push
40 Double Unders
40 XPO Sled Push
20 Double Unders
20 XPO Sled Push
10 Double Unders
10m XPO Sled Push

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ALIGNING THE FRONT WHEEL AND ADJUSTING CHAIN TENSION:
Each XPO Sled has been assembled, aligned,
and had its chain tensioned prior to shipment
so that no adjustment should be necessary. If
required, adjustments can be made in just a
few minutes. Chain tension may need to be
adjusted over time as the chain stretches
slightly under use.
Two adjustable wrenches will be required for
this process. You will use one wrench on each
front axle nut at the same time. One of the
adjustable wrenches will later be used on the
chain tensioner nuts.
Front wheel alignment and chain tension are
controlled by the two chain tensioners on the
very front of the forks. The tensioners each
pull one side of the axle forward, and by
adjusting them you can change the angle of the
front wheel as well as change the chain
tension. Turning the nuts on the chain
tensioners clockwise will tighten the tensioner
and pull that side of the axle forward. Turning
them counter clockwise will loosen the
tensioner and allow the axle to move
backwards, but it may be necessary to firmly
strike the front wheel to pull the axle back after
loosening the tensioner.
Before starting, it is very important to realize
that adjusting the front wheel in any way
affects chain tension. It is critical that the
chain not be overly tightened, as this may
damage the resistance motor. When making
the adjustments described below, frequently
check the chain tension. The chain should
move up and down between ⅛” and ¼” under
firm fingertip pressure.
If it does not, turn both chain tensioning nuts
counter clockwise an equal number of turns
and push the front wheel towards the rear of
the XPO Sled until the chain is loose enough to
move up and down at least ¼ inch.

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CHAIN TENSION:
1. Loosen the front axle nuts by placing a
wrench on each nut, and turning either
one counter-clockwise. No more than a
full turn is necessary. You do not need
to remove the nuts, just make them
loose enough that the wheel can be
adjusted.
2. To loosen the chain, turn each chain
tensioner nut ½ turn counter clockwise
and firmly strike the front wheel with
your hand to move it back. To tighten
the chain, turn each chain tensioner nut
½ turn clockwise. The tensioner will
pull the wheel forward and tighten the
chain.
3. Check the chain tension. Between ⅛
inch and ¼ inch of movement up and
down under firm fingertip pressure is
ideal. Repeat step 2 until the correct
chain tension is achieved.

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4. Place a wrench on both front axle nuts,
and tighten by turning clockwise. It is
best to tighten by pushing the wrench
towards the rear of the XPO Sled.
Pulling the wrench towards the front of
the XPO Sled may pull that side of the
axle forwards and ruin the alignment.
It is not necessary to tighten forcefully.
5. By moving both chain tensioners equally, the alignment of the front wheel should be preserved.
Check alignment and if the XPO Sled does not roll straight, follow the steps for alignment.
ALIGNMENT:
We highly recommend that you watch the XPO Sled Front Wheel Alignment Demo video posted on our
website, prior to following these steps. You can find this and more video demonstrations at
www.ArmoredFitness.com. Once there, click on the Support menu.
1. Loosen the front axle nuts by placing a
wrench on each nut, and turning either
one counter-clockwise. No more than a
full turn is necessary. You do not need
to remove the nuts, just make them
loose enough that the wheel can be
adjusted.

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2. Disconnect the resistance motor
connections so the XPO Sled will roll
freely. Pull on the connectors
themselves; do not pull on the wire, as
this may cause the wire and the
connector to separate.
3. Firmly push the XPO Sled on a level
surface. Let go, and note the direction
in which the XPO Sled is turning.
This is easiest to do if there is a straight
line for reference, such as an expansion
joint or parking lot painted lines.

© 2013 Armored Fitness Equipment, LLC Page 17
4. Tighten (turn clockwise) ½ turn the
chain tensioner nut on the side to
which the XPO Sled is turning. If the
XPO Sled turned to the left (as in the
photo above in step 3), tighten the left
side tensioner, and vice versa.
5. Repeat steps 3 and 4 until the XPO Sled
rolls straight. Be certain to check chain
tension after every adjustment to avoid
damaging the resistance motor. If at
any point the chain is too tight, adjust
BOTH chain tensioner nuts counter
clockwise until the chain has loosened
to ⅛” flex under firm fingertip pressure
and resume alignment.

© 2013 Armored Fitness Equipment, LLC Page 18
6. When the XPO Sled rolls straight, place
a wrench on both front axle nuts, and
tighten by turning clockwise. It is best
to tighten by pushing the wrench
towards the rear of the XPO Sled.
Pulling the wrench towards the front of
the XPO Sled may pull that side of the
axle forwards and ruin the alignment.
It is not necessary to tighten forcefully.
7. Retest the XPO Sled after tightening the
axle nuts. When satisfied with the
alignment, reconnect the resistance
motor connections. Be certain
connectors are fully seated (fit snugly)
before using the XPO Sled.

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XPO SLED DUTY CYCLE:
The XPO Sled has a 50% duty cycle when performing at high loads in repetitive or team/relay exercises.
In our experience, a single individual is not capable of overloading the capacity of the XPO Sled.
However, continuous use by a team of athletes may overload the ability of the motor to dissipate
excess heat. To avoid this, do not operate the XPO Sled continuously for more than 5 minutes in a
team setting. Allow cooling time equal to the time in use before repeating. If at any point, the
resistance motor begins to smoke or emit a burning smell, discontinue use and allow the XPO Sled to
cool. Armored Fitness Equipment, LLC is not responsible for replacing motors that have been damaged
by repeated overheating from this type of misuse.
TIPS TO EXTEND THE LIFE OF YOUR XPO SLED:
•Although the XPO Sled is ruggedly built, use caution NOT to drop the front wheel down when
turning around. Set the front wheel down carefully -- especially with weight plates on the
center post and/or pulling attachment post.
•Do not drop weight plates onto the XPO Sled. Violently dropping the plates can damage the
front wheel components over time.
•Never place more than 100 pounds of weight on the weight plate post; or place more than 180
pounds total weight on the XPO Sled (using the optional pulling attachment). A good general
rule is: Do not use more weight than is required to keep the front tire from skidding on the
particular surface you are pushing on.
•Do not step on the chain guard.
•Pay special attention to parts that are subject to wear as outlined in the Preventive
Maintenance section.
•It is imperative that you adhere to the duty cycle as specified in this manual.
PREVENTIVE MAINTENANCE BEFORE DAILY USE:
•Inspect the tires for proper inflation. Maximum pressure for the rear tires is 20 PSI; the
maximum pressure for the front tire is 40 PSI.
•Inspect all weld points for cracks.
•Inspect all assembly bolts to ensure they are tight.
•Inspect the chain for alignment and proper tension. (Please see the ALIGNMENT and CHAIN
TENSION sections above)
Lubricate the chain using any quality spray lubricant.
HOW TO GET PARTS & SERVICE:
All returns must be pre-authorized by Armored Fitness Equipment. Armored Fitness Equipment’s
obligation under the warranty is limited to replacing or repairing the product at our option. Parts
reconditioned to As New Condition may sometimes be supplied as warranty replacement parts and
constitute fulfillment of warranty terms.
Please retain your proof of purchase, such as your bill of sale or receipt. Simply call Customer Service
at (+1) 469-547-SLED (469-547-7533), Monday through Friday from 9:00 a.m. to 5:00 p.m. Central Time,
and have your name, address, phone and product serial number ready. We will assist in getting your
XPO Sled back in service. The serial number is located under the motor mount plate.