I S TECHNOLOGY SOLUTIONS BRAKE PRO S-4027 User manual

I S TECHNOLOGY SOLUTIONS
BRAKE PRO™
AUTOMATIC SINGLE CAR TESTING DEVICE
FOR FREIGHT CARS
FOR TESTING AS REQUIRED BY
THE ASSOCIATION OF AMERICAN RAILROADS
SPECIFICATION S-4027
OPERATING MANUAL
UPDATED FEBRUARY 2021
DESIGNED AND PRODUCED BY:
I S TECHNOLOGY SOLUTIONS
5410 W ROOSEVELT RD, STE 209
CHICAGO, IL 60644 USA
[phone]
WWW.ISTECHNOLOGYSOLUTIONS.COM
[email protected]

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Table of Contents
Operating Instructions .................................................................................................................... 3
Introduction .................................................................................................................................. 3
Charging the Brake Pro™ - older models with external battery.................................................... 3
Charging the Brake Pro™ - newer models with internal battery ................................................... 3
Additional Handheld Tablet Information ....................................................................................... 5
Preparing to Test .......................................................................................................................... 7
Attaching Air Hoses for the Daily Test ........................................................................................... 7
Attaching Air Hoses for the Single Car Test .................................................................................. 9
Running the Brake Pro™ Application............................................................................................ 11
Re-Pairing the Tablet..................................................................................................................... 12
Screen Brightness......................................................................................................................... 13
Touch Mode Setting ...................................................................................................................... 13
Calibration Info.............................................................................................................................. 14
Program Start & Connection ......................................................................................................... 15
Screen Layout............................................................................................................................... 15
Stop Test Button............................................................................................................................ 15
Running the Single Car Test ......................................................................................................... 16
Car Setup...................................................................................................................................... 16
Regulator Protection ..................................................................................................................... 20
Manual Control Program............................................................................................................... 21
Connecting the Tablet to a WiFi Network ..................................................................................... 22
Printing and Transferring Reports ................................................................................................. 22
Transferring Reports ..................................................................................................................... 24
International Options ....................................................................................................................... 26
Software Operations ........................................................................................................................ 28
Version Number ............................................................................................................................ 28
Installing the Brake Pro™ Application ........................................................................................... 28
Updating the Brake Pro™ Application........................................................................................... 28
Reading the Conguration File...................................................................................................... 29
Warranty ........................................................................................................................................... 31
Contact .............................................................................................................................................. 33
Intellectual Property Notice ............................................................................................................ 34
Air Connections................................................................................................................................ 35

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Operating Instructions
Introduction
The Brake Pro™ is an automatic single car testing device that enables all operators to perform air
brake testing. The Brake Pro™ does this by walking the operator through the test, and basing the
testing parameters on the car’s properties.
The Brake Pro™ initially requires the device to pass the Daily Test for the testing method to be
used. Once the Daily Test has been passed, the operator will be prompted for the testing method: 2
Pressure End-Of-Car, 4 Pressure End-Of-Car or 4 Pressure Adapter. The operator then enters the
car’s properties. The software will then automatically formulate the correct parameters to test the
brakes completely and accurately. Throughout the remainder of the test procedure all display screens
are self-prompting for ease of use. Any required entries will be clearly prompted so the operator
knows the next step. In the case of PASS/FAIL questions asked of the operator, the passing option is
shown in green and the failing option in red.
Charging the Brake Pro™ - older models with external battery
The Brake Pro™ single car testing device is equipped with an external GFCI charging cable. Please
take precaution when charging the Brake Pro™ in standing water or rain. Directly handling electrical
cables when in direct contact with water is not suggested. The internal charger is a “Smart Charger”,
it will not over-charge the battery and can be left plugged in for long periods of time. To charge the
Brake Pro™, simply follow the steps below.
NOTE: It is highly recommended that new devices be charges for several hours when rst
received.
1. Insert the black GFCI plug into any 110V outlet (or appropriate outlet for international devices).
2. To begin charging, push the RESET button located on the GFCI plug.
3. A red light will appear on the main face of the Brake Pro™ indicating the unit has begun
charging.
4. Once the unit has reached a full charge, the aforementioned light will change to green.
5. When fully charged, the Brake Pro™is capable of running for up to 8 hours. If, however,
the battery runs down to an unacceptable voltage, the Brake Pro™ may experience
di󰀩culties communicating with the handheld tablet or operating the internal components. If
communication problems are experienced, charging the Brake Pro™ is recommended.
NOTE: Brake Pro™ should be charged when volt meter falls below 12V, and should never be
used with volt meter below 11V.
Charging the Brake Pro™ - newer models with internal battery
The Brake Pro™ single car testing device is equipped with an external GFCI charging cable. Please
take precaution when charging the Brake Pro™ in standing water or rain. Directly handling electrical

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cables when in direct contact with water is not suggested. The internal charger is a “Smart Charger”,
it will not over-charge the battery and can be left plugged in for long periods of time. To charge the
Brake Pro™, simply follow the steps below.
NOTE: It is highly recommended that new devices be charges for several hours when rst
received.
1. Insert the black GFCI plug into any 110V outlet (or appropriate outlet for international devices).
2. To begin charging, push the RESET button located on the GFCI plug.
3. No light will appear if the unit is o󰀨. To check if the unit is charging, turn the unit on. A voltage
reading of 14+V indicates the unit is charging. Once the reading drops to 13.0 - 13.2V, the unit
has charged. Turn the unit o󰀨 to charge the unit faster.
4. A fully charged battery without AC power (not plugged in) will show 12.6 - 12.8V.
5. When fully charged, the Brake Pro™is capable of running for up to 8 hours. If, however,
the battery runs down to an unacceptable voltage, the Brake Pro™ may experience
di󰀩culties communicating with the handheld tablet or operating the internal components. If
communication problems are experienced, charging the Brake Pro™ is recommended.
NOTE: Brake Pro™ should be charged when volt meter falls below 12V, and should never be
used with volt meter below 11V.
The Brake Pro™ unit comes with a handheld tablet for operating the device. The tablet runs on a
rechargeable battery that needs to be maintained in order to operate properly. To charge the tablet,
follow the steps below.
1. Plug the black charger, included with the shipment, into any standard 110V outlet (or
appropriate outlet for international devices).
2. Plug the round end of the charger into the charging port. This is found underneath the tab on
the edge of the tablet.
3. The tablet will display a green light next to the battery icon on the right edge of the tablet if all
connections are correct.

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Panasonic ToughPad®
Note: Model FZ-L1 pictured. Older models may be di󰀨erent.
Power Button
Volume
Keys
Charging Port
(Micro-USB)
Additional Handheld Tablet Information
Turning Tablet On and O󰀨
To turn the tablet on, press and hold the Power button until “Powered by android” appears on the
screen.
To put the tablet into Standby mode, press and quickly release the Power Button once. This will put
the tablet into Standby mode, which turns o󰀨 the screen, but does not shutdown the tablet. This can
be used to temporarily preserve battery life.
To completely shutdown the tablet, press and hold the Power Button until prompted to conrm the
shutdown of the device. This will completely power down the tablet. Powering down the tablet is
recommended when it will not be used for prolonged periods to preserve battery life.

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To unlock the tablet and access the applications, press the Lock icon (padlock).
Preparing to Test
NOTE: A coalescing lter MUST be used when operating the Brake Pro™. Failure to do so
will increase the chance of contamination damaging the internal electronic components.
Contamination is NOT covered by warranty.
IMPORTANT SAFETY NOTICE: Quick connect ttings must always be used in accordance with good
practice and the instructions and regulations of the manufacturer and your employer. Always ensure
connecting ttings are rmly and properly engaged, locked in place, and cannot accidentally become
disengaged. An improperly installed tting may be dangerous and could cause serious injury or death
if it becomes disengaged while pressurized. I S Technology Solutions does not accept responsibility
for the installation of improper ttings or the misuse of ttings.
Attaching Air Hoses for the Daily Test
To prepare for the 2 Pressure End-Of-Car Daily Test:
1. Connect the coalescing lter to the SUPPLY tting on the Brake Pro™.
2. Connect the shop air supply hose to the coalescing lter. Supply must be greater than the
Operating pressure (90psi).
3. Connect the BLACK Brake Pipe hose with Gladhand to the Brake Pipe tting on the Brake
Pro™.
4. Connect the BLACK Brake Cylinder hose to the Brake Cylinder tting on the Brake Pro™.
5. Insert the dummy coupling into the gladhand.
6. Connect the Brake Cylinder Hose to the pressure tap on the dummy coupling.
7. Run the Daily Test on the application from the Main Menu and select 2P EOC.
8. When nished, disconnect the hos from the dummy coupling pressure tap. Remove the
dummy coupling from the gladhand.

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To prepare for the 4 Pressure End-Of-Car Daily Test:
1. Connect the coalescing lter to the SUPPLY tting on the Brake Pro™.
2. Connect the shop air supply hose to the coalescing lter. Supply must be greater than the
Operating pressure (90psi).
3. Connect the BLACK Brake Pipe hose with Gladhand to the Brake Pipe tting on the Brake
Pro™.
4. Connect the BLUE Auxiliary Reservoir Hose to the Auxiliary tting on the Brake Pro™.
5. Connect the YELLOWYELLOW Emergency Reservoir Hose to the Emergency tting on the Brake
Pro™.
6. Connect the GREEN Brake Cylinder Hose to the Brake Cylinder tting on the Brake Pro™.
7. Insert the Dummy Coupling with Pressure Tap into the Brake Pipe Gladhand.
8. Connect the Downstream BC Hose to the pressure tap on the dummy coupling.
9. Run the Daily Test on the application from the Main Menu and select 4P EOC.
10.When nished, disconnect the hose from the dummy coupling pressure tap. Remove the
dummy coupling from the gladhand.
To prepare for the 4 Pressure Adapter Daily Test:
1. Connect the coalescing lter to the SUPPLY tting on the Brake Pro™.
2. Connect the shop air supply hose to the coalescing lter. Supply must be greater than the
Operating pressure (90psi).
3. Connect the BLACK Brake Pipe hose with Gladhand to the Brake Pipe tting on the Brake
Pro™.
4. Connect the BLUE Auxiliary Reservoir Hose to the Auxiliary tting on the Brake Pro™.
5. Connect the YELLOWYELLOW Emergency Reservoir Hose to the Emergency tting on the Brake
Pro™.
6. Connect the GREEN Brake Cylinder Hose to the Brake Cylinder tting on the Brake Pro™.
7. Connect the BLACK Downstream Brake Cylinder Hose to the Downstream BC tting on the
Brake Pro™.
8. Connect the BLACK 4P Adapter Hose to the 4P Adapter tting on the Brake Pro™.
9. Connect the Brake Cylinder Hose, Auxiliary Hose, Emergency Hose, and 4P Adapter Tube to
the quick-connect ttings on the 4 Pressure Adapter.
10.You will also need the Adapter Blanking Plate for the Daily Test, but this should not be mounted
to start the Daily Test. You will be prompted during the test when to attach the blanking plate to

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the adapter, and the Downstream Brake Cylinder hose to the blanking plate.
11. Run the Daily Test on the application from the Main Menu and select 4P Adapter.
12.When nished, remove the blanking plate from the 4 Pressure Adapter.
Attaching Air Hoses for the Single Car Test
To prepare for the 2 Pressure End-Of-Car Test:
1. Connect the coalescing lter to the SUPPLY tting on the Brake Pro™.
2. Connect the shop air supply hose to the coalescing lter. Supply must be greater than the
Operating Pressure (> 95psi).
3. Connect the BLACK Brake Pipe hose to the Brake Pipe tting on the Brake Pro™ and the
hose gladhand to the gladhand of the car to be tested.
4. Connect the BLACK Brake Cylinder hose to GREEN Brake Cylinder tting on the Brake Pro™
and the other end to the pressure tap on the car to be tested. You will need to use the correct
tting on the Downstream Brake Cylinder hose. The Brake Cylinder pressure tap must be
downstream of the Empty/Load Valve, if applicable.
5. Do NOT yet install the Dummy coupling on the gladhand at the other end of the car. You will
be instructed to do so by the application after starting the test and checking for Brake Pipe
blockage.
6. Run the Single Car Test on the application and select 2P EOC.
To prepare for the 4 Pressure End-Of-Car Test:
1. Connect the coalescing lter to the SUPPLY tting on the Brake Pro™.
2. Connect the shop air supply hose to the coalescing lter. Supply must be greater than the
Operating Pressure (> 95psi).
3. Connect the BLACK Brake Pipe hose to the Brake Pipe tting on the Brake Pro™ and the
hose gladhand to the gladhand of the car to be tested.
4. Connect the BLUE Auxiliary Reservoir Hose to the Auxiliary tting on the Brake Pro™.
Connect the other end to the Auxiliary Quick Connect on the car.
5. Connect the YELLOWYELLOW Emergency Reservoir Hose to the Emergency tting on the Brake
Pro™. Connect the other end to the Emergency Quick Connect on the car.
6. Connect the GREEN Brake Cylinder Hose to the Brake Cylinder tting on the Brake Pro™.
Connect the other end to the Brake Cylinder pressure tap on the car. This pressure tap must
be downstream of the Empty/Load Valve, if applicable.
7. Do NOT yet install the Dummy coupling on the gladhands at the other end of the car. You will
be instructed to do so by the application after starting the test and checking for Brake Pipe
blockage.

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8. Run the Single Car Test on the application and select 4P EOC.
To prepare for the 4 Pressure Adapter Test:
1. Connect the coalescing lter to the SUPPLY tting on the Brake Pro™.
2. Connect the shop air supply hose to the coalescing lter. Supply must be greater than the
Operating Pressure (> 95psi).
3. When connecting the 4 Pressure Adapter, it is usually easier to mount it without the hoses
attached. Once the adapter is mounted, the hoses attach via quick couplings.
4. Connect the BLACK Brake Pipe hose to the Brake Pipe tting on the Brake Pro™ and the
other end to the 4 Pressure Adapter.
5. Connect the BLUE Auxiliary Reservoir Hose to the Auxiliary tting on the Brake Pro™ and the
other end to the 4 Pressure Adapter.
6. Connect the YELLOWYELLOW Emergency Reservoir Hose to the Emergency tting on the Brake Pro™
and the other end to the 4 Pressure Adapter.
7. Connect the GREEN Brake Cylinder Hose to the Brake Cylinder tting on the Brake Pro™. and
the other end to the 4 Pressure Adapter. Connect the BLACK 4 Pressure Adapter tube to the
4P Adapter tting on the Brake Pro™ and the other end to the 4 Pressure Adapter.
8. If the car has an Empty/Load Valve, connect the BLACK lightweight Brake Cylinder hose
to the Downstream BC tting on the Brake Pro™ and the other end to the Brake Cylinder
pressure tap on the car. This pressure tap must be downstream of the Empty/Load Valve, if
applicable.
9. Do NOT yet install the Dummy coupling on the gladhands of the car. You will be instructed to
do so by the application after starting the test and checking for Brake Pipe blockage.
10.Run the Single Car Test on the application and select 4P Adapter .

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Running the Brake Pro™ Application
NOTE: It is important to turn on the Brake Pro™ testing device BEFORE starting the Brake Pro™
application. This will ensure that the devices pair and connect easily the rst time.
Do NOT turn the Brake Pro™ testing device on, or leave it on for long periods of time, without
a supply of pressurized air to the device. Leaving the device on for long periods without a
supply of pressurized air can permanently damage the electronic regulator.
Tap the Brake Pro™ icon on the home screen. The program will start and ask for your Operator ID.
Enter what your company has chosen to use for Operator IDs.
Brake Pro™ Home Screen
Brake Pro™
App
Home Button Show Open Apps
Back Button
Google
Play Store
Settings
Google
Drive
File
Manager +
Gmail
Application Drawer:
Swipe from bottom to top
anywhere on the screen