S-1695 Service Bulletin/Repair Instructions

Bendix® GSAT® (Global Scalable Air Treatment) Core Module Replacement Kits

for Volvo® Trucks

KIT COMPONENTS

See Figure 1. The following components are in the Bendix®

GSAT® (Global Scalable Air Treatment) core module kits

for Volvo® trucks:

Item No.
Component
Quantity
1
Core Module 2X EPB for

Attached Air Dryer Variant
1
2
Seal
1
Bendix Volvo Kit Part Number: K202682K57

Volvo Kit Part Number: 24865982

Bendix Mack® Kit Part Number: K202683K57

Mack Kit Part Number: 24865984

Item No.
Component
Quantity
3
Core Module 2X EPB for

Detached Air Dryer Variant
1
Bendix Volvo Kit Part Number: K273506SC

Bendix Mack Kit Part Number: K273508SC

Item No.
Component
Quantity
4
Core Module 2X EPB CFL for

Detached Air Dryer Variant
1
Bendix Volvo Kit Part Number: K273509SC

Bendix Mack Kit Part Number: K273510SC

Item No.
Component
Quantity
5
Core Module 1X EPB for

Attached Air Dryer Variant
1
6
Seal
1
Bendix Volvo Kit Part Number: K202680K57

Volvo Kit Part Number: 24865981

Bendix Mack Kit Part Number: K202681K57

Mack Kit Part Number: 24865983

Item No.
Component
Quantity
7
Core Module 1X EPB for

Detached Air Dryer Variant
1
Bendix Volvo Kit Part Number: K273511SC

Bendix Mack Kit Part Number: K273512SC
1
GENERAL SAFETY GUIDELINES
WARNING! PLEASE READ AND

FOLLOW THESE INSTRUCTIONS

TO AVOID PERSONAL INJURY OR DEATH:
When working on or around a vehicle, the following

guidelines should be observed AT ALL TIMES:

▲Park the vehicle on a level surface, apply the parking

brakes and always block the wheels. Always wear personal

protection equipment.

▲Stop the engine and remove the ignition key when working

under or around the vehicle. When working in the engine

compartment, the engine should be shut oﬀ and the ignition

key should be removed. Where circumstances require that

the engine be in operation, EXTREME CAUTION should be

used to prevent personal injury resulting from contact with

moving, rotating, leaking, heated or electrically-charged

components.

▲Do not attempt to install, remove, disassemble or

assemble a component until you have read, and thoroughly

understand, the recommended procedures. Use only the

proper tools and observe all precautions pertaining to use

of those tools.

▲If the work is being performed on the vehicle’s air brake

system, or any auxiliary pressurized air systems, make

certain to drain the air pressure from all reservoirs before

beginning ANY work on the vehicle. If the vehicle is

equipped with a Bendix® AD-IS® air dryer system, a Bendix®

DRM™ dryer reservoir module, a Bendix ® AD-9si ®, AD-HF®,

or AD-HFi ® air dryer, be sure to drain the purge reservoir.

▲Following the vehicle manufacturer’s recommended

procedures, deactivate the electrical system in a manner

that safely removes all electrical power from the vehicle.

▲Never exceed manufacturer’s recommended pressures.

▲Never connect or disconnect a hose or line containing

pressure; it may whip and/or cause hazardous airborne

dust and dirt particles. Wear eye protection. Slowly open

connections with care, and verify that no pressure is

present. Never remove a component or plug unless you are

certain all system pressure has been depleted.

▲Use only genuine Bendix ® brand replacement parts,

components and kits. Replacement hardware, tubing, hose,

fittings, wiring, etc. must be of equivalent size, type and

strength as original equipment and be designed specifically

for such applications and systems.

▲Components with stripped threads or damaged parts should

be replaced rather than repaired. Do not attempt repairs

requiring machining or welding unless specifically stated

and approved by the vehicle and component manufacturer.

▲Prior to returning the vehicle to service, make certain all

components and systems are restored to their proper

operating condition.

▲For vehicles with Automatic Traction Control (ATC), the ATC

function must be disabled (ATC indicator lamp should be

ON) prior to performing any vehicle maintenance where

one or more wheels on a drive axle are lifted oﬀ the ground

and moving.

▲The power MUST be temporarily disconnected from the

radar sensor whenever any tests USING A DYNAMOMETER

are conducted on a vehicle equipped with a Bendix ®

Wingman ® system.

▲You should consult the vehicle manufacturer's operating

and service manuals, and any related literature, in

conjunction with the Guidelines above.
DESCRIPTION

IMPORTANT

Do not install the core module included in this kit if it

does not match the one being removed.

These kits are used to replace the Bendix® GSAT® (Global

Scalable Air Treatment) core module. These are not retrofit

kits. These kits cannot be installed on vehicles that do

not have an existing GSAT system. As shown in Figure 1,

there are several variants of the GSAT air dryer. Be sure to

verify the core module included in this kit is identical

to the core module you are replacing. Ensure both core

modules have the same port and mounting configurations

in the same locations.
When replacing the core module assembly, it is mandatory

that the air dryer cartridge and carbon filter be replaced.

For replacement kit part numbers and instructions, refer

to S-1693, Bendix® GSAT® (Global Scalable Air Treatment)

Air Dryer Cartridge and Carbon Filter Kits for Volvo®

Trucks, on B2Bendix.com.

NOTE: When replacing the air dryer cartridge, the cartridge

lifetime wear and wetness content will need to be reset. Use

Bendix® ACom® Diagnostic Software, or a Volvo® diagnostic

tool, to initiate the cartridge reset routines.
VEHICLE PREPARATION

1. Park the vehicle on a level surface and chock the wheels.

2. Turn the ignition switch OFF.

3. Drain all reservoirs to 0 psi (0 kpa).

4. Clean the exterior of the air dryer body to remove any

dirt and debris.
Always depressurize all air dryers and air reservoirs on

the vehicle to 0 psi (0 kpa) before servicing the air dryer.

Failure to drain the air pressure from all air dryers and

air reservoirs may result in injury and/or death.
Figure 1 – Core Module Kits
2
Air Connection

Port ID
Function/

Connection
Port Size

ISO 4039-2
Maximum

Torque
11 IN
Energy Inlet

Compressor
M22x1.5
44 ft-lb

(60 N•m)
12 IN
Energy Inlet

External Air Fill
M22x1.5
44 ft-lb

(60 N•m)
2.1 DEL
Energy Outlet to

Detached Core

Module
M22x1.5
44 ft-lb

(60 N•m)
4.5 CON
Control Line to

Detached Core

Module
M12x1.5
22 ft-lb

(30 N•m)
3 EXH
Exhaust
n/a
n/a
13
Supply from

Detached Dryer*
M22x1.5
29.5 + 5 ft-lb

(40 + 7 N•m)
14
Supply from

Secondary Dryer

(CFL)
M22x1.5
29.5 + 5 ft-lb

(40 + 7 N•m)
21
Energy Outlet

Service Brake

Front Axle
M22x1.5
29.5 + 5 ft-lb

(40 + 7 N•m)
22
Energy Outlet

Service Brake Rear

Axle
M22x1.5
29.5 + 5 ft-lb

(40 + 7 N•m)
23
Energy Outlet

Clutch and

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