Atlas Copco ZR160–275 Intercooler (IC) Service Kit Replacement – 2906039400

Atlas Copco 2906039400 – ZR160–275 Intercooler (IC) Service Kit

The Atlas Copco 2906039400 (2906-0394-00) is an IC Service Kit designed for servicing the intercooler system of compatible ZR160–275 oil-free compressors.

The intercooler is an important part of the compressor cooling system. Its primary function is to reduce the temperature of compressed air between compression stages. Proper intercooling helps control air temperature, improve compression efficiency and protect downstream compressor components.

The 2906039400 service kit contains replacement O-rings, plugs and sealing washers required for servicing and re-establishing leak-tight connections within the intercooler assembly.

Working Process:

During normal operation, atmospheric air enters the first compression stage of the ZR-series oil-free compressor.

The first-stage compression increases the pressure and temperature of the air.

The hot compressed air then passes through the intercooler before entering the next compression stage.

The intercooler transfers heat from the compressed air to the cooling medium, reducing the air temperature.

Cooling the air between stages improves the efficiency of the subsequent compression stage and helps control the overall compressor operating temperature.

After passing through the intercooler, the cooled air proceeds to the next compression stage where it is compressed further.

The intercooler assembly contains multiple connections and sealing interfaces. Over time, O-rings and sealing components can become hardened, compressed, damaged or otherwise deteriorated.

During scheduled maintenance, the applicable intercooler connections are opened and the old sealing components are replaced using the 2906039400 IC Service Kit.

New O-rings, plugs and Dowty sealing washers restore the required sealing condition.

After reassembly, the intercooler circuit can operate with the required pressure containment and reduced risk of air or cooling-medium leakage.

Main Functions:

• Supports servicing of the intercooler assembly.
• Replaces deteriorated O-rings.
• Replaces applicable plugs.
• Replaces Dowty sealing washers.
• Restores sealing at intercooler connections.
• Helps prevent compressed-air leakage.
• Helps prevent cooling-medium leakage at serviced connections.
• Supports efficient intercooling.
• Helps maintain reliable compressor operation.

Official Kit Components:

Atlas Copco’s official catalog lists the following components in the 2906039400 IC Service Kit:

• O-ring – 1 pc
• Plug 1/4 A A – 2 pcs
• O-ring – 1 pc
• O-ring – 1 pc
• O-ring – 3 pcs
• O-ring 279.3 × 5.7 – 2 pcs
• Dowty Seal Washer 1/4 – 2 pcs
• O-ring – 1 pc

The Atlas Copco official catalog lists the kit weight as approximately 1.17 lb (about 0.53 kg).

Intercooler Operating Cycle:

1. Air Intake: Atmospheric air enters the compressor.
2. First-Stage Compression: The first compressor element compresses the air.
3. Temperature Increase: Compression increases the air temperature.
4. Intercooler Entry: Hot compressed air enters the intercooler.
5. Heat Transfer: Heat is transferred from the compressed air to the cooling medium.
6. Air Cooling: The compressed air temperature decreases.
7. Second-Stage Compression: The cooled air enters the next compression stage.
8. Final Compression: The air is compressed to the required final pressure.
9. Compressed-Air Delivery: The final compressed air proceeds through the downstream system.

Importance of Intercooler Sealing:

The intercooler operates under pressure and contains multiple connections.

Effective sealing is therefore essential.

A deteriorated O-ring or sealing washer can result in leakage from the intercooler circuit.

Possible consequences include:

• Reduced compressor efficiency.
• Loss of compressed air.
• Cooling-system leakage.
• Increased operating temperature.
• Reduced intercooling performance.
• Unstable compressor operation.
• Increased maintenance requirements.

Replacing the sealing components during intercooler service helps restore the integrity of the assembly.

Possible Failure Conditions:

Long-term operation can cause sealing components to deteriorate because of:

• Temperature cycling
• Pressure fluctuations
• Ageing
• Compression set
• Contamination
• Improper installation
• Mechanical damage
• Incorrect sealing-surface condition

Typical symptoms may include:

• Air leakage around intercooler connections.
• Cooling-medium leakage.
• Increased discharge/interstage temperature.
• Reduced compressor efficiency.
• Abnormal pressure behavior.
• Visible contamination around connections.
• Repeated leakage after previous maintenance.

A leak around an intercooler should be diagnosed carefully because leakage may originate from fittings, tubing, gaskets, valves or other nearby components.

Maintenance Procedure:

Before servicing the intercooler, stop the compressor and isolate all relevant electrical and pneumatic energy sources.

Completely depressurize the compressor and allow hot components to cool to a safe working temperature.

Access the intercooler assembly according to the applicable Atlas Copco service procedure.

Inspect:

• O-rings
• Sealing surfaces
• Plugs
• Dowty washers
• Intercooler connections
• Housing surfaces
• Signs of corrosion or contamination
• Evidence of air or cooling-medium leakage

Remove the old sealing components carefully.

Clean the mating and sealing surfaces.

Install the replacement O-rings, plugs and Dowty sealing washers from the 2906039400 service kit.

Ensure that:

• O-rings are correctly sized and seated.
• O-rings are not twisted or damaged.
• Sealing surfaces are clean.
• Plugs are correctly positioned.
• Dowty washers are correctly installed.
• Connections are properly secured.
• No foreign material remains in the intercooler circuit.

After assembly, perform the applicable pressure/leak checks.

Restart the compressor according to the manufacturer’s procedure.

Monitor the intercooler during operation for:

• Air leakage
• Cooling-medium leakage
• Abnormal temperature
• Abnormal pressure
• Unusual noise
• Reduced compressor performance

Service Benefits:

Using the Atlas Copco 2906039400 IC Service Kit during appropriate maintenance helps:

• Restore intercooler sealing.
• Reduce leakage risk.
• Maintain proper interstage cooling.
• Support compressor efficiency.
• Protect downstream compression components.
• Reduce unplanned downtime.
• Maintain reliable oil-free compressor operation.

The kit is particularly useful when the intercooler assembly is opened during scheduled maintenance and the original sealing components should not simply be reused.

Part Number: 2906039400
Alternative Number: 2906-0394-00 / 2906 0394 00
Brand: Atlas Copco
Official Description: IC Service Kit for ZR/ZT Oil-Free Compressors
Common Application Reference: ZR160–275
Component Type: Intercooler service/sealing kit
Primary Function: Restores sealing of the intercooler assembly
Main Components: O-rings, 1/4 plugs and Dowty seal washers
Official Listed Weight: Approximately 1.17 lb / 0.53 kg
Operating Function: Supports leak-tight intercooler connections during multi-stage compression
Main Benefits: Reduced leakage, restored intercooler sealing, reliable interstage cooling and dependable compressor performance.

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