Atlas Copco ZR55–90 Cooler Service Kit Replacement – 2906067300

Atlas Copco 2906067300 – ZR55–90 Cooler Service Kit

The Atlas Copco 2906067300 (2906-0673-00) is a Cooler Service Kit for ZR55–90 oil-free compressors. It is designed for servicing the cooler assembly and replacing the sealing components required to maintain reliable operation.

The kit is intended for Atlas Copco ZR and ZT stationary oil-free compressors. Atlas Copco lists the kit weight as approximately 470 g.

Working Process:

During normal operation, atmospheric air enters the oil-free compressor and passes through the compression stages.

Compression increases both the pressure and temperature of the air. The heated compressed air then passes through the applicable cooler, where heat is transferred from the compressed air to the cooling medium.

As heat is removed, the compressed-air temperature decreases. The cooled air can then continue to the next stage of compression or downstream compressed-air system, depending on the compressor configuration.

The cooler therefore helps control operating temperature and maintain efficient compressor performance.

During scheduled maintenance, the cooler assembly and its sealing points are inspected. O-rings, Dowty washers and gaskets can deteriorate due to temperature, pressure cycling, vibration and ageing.

The 2906067300 Cooler Service Kit supplies replacement sealing components to restore the sealing integrity of the cooler assembly.

Main Functions:

• Supports cooler servicing on ZR55–90 compressors.
• Replaces worn or deteriorated sealing components.
• Helps prevent compressed-air leakage.
• Helps prevent cooling-medium leakage.
• Maintains pressure integrity of cooler connections.
• Supports effective heat transfer.
• Helps maintain proper compressor temperature.
• Supports reliable oil-free compressor operation.
• Helps reduce maintenance-related downtime.

Official Product Information:

Part Number: 2906067300
Alternative Number: 2906-0673-00 / 2906 0673 00
Official Description: ZR55–90 Cooler Service Kit
Used In Product: ZR, ZT
Product Family: Stationary Oil Free Compressor
Official Listed Weight: 470 g

Officially Listed Components:

Atlas Copco lists the following components in the kit:

• O-Ring 50 × 3.5 – 2 pcs
• O-Ring – 1 pc
• O-Ring – 1 pc
• O-Ring – 2 pcs
• O-Ring – 1 pc
• O-Ring – 1 pc
• O-Ring – 1 pc
• O-Ring – 3 pcs
• O-Ring 59.5 × 3 – 1 pc
• O-Ring – 1 pc
• O-Ring 114.5 × 3 – 2 pcs
• O-Ring – 1 pc
• Seal Washer Dowty 1/4 – 5 pcs
• Gasket – 1 pc

Cooler Operating Cycle:

1. Air Intake: Atmospheric air enters the compressor.
2. Compression: Air is compressed and its temperature rises.
3. Hot-Air Flow: Heated compressed air reaches the cooler.
4. Heat Transfer: Heat moves from the compressed air to the cooling medium.
5. Temperature Reduction: The compressed-air temperature decreases.
6. Cooled-Air Flow: Cooled air continues through the compressor system.
7. Continuous Cooling: The process continues while the compressor operates.

Role of O-Rings:

The O-rings provide leak-tight sealing between applicable cooler components.

During long-term operation, O-rings can be affected by:

• Temperature cycling
• Pressure fluctuations
• Vibration
• Compression set
• Ageing
• Loss of elasticity
• Mechanical damage

A deteriorated O-ring can allow leakage and reduce the integrity of the cooler assembly. Replacing the O-rings during scheduled maintenance restores the required sealing condition.

Role of Dowty Seal Washers:

The 1/4-inch Dowty seal washers are installed at applicable threaded connections.

When the connection is correctly tightened, the elastomer sealing element forms a barrier against leakage while the metal portion provides mechanical support.

Role of Gasket:

The gasket provides sealing between the applicable mating surfaces.

When compressed during assembly, it fills minor surface irregularities and prevents the operating medium from escaping through the joint.

Possible Failure Conditions:

Cooler sealing or performance can deteriorate because of:

• Normal seal ageing.
• High operating temperature.
• Pressure cycling.
• Vibration.
• Contamination.
• Corrosion.
• Damaged mating surfaces.
• Incorrect installation.
• Over-tightening.
• Under-tightening.
• Reuse of old sealing components.

Possible symptoms include:

• Air leakage.
• Cooling-medium leakage.
• Increased discharge temperature.
• Reduced cooling performance.
• High-temperature alarms.
• Increased compressor energy consumption.
• Reduced compressor efficiency.
• Compressor shutdown.

These symptoms may also be caused by restricted cooling flow, contaminated heat-transfer surfaces, sensors, fans or other cooling-system components, so proper diagnosis is required.

Maintenance Procedure:

Before servicing the cooler, shut down the compressor according to the applicable Atlas Copco procedure.

Isolate the electrical supply and relevant pneumatic/cooling circuits.

Depressurize the applicable system and allow hot components to cool to a safe working temperature.

Inspect the cooler for:

• Leakage.
• Dirt and contamination.
• Corrosion.
• Damaged O-rings.
• Damaged washers.
• Damaged gaskets.
• Scratched mating surfaces.
• Mechanical damage.
• Restricted cooling passages.

Remove the old sealing components.

Clean the applicable mating and sealing surfaces.

Install the replacement components supplied with the 2906067300 Cooler Service Kit.

Ensure:

• Correct O-ring sizes are used.
• O-rings are properly seated.
• O-rings are not twisted or pinched.
• Dowty washers are correctly positioned.
• The gasket is correctly installed.
• Mating surfaces are clean.
• Cooling passages are free of foreign material.
• Connections are tightened according to the applicable Atlas Copco service procedure.

After assembly, perform the applicable leak and functional checks.

Restart the compressor and allow it to reach normal operating conditions.

Monitor:

• Compressor temperature.
• Cooler performance.
• Air pressure.
• Cooling-medium flow.
• Air leakage.
• Cooling-medium leakage.
• Alarm conditions.
• Overall compressor stability.

Service Benefits:

Using the Atlas Copco 2906067300 Cooler Service Kit during appropriate maintenance helps:

• Restore cooler sealing.
• Reduce leakage.
• Maintain effective cooling.
• Support proper operating temperature.
• Protect compressor components.
• Maintain pressure integrity.
• Improve compressor reliability.
• Reduce the risk of unexpected downtime.

Technical Summary:

Part Number: 2906067300
Alternative Part Number: 2906-0673-00
Brand: Atlas Copco
Official Description: ZR55–90 Cooler Service Kit
Application: ZR / ZT stationary oil-free compressors
Official Weight: 470 g
Component Type: Cooler maintenance/service kit
Primary Function: Replacement of cooler sealing components
Operating Function: Maintains leak-tight cooler connections while supporting effective heat transfer
Main Components: O-rings, Dowty seal washers and gasket
Main Benefits: Reliable sealing, reduced leakage, effective cooling and dependable compressor operation.

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