Atlas Copco HP Element Exchange Kit Replacement – 2906038700

The Atlas Copco 2906038700 HP Element Exchange Kit is used for replacement/service of the high-pressure (HP) compressor element in ZR160–275 oil-free compressors. The HP element performs the second stage of compression, receiving air from the LP stage and raising it to the required final pressure.

Working Process

1. Air Intake – Atmospheric air enters the compressor.
2. LP Compression – The low-pressure element performs the first compression stage.
3. Intercooling – Partially compressed air is cooled before entering the HP stage.
4. HP Compression – The HP element further increases the air pressure.
5. Element Exchange – During major maintenance, the worn HP element is replaced using this exchange kit.
6. Sealing & Alignment – The replacement components ensure proper sealing and correct element positioning.
7. Final Compression – The HP stage supplies compressed air toward the aftercooler and outlet system.
8. Continuous Operation – The two-stage oil-free compression cycle continues during normal operation.

Main Functions

• Supports HP compressor-element replacement.
• Helps restore compression performance.
• Provides required service/sealing components.
• Helps maintain correct element alignment.
• Reduces the risk of compressed-air leakage.
• Supports reliable two-stage oil-free compression.
• Helps reduce downtime during major service.

Possible Failure Symptoms

A worn HP element or damaged sealing components can contribute to:

• Reduced discharge pressure.
• Reduced air delivery.
• Increased energy consumption.
• Abnormal vibration or noise.
• Increased operating temperature.
• Air leakage.
• Reduced compressor efficiency.
• Compressor performance alarms.

Maintenance / Exchange Procedure

1. Shut down the compressor according to the applicable Atlas Copco service procedure.
2. Isolate and lock out the electrical supply.
3. Fully depressurize the compressor.
4. Allow the equipment to cool.
5. Remove the required HP-stage covers and connections.
6. Disconnect and remove the existing HP element.
7. Inspect the housing, shaft and mounting surfaces.
8. Clean the mating surfaces.
9. Install the replacement HP element and components from 2906038700.
10. Replace the applicable seals and gaskets.
11. Check shaft alignment and free rotation.
12. Tighten mounting hardware according to Atlas Copco specifications.
13. Reconnect all air and service connections.
14. Restart the compressor.
15. Check for leakage, abnormal vibration and noise.
16. Verify discharge pressure, temperature and overall performance.

Technical Summary

Recommended catalog title:
Atlas Copco 2906038700 – ZR160–275 HP Compressor Element Exchange Kit, 2906-0387-00.

Atlas Copco’s official page confirms 2906038700 as the ZR160–275 HP Element Exchange Kit. Independent parts references also identify 2906-0387-00 / 2906038700 specifically for the ZR160–275 HP application.

Related part: 2906038600 is the corresponding ZR160–275 LP Element Exchange Kit.

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