Atlas Copco LP Element Exchange Kit Replacement – 2906038600

The Atlas Copco 2906038600 LP Element Exchange Kit is a service kit used when replacing the low-pressure (LP) compressor element in applicable ZR160–275 oil-free compressors. The kit contains replacement sealing components required to correctly install the LP element and maintain airtight connections.

The LP element performs the first stage of compression in the two-stage oil-free compression system. After the LP stage, the partially compressed air is cooled and then sent to the high-pressure stage.

Working Process

1. Air Intake – Atmospheric air enters the LP compressor element.
2. LP Compression – The rotating compression element increases the air pressure.
3. Intercooling – The partially compressed air is cooled before entering the HP stage.
4. Element Exchange – During major maintenance, the worn LP element is replaced.
5. Sealing – O-rings and seal washers supplied in the kit provide leak-tight connections.
6. Alignment – Correct installation maintains proper shaft and element alignment.
7. HP Compression – The pre-compressed air continues to the high-pressure element.
8. Continuous Operation – The two-stage compression cycle continues during normal compressor operation.

Kit Components

Atlas Copco’s official Web Shop lists components including:

Kit weight: approximately 504 g.

Main Functions

• Supports replacement of the LP compressor element.
• Provides replacement sealing components.
• Prevents compressed-air leakage.
• Helps maintain correct element alignment.
• Restores LP-stage compression performance.
• Supports reliable two-stage oil-free compression.
• Helps reduce downtime during major service.

Possible Failure Symptoms

A worn LP element or damaged sealing components may cause:

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

Maintenance / Element Exchange Procedure

1. Shut down the compressor following 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 LP-stage connections and covers.
6. Disconnect and remove the existing LP element.
7. Inspect the housing, shaft and mounting surfaces.
8. Clean all mating surfaces.
9. Install the replacement LP element.
10. Replace the O-rings, washer and Dowty seal washers supplied with 2906038600.
11. Ensure all seals are correctly seated and undamaged.
12. Check shaft alignment and free rotation.
13. Tighten mounting hardware according to applicable Atlas Copco specifications.
14. Reconnect the air and service connections.
15. Restart the compressor.
16. Check for air leakage, abnormal vibration and noise.
17. Verify pressure, temperature and overall compressor performance.

Technical Summary

Recommended catalog title:
Atlas Copco 2906038600 – ZR160–275 LP Compressor Element Exchange Kit for Oil-Free Compressors, 2906-0386-00.

Atlas Copco’s official listing confirms 2906038600 as the ZR160–275 LP Element Exchange Kit, while its Web Shop provides the component list and 504 g kit weight.

Note: The related 2906038700 is listed as the next element exchange kit in the same parts sequence, while 2906038600 is specifically the LP kit.