Atlas Copco ZR110–145 Cooler Service Kit Replacement – 2906073400

Atlas Copco 2906073400 – ZR110–145 Cooler Service Kit

The Atlas Copco 2906073400 (2906-0734-00) is a Cooler Service Kit for ZR110–145 oil-free compressors. It is intended for servicing the compressor cooling assemblies and replacing worn sealing components during preventive maintenance or cooler overhaul.

The cooler system plays an important role in controlling the temperature of the compressed air and compressor components. During compression, air temperature increases substantially. Effective cooling removes this heat and helps the compressor operate within its designed temperature range.

The 2906073400 service kit provides replacement sealing components used at cooler connections. Replacing these components during scheduled maintenance helps restore leak-tight connections and maintain the integrity of the cooling system.

Working Process:

During operation, atmospheric air enters the Atlas Copco ZR compressor.

The air is compressed through the compressor stages, causing its pressure and temperature to increase.

The heated compressed air passes through the applicable cooling assemblies.

Cooling removes heat from the compressed air and transfers it to the cooling medium.

The cooled air then continues through the compressor process toward the next stage or downstream system, depending on the particular cooler being serviced.

For the cooling system to operate correctly, its connections must remain properly sealed.

During maintenance, the cooler assembly is opened or disconnected as required. Existing washers and O-rings may have become hardened, flattened, damaged or permanently compressed after prolonged operation.

The 2906073400 Cooler Service Kit provides replacement sealing components for these service points.

After installation and correct tightening, the new seals create a leak-tight barrier between the mating surfaces.

This helps maintain the required cooling-system pressure and prevents unwanted leakage.

Main Functions:

• Provides replacement seals for ZR110–145 cooler servicing.
• Supports preventive cooler maintenance.
• Helps restore sealing performance.
• Helps prevent air leakage.
• Helps prevent cooling-medium leakage.
• Supports effective heat transfer.
• Helps maintain proper compressor temperature.
• Supports reliable compressor operation.
• Helps reduce the risk of unplanned downtime.

Application:

Part Number: 2906073400
Alternative Number: 2906-0734-00 / 2906 0734 00
Official/Parts Description: ZR110–145 Cooler Service Kit
Application: Atlas Copco ZR110–145 compressors

Parts references identify 2906073400 as the ZR110–145 Cooler Service Kit, while a DEWA procurement document specifies it for a ZR145 compressor.

Known Kit Components:

A DEWA procurement document identifies the following components under the 2906073400 kit:

• Washer M12 – PN 661100038
• Seal Washer Dowty 1/2+ – PN 661100039
• Seal Washer M32 – PN 661100044
• Washer M48 – PN 661100046
• Seal Washer M14 – PN 661100060
• Seal Washer 1-1/2+ – PN 661100061
• O-Ring – PN 663210725
• O-Ring – PN 663210727
• Additional O-ring/sealing components included in the service kit.

The procurement document specifically identifies the kit as KIT; COOLER; SERVICE; ZR145.

Cooling Operating Cycle:

1. Air Intake: Atmospheric air enters the compressor.
2. Compression: The compressor raises the air pressure.
3. Heat Generation: Compression increases air temperature.
4. Cooler Entry: Hot compressed air reaches the applicable cooler.
5. Heat Transfer: Heat is transferred from the compressed air to the cooling medium.
6. Temperature Reduction: The compressed-air temperature decreases.
7. Continued Compression/Delivery: Cooled air continues through the compressor system.
8. Continuous Operation: Cooling continues while the compressor operates.

Importance of Cooler Servicing:

A cooler that is contaminated, restricted or improperly sealed may not provide the required cooling performance.

Possible consequences include:

• Increased air temperature.
• Higher interstage or discharge temperature.
• Increased thermal stress.
• Reduced compressor efficiency.
• High-temperature alarms.
• Increased energy consumption.
• Reduced compressor reliability.
• Compressor shutdown.

Regular cooler inspection and replacement of deteriorated seals help maintain the cooling system’s operating integrity.

Role of Sealing Washers:

The sealing washers supplied in the kit are installed at applicable threaded and bolted cooler connections.

When the connection is tightened correctly, the washer is compressed against the mating surface.

This creates a barrier that prevents the operating medium from escaping.

Damaged or reused sealing washers may not provide the required sealing performance.

Role of O-Rings:

O-rings provide sealing between applicable cooler components.

During long-term compressor operation, O-rings can experience:

• Heat exposure.
• Pressure cycling.
• Vibration.
• Compression set.
• Hardening.
• Loss of elasticity.
• Surface damage.

Replacing them during cooler servicing restores the sealing condition of the assembly.

Possible Failure Conditions:

Cooler sealing and performance may deteriorate because of:

• Normal seal ageing.
• High temperature.
• Vibration.
• Incorrect installation.
• Over-tightening.
• Under-tightening.
• Dirty mating surfaces.
• Corrosion.
• Cooler contamination.
• Damaged sealing surfaces.
• Reuse of old seals.

Possible symptoms include:

• Air leakage.
• Cooling-medium leakage.
• High compressor temperature.
• Increased discharge temperature.
• Reduced cooling performance.
• Pressure instability.
• High-temperature alarms.
• Increased energy consumption.
• Unexpected compressor shutdown.

Maintenance Procedure:

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

Isolate the electrical supply.

Isolate the applicable pneumatic and cooling circuits.

Depressurize the relevant system.

Allow hot components to cool to a safe working temperature.

Inspect the cooler and connections for:

• Leakage.
• Corrosion.
• Dirt.
• Damaged seals.
• Damaged washers.
• Scratched mating surfaces.
• Mechanical damage.
• Restricted cooling passages.

Remove the old sealing components.

Clean all mating and sealing surfaces.

Select the correct replacement components from the 2906073400 Cooler Service Kit.

Install each washer and O-ring at its designated location.

Ensure:

• O-rings are not twisted.
• Seals are not cut or damaged.
• Washers are correctly positioned.
• Mating surfaces are clean.
• Correct component sizes are used.
• Connections are tightened according to the applicable Atlas Copco service procedure.

After reassembly, perform the applicable leak checks.

Restore the cooling system.

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 operation.

Service Benefits:

Using the Atlas Copco 2906073400 Cooler Service Kit during appropriate maintenance helps:

• Restore cooler sealing.
• Reduce leakage.
• Maintain cooling-system integrity.
• Support effective heat transfer.
• Control compressor operating temperature.
• Reduce thermal stress.
• Support compressor efficiency.
• Improve equipment reliability.
• Reduce unexpected downtime.

Part Number: 2906073400
Alternative Number: 2906-0734-00 / 2906 0734 00
Brand: Atlas Copco
Description: ZR110–145 Cooler Service Kit
Application: ZR110–145 oil-free compressors
Component Type: Cooler maintenance/service kit
Primary Function: Replacement of cooler sealing components
Operating Function: Maintains leak-tight cooler connections and supports effective cooling
Main Components: Washers, Dowty seal washers, seal washers and O-rings
Main Benefits: Reliable sealing, reduced leakage, effective cooling and dependable compressor operation.

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