Atlas Copco ZR5 Aftercooler Service Kit Replacement – 2910501900

The Atlas Copco 2910501900 is a service kit for the aftercooler/cooling system of applicable oil-free compressors, particularly the ZR5 configuration. Atlas Copco’s official listing specifies that the service kit is designed for stationary oil-free ZR/ZT/ZW/ZRV compressors and provides service coverage of up to 8,000 operating hours. The official listed kit weight is 790 g.

The aftercooler reduces the temperature of compressed air after compression. Because compression generates considerable heat, effective aftercooler performance is necessary to maintain the required compressed-air temperature and protect downstream equipment.

Working Process

1. Air Compression – Atmospheric air enters the oil-free compressor and is compressed.
2. Heat Generation – Compression raises the temperature of the compressed air.
3. Hot-Air Transfer – The heated compressed air flows toward the aftercooler.
4. Heat Exchange – Heat is transferred from the compressed air through the aftercooler surfaces to the cooling medium.
5. Air Cooling – The compressed-air temperature is reduced.
6. Condensation – Cooling can cause moisture to condense from the compressed air.
7. Moisture Management – The downstream system removes or manages the resulting condensate.
8. Cooled-Air Delivery – The cooled compressed air continues toward the plant air system.
9. Continuous Operation – The cooling cycle continues whenever the compressor is operating.

Main Functions

• Services the ZR5 aftercooler assembly.
• Replaces worn gaskets, O-rings and sealing washers.
• Restores reliable sealing.
• Helps prevent air leakage.
• Supports efficient heat transfer.
• Maintains appropriate compressed-air temperature.
• Helps protect downstream equipment.
• Supports reliable compressor operation.

Official Kit Information

Atlas Copco lists the following specifications for 2910501900:

Kit Components

Atlas Copco’s official listing includes multiple sealing components, including:

• O-rings
• Gaskets
• Gasket 60 × 68 × 2.5
• Gasket 21 × 26 × 1.5
• Seal Washer M32
• Gasket Type 1 – 121 × 162 × 2
• Gasket Type 1 – 90 × 142 × 2
• Seal Washer 21.5 × 28 × 2.5
• Lock washers
• O-ring 199.3 × 5.7
• Gasket 13 × 20 × 1.5
• Gasket 250 × 212 × 2
• Dowty Seal Washer 1/2+

The exact quantity varies by component; Atlas Copco’s official listing provides the individual quantities.

Role of the Sealing Components

The O-rings, gaskets and sealing washers maintain leak-tight joints within the aftercooler assembly.

They help prevent:

• Compressed-air leakage
• Cooling-medium leakage
• Pressure loss
• Unwanted contamination

With operating time, seals can experience hardening, compression set, thermal ageing, vibration and surface deterioration. Replacing these components during scheduled service restores the sealing condition.

Possible Failure Symptoms

Poor aftercooler condition or deteriorated seals can result in:

• High compressed-air outlet temperature
• Reduced cooling performance
• Air leakage
• Cooling-medium leakage
• Excessive condensate
• Increased thermal stress
• Temperature alarms
• Reduced compressor efficiency
• Compressor shutdown

Maintenance Procedure

1. Shut down the compressor according to the applicable Atlas Copco procedure.
2. Isolate the electrical supply.
3. Depressurize the compressed-air system.
4. Allow hot components to cool.
5. Isolate the applicable cooling circuit.
6. Remove the aftercooler service connections.
7. Inspect the cooler and sealing surfaces.
8. Remove old gaskets, O-rings and sealing washers.
9. Clean the mating surfaces.
10. Install the replacement components from 2910501900.
11. Ensure O-rings are correctly seated and not twisted or pinched.
12. Install gaskets and sealing washers in their specified locations.
13. Reassemble the aftercooler according to the applicable service procedure.
14. Restore the air and cooling circuits.
15. Restart the compressor.
16. Check for air/cooling-medium leakage.
17. Monitor compressed-air temperature and compressor operation.

Service Benefits

Using the 2910501900 ZR5 Aftercooler Service Kit during the appropriate service interval helps:

• Restore aftercooler sealing.
• Maintain cooling efficiency.
• Reduce leakage.
• Maintain proper compressed-air temperature.
• Protect downstream equipment.
• Improve compressor reliability.
• Reduce unexpected maintenance downtime.

Technical Summary

Part Number: 2910501900
Alternative: 2910-5019-00
Brand: Atlas Copco
Description: ZR5 Service Kit / Aftercooler Service Kit
Application: Oil-free ZR/ZT/ZW/ZRV compressor families
Service Interval: Up to 8,000 hours
Weight: 790 g
Primary Function: Aftercooler servicing and replacement of sealing components
Main Benefit: Reliable cooling, sealing and compressor performance.

Recommended catalog title: Atlas Copco 2910501900 – ZR5 Aftercooler Service Kit, 2910-5019-00, for Oil-Free Compressors.

Compatibility note: There is some variation in aftermarket descriptions—some sources call it an intercooler kit, while Atlas Copco’s own current listing identifies 2910501900 as a ZR5 Service Kit. For cataloging, the Atlas Copco official description should take priority.