Product
Ingersoll Rand 49164395 Air Filter Element | Donaldson FPG10 RadialSeal
Ingersoll Rand 49164395 air filter element built to Donaldson FPG10 two-stage RadialSeal specification for screw compressors. 99.9% filtration efficiency (ISO 5011), 208 mm OD x 106 mm ID x 409 mm length, tangential pre-cleaner removes up to 85% of coarse dust, tool-free installation.
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Product Overview
49164395 is the intake air filter element for Ingersoll Rand screw air compressors, manufactured to the Donaldson FPG10 specification. It is a two-stage RadialSeal primary element, not a conventional single-stage filter.
Air first passes through an integrated tangential pre-cleaner, where high-speed rotation throws coarse particles against the housing wall. Approximately 85% of coarse dust is separated before reaching the main element and is discharged automatically through the Vacuator dust valve at the housing base. The pre-cleaned air then enters the main cellulose filter for fine filtration. This two-stage design is most valuable in dusty environments: the primary element carries only fine-particle load, maintaining longer service life under high dust conditions.
Sealing differs from traditional axial filters. FPG uses Donaldson RadialSeal technology: a one-piece molded polyurethane end cap forms a radial seal directly against the housing outlet tube, eliminating the glued gasket of older axial elements. Fewer parts mean fewer failure points — gasket aging, detachment, and misalignment are eliminated, and no tools are required for installation or removal.
Core Specifications
| Item | Value |
|---|---|
| Part Number | 49164395 |
| Name | Air Filter Element |
| Brand | Ingersoll Rand |
| Specification Source | Donaldson FPG10 (two-stage RadialSeal) |
| Role in Assembly | Primary Element |
| Dimensions | 208 mm OD x 106 mm ID x 409 mm length |
| Sealing | RadialSeal (polyurethane end cap, no gasket) |
| Net Weight | Approx. 1.88 kg |
| Filtration Efficiency | 99.9% (ISO 5011) |
| Pre-Cleaner Efficiency | Up to 85% coarse dust removal |
| Rated Airflow | ≤346 cfm / 9.8 m³/min |
| Recommended Change Interval | 2000 hours or 3 months |
Technical Parameters
Filtration Performance
| Parameter | Value / Description |
|---|---|
| Filtration Rating | 5 μm (primary element) |
| Filtration Efficiency | 99.9% (per ISO 5011) |
| Pre-Cleaner Efficiency | Up to 85% coarse dust removal (tangential stage) |
| Filter Class | Two-stage: centrifugal pre-cleaner + cellulose primary element; EN 779 HVAC classification not applicable |
| Dust Holding Capacity | Approx. 1200 g |
Practical difference of the two-stage design: a single-stage filter paper must handle both coarse and fine particles, causing rapid surface loading, faster pressure rise, and shorter life. By transferring coarse dust load to the centrifugal pre-cleaner, the FPG10 significantly improves the primary element's load profile — a key reason it is widely adopted on construction machinery and generator sets in dusty conditions.
Flow and Pressure Drop
| Parameter | Value / Description |
|---|---|
| Rated Airflow | ≤346 cfm / 9.8 m³/min (filter assembly rating) |
| Filtration Face Velocity | Approx. 0.038 m/s |
| Initial Pressure Drop | Approx. 0.5–1.0 kPa (50–100 mmH₂O) |
| Operating Differential Range | From new-element initial resistance to clogging alarm |
| Alarm / Final Resistance | Per unit restriction indicator yellow/red zone |
| Pressure Drop vs. Energy | Each 1 kPa intake resistance increase raises unit energy consumption by approx. 1% |
Rising intake resistance lowers intake pressure and density, forcing the compressor to work harder to maintain set discharge pressure and flow, increasing specific power. Based on 0.7 MPa discharge pressure and 101.3 kPa atmospheric pressure:
| Intake Resistance | Compression Ratio | Relative Energy Increase |
|---|---|---|
| 0 kPa (new element) | 7.91 | Baseline |
| 2 kPa | 8.07 | +2.0% |
| 4 kPa | 8.24 | +4.1% |
| 6 kPa | 8.41 | +6.3% |
From new to severely clogged (0 → 6 kPa), unit energy consumption rises by approximately 6%. This ongoing electricity cost typically far exceeds the price of a filter element — which is why the FPG10 housing includes a restriction indicator port: replacement timing is determined by actual resistance, not calendar estimates.
Dimensions and Installation
| Parameter | Value / Description |
|---|---|
| Dimensions | 208 mm OD x 106 mm ID x 409 mm length |
| Type | Pleated cylindrical element, two-stage RadialSeal primary |
| Effective Filter Area | Approx. 4.3 m² |
| Pleat Count | Approx. 103 pleats |
| Pleat Spacing | Approx. 4.8 mm |
| Mounting Interface | Radial push-in, end cap seals against housing outlet tube |
| Sealing | RadialSeal; one-piece molded polyurethane end cap forms radial seal, no separate gasket |
| Companion Element | Safety Element, inside primary element as backup protection |
Procurement note: When cross-referencing replacements, verify all three dimensions: 208 mm OD, 106 mm ID, 409 mm length. The FPG design uses radial sealing — push in until the end cap contacts the outlet tube; no additional gasket is needed or permitted. Adding a gasket will compromise the radial seal fit.
Material Construction
| Parameter | Value / Description |
|---|---|
| Filter Media | Cellulose paper, per FPG10 specification |
| Media Weight | Approx. 130 g/m² |
| Inner/Outer Support | Galvanized steel perforated cage (inner + outer mesh) |
| End Cap | One-piece molded polyurethane (PU), encapsulating media ends and sealing surface |
| Seal | RadialSeal formed by PU end cap body; no separate O-ring or gasket |
| Bonding | Integrally molded with end cap; no additional adhesive layer |
Construction note: Traditional axial elements consist of metal end cap + glued gasket + separate seal ring — aging of any one causes bypass. FPG encapsulates the end cap, sealing surface, and media ends in a single polyurethane body, reducing part count and improving seal reliability — the basis for tool-free installation.
Operating Conditions
| Parameter | Value / Description |
|---|---|
| Operating Temperature | Continuous 83 °C |
| Relative Humidity | ≤80% RH, no condensation |
| Burst Strength | Filter paper approx. 200–400 kPa (per ISO 2758) |
| Collapse Resistance | Element withstands intake alarm differential without collapse (RadialSeal layered support) |
| Special Features | Two-stage filtration (integrated tangential pre-cleaner) + Vacuator automatic dust valve |
| Housing | FPG housing is molded plastic, corrosion-resistant, vibration-resistant |
Service Life and Maintenance
| Parameter | Value / Description |
|---|---|
| Service Life | 2000 hours or 3 months, whichever comes first |
| High-Dust Environments | Follow restriction indicator; schedule replacement when entering yellow zone |
| Shelf Life | Approx. 2–3 years (unopened, dry, ventilated storage) |
Standards
| Item | Content |
|---|---|
| Product Standard | ISO 5011 (intake air filters for internal combustion engines and compressors — performance testing); efficiency figures measured accordingly |
| Structural Standard | Donaldson FPG / FRG series filter specification (RadialSeal sealing system) |
| Commonly Cited Test Standards | ISO 2941 / 2942 / 2943 / 3723 / 3724 / 3968 |
| Standard Applicability Note | The ISO 29xx / 37xx series are hydraulic filter test methods. If a supplier can only provide hydraulic filter standards, request ISO 5011 or the OEM specification sheet. |
Installation and Maintenance Steps
The FPG design enables tool-free maintenance; a single service takes approximately 15 minutes.
Shut down, verify zero pressure, lock out/tag out. Stop the unit, disconnect main power and lock out/tag out. Criterion: controller shows system pressure at 0.
Open the FPG filter service cover. Release the cover clips — FPG uses two spring clips or a twist-off cover, no tools required. Criterion: clips intact, cover not deformed.
Remove the old element. Grip the polyurethane end cap and pull straight out. Criterion: note that RadialSeal has no gasket to peel. If a residual gasket is found on the housing outlet tube, a non-OEM part was previously installed — clean it off completely.
Inspect the Vacuator dust valve. Check the rubber duckbill valve at the housing base. Criterion: valve opens and closes freely, no dust caking, no obstruction. This is the most commonly skipped step in FPG maintenance and has the most serious consequences — a blocked dust valve disables the pre-cleaner, transferring all dust load to the primary element and greatly shortening its life.
Inspect pre-cleaner stage and housing for dust traces. Look for dust bypass tracks inside the housing and abnormal accumulation in the pre-cleaner swirl zone. Criterion: no dust tracks on inner walls; if tracks exist, check sealing surfaces.
Install the new element. Push 49164395 into the housing until the polyurethane end cap contacts the outlet tube. Criterion: end cap seats fully against outlet tube; no gasket is needed or permitted.
Reinstall cover and check restriction indicator. Refit the service cover and secure clips. Confirm the intake restriction indicator is in the green zone; if resettable, press reset and verify it returns properly. Criterion: green zone reading, indicator functions normally.
Start up and record. Start the unit, run to operating temperature, and read intake resistance. Criterion: resistance within new-element baseline range; record date, running hours, and resistance reading.
Installation rule: Do not start the unit before the element is fully seated. If the RadialSeal element is not pushed fully in, air bypasses directly through the gap between end cap and outlet tube, disabling both the pre-cleaner and primary element — equivalent to running without a filter.
Frequently Asked Questions
What specification is the 49164395?
A two-stage RadialSeal primary element manufactured to Donaldson FPG10 specification. The integrated tangential pre-cleaner removes approximately 85% of coarse dust first; the primary element handles fine filtration.
Is it interchangeable with 49101637?
No. 49101637 is FPG09, with different dimensions and rated airflow. To confirm: read the specification marking on the end cap of the currently installed element. If it reads FPG10, order this part; if FPG09, order 49101637.
Why does this element have no gasket?
Because it uses RadialSeal radial sealing. The polyurethane end cap body seals directly against the housing outlet tube, requiring no glued gasket or separate seal ring. Fewer parts, fewer failure points, and less chance of misinstallation.
What does the Vacuator dust valve do?
It is the pre-cleaner dust discharge port. Coarse dust separated by centrifugal force in the pre-cleaner falls by gravity to the housing base and is discharged automatically through the Vacuator valve. If the valve clogs, the pre-cleaner is completely disabled and all dust is pressed onto the primary element. Check it at every element change — this is the critical maintenance action for the FPG design.
How often should it be replaced?
Recommended interval is 2000 hours or 3 months, whichever comes first. More accurately, follow the intake restriction indicator: schedule replacement when resistance enters the yellow zone. In high-dust sites, replace earlier based on indicator readings.
Can the element be blown clean and reused?
No. This is a dry, disposable element — it cannot be washed or reverse-blown with compressed air. Reverse blowing damages the filter paper fiber structure, creating invisible channels that let unfiltered air pass through — more dangerous than not changing the filter at all.
Can I add a gasket to improve sealing?
No, and it is unnecessary. RadialSeal relies on radial compression of the end cap body. Adding a gasket pushes the element away from the outlet tube, compromising the seal fit and causing bypass.
The restriction indicator never moves — is that normal?
No. A stuck indicator is a common failure point, giving a "clean" reading even when the element is actually clogged. Press-check it at every service; if it has failed, use conservative time-based replacement until repaired.
How does the FPG plastic housing compare to metal housings?
The FPG molded housing is corrosion-resistant, lightweight, and vibration-resistant — it will not rust in coastal salt-spray or humid environments. The tool-free design also speeds up field maintenance. This is why the FPG series is widely used on construction machinery and mobile equipment.
How can I be 100% sure this is the right part?
Three steps: ① Read the specification marking on the currently installed element's end cap to confirm FPG10; ② Measure the old part's OD and length to verify 208 mm and 409 mm; ③ If the old part is discarded, provide the filter housing model marking and we will cross-reference by FPG specification.
Compatible Equipment
This part is supplied to Donaldson FPG10 specification, suitable for Ingersoll Rand screw air compressors equipped with the FPG10 air filter housing.
FPG10 is a Donaldson finished filter assembly specification adopted by OEMs as a standard intake filtration unit. Key identification points:
| Item | Specification |
|---|---|
| Filter Specification | Donaldson FPG10 (element interchangeable with FRG10 series) |
| Rated Airflow | ≤346 cfm / 9.8 m³/min |
| Role in Assembly | Primary Element |
| Other Specifications in Series | FPG09; part number 49101637, different dimensions and airflow, not interchangeable |
| Sealing System | RadialSeal (polyurethane end cap radial seal) |
How to Confirm Compatibility
- Preferred: Read the specification marking on the currently installed element's end cap. FPG10 = this part applies; FPG09 = order 49101637.
- Alternative: Measure the old part's OD and length to verify 208 mm x 409 mm.
- Fallback: Provide the filter housing model marking or unit nameplate photo; we will cross-reference by FPG specification.
Model Coverage Note
Donaldson FPG10 is a universal filter assembly adopted by multiple OEMs, so this part's compatibility is not limited to a specific list of machine models. The determining factor is whether the filter specification is FPG10, not the machine model itself. If the unit nameplate does not indicate the filter specification, use any of the three methods above to confirm.
Related Components
The FPG10 filter is a complete system. In addition to the primary element, 7 companion parts are serviced together with this part. Listed by component — function — inspection point:
| Component | Function | Inspection Point |
|---|---|---|
| Safety Element | Backup element inside the primary; protects downstream if primary is damaged or during change intervals | Generally replaced on same or alternate cycle; check media for damage |
| Vacuator Dust Valve | Pre-cleaner automatic dust discharge port; expels centrifugally separated coarse dust from housing | Check at every element change: valve must open/close freely, no dust caking, no obstruction |
| Restriction Indicator | Indicates element clogging level; authoritative basis for replacement timing | Check needle returns properly; connecting line must be clear |
| Service Cover and Clips | FPG housing tool-free opening structure | Check clips for breakage, cover for deformation; no air leakage when secured |
| FPG Housing Assembly | Molded plastic housing with tangential inlet and pre-cleaner swirl zone | Check inner walls for dust bypass tracks; plastic for cracks |
| Intake Hose and Clamps | Connects filter housing to main intake | Check for cracks, aging, looseness; bypass leakage is as harmful as no filter |
| Other Primary Elements in Series | FPG09; part number 49101637 | Different dimensions and airflow, not interchangeable; distinguish when stocking |
Companion replacement recommendation: The maintenance value of the FPG10 system centers on whether the pre-cleaner is working properly. When changing the primary element, inspect the Vacuator valve and restriction indicator at the same time. If either small part fails, primary element life is significantly shortened. Their cost is far lower than the primary element, yet they determine how long it lasts.