Product
Ingersoll Rand 49164395 Air Filter Element | Donaldson FPG10 RadialSeal
Ingersoll Rand 49164395 air filter element built to Donaldson FPG10 two-stage RadialSeal specification. 208 mm OD x 106 mm ID x 409 mm length, 99.9% filtration efficiency (ISO 5011), tangential pre-cleaner removes up to 85% coarse dust. Tool-free installation, 2000-hour service interval.
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Product Overview
49164395 is the intake air filter element used on Ingersoll Rand screw air compressors, manufactured to the Donaldson FPG10 specification. It serves as the primary element in a two-stage RadialSeal filtration system.
The FPG10 design differs from conventional single-stage filters. Air first passes through an integrated tangential pre-cleaner: entering at high velocity, the airstream spins and centrifugal force throws coarse particles against the housing wall. Approximately 85% of coarse dust is separated before reaching the main element and is automatically discharged through the Vacuator dust valve at the bottom of the housing. Pre-cleaned air then enters the main element, where cellulose filter media performs fine filtration. In dusty environments this architecture extends element life because the main filter only handles fine particles.
Sealing also differs from traditional designs. FPG uses Donaldson RadialSeal technology: a one-piece molded polyurethane end cap forms a radial seal directly against the housing outlet tube, eliminating the adhesive gasket used on 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.
Key Specifications
| Item | Value |
|---|---|
| Part Number | 49164395 |
| Product 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 radial seal, 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 / Note |
|---|---|
| Filtration Rating | 5 μm (main 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 main element; not classified under EN 779 HVAC standards |
| Dust Holding Capacity | Approx. 1200 g |
Practical difference of the two-stage design: a single-stage element must handle both coarse and fine particles, so coarse dust builds up rapidly on the media surface, resistance rises quickly, and service life shortens. By shifting the coarse dust load to the centrifugal pre-cleaner, FPG10 significantly improves the main element's loading profile — a key reason it is widely used on construction machinery and generator sets in dusty conditions.
Flow and Pressure Drop
| Parameter | Value / Note |
|---|---|
| Rated Airflow | ≤346 cfm / 9.8 m³/min (filter assembly rated intake) |
| Filtration Face Velocity | Approx. 0.038 m/s |
| Initial Pressure Drop | Approx. 0.5–1.0 kPa (50–100 mmH₂O) |
| Operating Differential | From new-element initial resistance to blockage alarm value |
| Alarm / Final Resistance | Per the unit's restriction indicator yellow/red zone |
| Pressure Drop vs. Energy | Each 1 kPa rise in intake resistance increases unit energy consumption by approx. 1% |
Pressure Drop and Energy Consumption
Rising intake resistance lowers intake pressure and density; the unit must 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 heavily clogged (0 → 6 kPa), unit energy consumption rises by about 6%. The resulting electricity cost typically far exceeds the price of a filter element. This is why the FPG10 housing includes a restriction indicator port — replacement timing should be based on actual resistance, not calendar estimates.
Dimensions and Installation
| Parameter | Value / Note |
|---|---|
| Dimensions | 208 mm OD x 106 mm ID x 409 mm length |
| Construction | Pleated cylindrical element, two-stage RadialSeal primary element |
| Effective Filtration 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 (inner element) as backup protection |
Procurement note: When cross-referencing replacements, verify all three dimensions — 208 mm OD, 106 mm ID, and 409 mm length. The FPG design uses a radial seal; push the element in until the end cap contacts the outlet tube. Do not add a gasket — it will disrupt the radial seal fit.
Materials
| Parameter | Value / Note |
|---|---|
| Media | Cellulose filter paper, per FPG10 specification |
| Media Weight | Approx. 130 g/m² |
| Inner/Outer Support | Galvanized steel perforated support (inner cage + outer mesh) |
| End Cap | One-piece molded polyurethane (PU) end cap, encapsulating media ends and sealing surface |
| Seal | RadialSeal formed by the polyurethane end cap body; no separate O-ring or gasket |
| Bonding | Molded integrally with end cap; no additional adhesive layer |
Design note: A traditional axial element consists of a metal end cap, adhesive gasket, and separate seal ring — aging of any one component can cause bypass. FPG encapsulates the end cap, sealing surface, and media ends in a single polyurethane body, reducing part count and improving seal reliability. This is also what enables tool-free installation.
Operating Conditions
| Parameter | Value / Note |
|---|---|
| Operating Temperature | Continuous 83 °C |
| Relative Humidity | ≤80% RH, no condensation |
| Burst Strength | Media burst strength 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 injection-molded plastic; corrosion-resistant, vibration-resistant |
Service Life and Maintenance
| Parameter | Value / Note |
|---|---|
| Service Life | 2000 hours or 3 months, whichever comes first |
| High-Dust Environments | Follow restriction indicator reading; schedule replacement when entering yellow zone |
| Shelf Life | Approx. 2–3 years (unopened, dry, ventilated storage) |
Standards
| Item | Content |
|---|---|
| Product Standard | ISO 5011 (inlet air filters for internal combustion engines and compressors — performance testing); efficiency figures measured to this standard |
| Design Standard | Donaldson FPG / FRG series filter specification (RadialSeal sealing system) |
| Commonly Referenced Test Standards | ISO 2941 / 2942 / 2943 / 3723 / 3724 / 3968 |
| 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
FPG design enables tool-free maintenance; a single service takes about 15 minutes.
Shut down, verify zero pressure, lock out/tag out. Stop the unit, disconnect main power, and apply lockout/tagout. Criterion: controller shows system pressure at 0.
Open the FPG filter service cover. Release the cover latches — FPG uses two spring latches or a twist-off cover, no tools required. Criterion: latches 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 outlet tube, a non-genuine part was previously installed and must be cleaned off.
Check the Vacuator dust valve. Inspect the rubber duckbill valve at the housing bottom. Criterion: valve opens and closes freely, no dust caking, no obstruction. This is the most commonly skipped step and the most consequential — a blocked valve disables the pre-cleaner, shifting the entire dust load to the main element and sharply reducing life.
Inspect pre-cleaner and housing interior. Look for dust bypass tracks inside the housing and abnormal buildup in the pre-cleaner swirl zone. Criterion: no dust tracks on inner walls; if tracks are present, inspect sealing surfaces.
Install the new element. Push 49164395 into the housing until the polyurethane end cap contacts the outlet tube. Criterion: end cap fully seated against outlet tube; no gasket required or permitted.
Reinstall cover and check restriction indicator. Refit the cover and secure latches. Confirm the restriction indicator is in the green zone; if resettable, press reset and verify it returns properly. Criterion: green zone reading, indicator functions correctly.
Start up and record. Start the unit, run to operating temperature, and read intake restriction. 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 is not pushed fully home, air bypasses directly through the gap between end cap and outlet tube — both pre-cleaner and main element become ineffective, equivalent to running with no filter.
FAQ
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 before the main element performs 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 installed element's end cap — if it shows 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 forms a seal directly against the housing outlet tube, eliminating the need for an adhesive gasket or separate seal ring. Fewer parts, fewer failure points, and less chance of incorrect installation.
What does the Vacuator dust valve do?
It is the pre-cleaner dust discharge port. Coarse dust separated by centrifugal action in the pre-cleaner falls by gravity to the housing bottom and is automatically discharged through the Vacuator valve. If the valve becomes blocked, the pre-cleaner is completely ineffective and all dust loads the main element. Check it at every element change — it is a critical maintenance point 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 restriction indicator: schedule replacement when resistance enters the yellow zone. In high-dust environments, replace earlier based on indicator readings.
Can the element be blown clean and reused?
No. This is a dry, disposable element. It must not be washed or reverse-blown with compressed air — reverse blowing damages the media fiber structure and creates invisible channels that allow unfiltered air to pass, which is more dangerous than not replacing it.
Can I add a gasket to improve sealing?
No, and it is unnecessary. RadialSeal relies on radial compression of the end cap body to form a seal. Adding a gasket would push the element away from the outlet tube and actually disrupt the seal, causing bypass.
The restriction indicator never moves — is that normal?
No. A stuck indicator is a common failure point; it can give a "clean" reading when the element is actually clogged. Check it at every service by pressing to verify it returns properly. If it has failed, replace the element on a conservative time-based schedule until the indicator is repaired.
What are the pros and cons of the FPG plastic housing versus metal?
The FPG injection-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 installed element's end cap — confirm FPG10. (2) Measure the old part's OD and length — verify 208 mm and 409 mm. (3) If the old part is discarded, provide the model marking on the filter housing and we will cross-reference to the FPG specification.
Compatible Equipment
This element is supplied to Donaldson FPG10 specification and fits Ingersoll Rand screw air compressors equipped with the FPG10 air filter housing.
FPG10 is a Donaldson complete filter assembly specification used by multiple 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 Specification in Series | FPG09; part number 49101637, different dimensions and airflow, not interchangeable |
| Sealing System | RadialSeal (polyurethane end cap radial seal) |
How to Confirm Fit
- Preferred: Read the specification marking on the installed element's end cap. FPG10 means this part applies; FPG09 means order 49101637.
- Alternative: Measure the old part's OD and length — verify 208 mm x 409 mm.
- Fallback: Provide the model marking on the filter housing or a photo of the unit nameplate; we will cross-reference to the FPG specification.
Note on Model Coverage
Donaldson FPG10 is a universal air filter assembly used by multiple OEMs, so this element's fitment is not limited to a specific machine model list. The determining factor is whether the filter specification is FPG10, not the machine model itself. If the unit nameplate does not show the filter specification, confirm using any of the three methods above.
Related Components
The FPG10 air filter is a complete system. In addition to the primary element, seven components are maintained together with this part. Listed by component — function — inspection point:
| Component | Function | Inspection Point |
|---|---|---|
| Safety Element | Backup element inside the primary element, protects downstream if primary is damaged or during change intervals | Generally replaced at the same interval or every other interval; check media for damage |
| Vacuator Dust Valve | Pre-cleaner automatic discharge port, expels centrifugally separated coarse dust | 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 Latches | Tool-free opening structure of the FPG housing | Check latches for cracks, cover for deformation; no air leak when locked |
| FPG Housing Assembly | Injection-molded plastic housing with tangential inlet and pre-cleaner swirl zone | Check inner walls for dust bypass tracks; check plastic for cracks |
| Intake Hose and Clamps | Connect filter housing to engine 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 |
Recommended companion replacement: The maintenance value of the FPG10 system centers on whether the pre-cleaner is working properly. When changing the primary element, also check the Vacuator valve and restriction indicator. If either fails, primary element life is significantly shortened. Their cost is far lower than the primary element, yet they determine how long it lasts.