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. 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.
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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.
Its two-stage design differs clearly from conventional single-stage filters. Air first passes through an integrated tangential pre-cleaner: entering tangentially, the airflow spins at high speed and centrifugal force throws coarse particles against the housing wall. About 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. This structure pays off most in dusty sites: the main element carries only the fine-particle load, maintaining long service life even in high-dust environments.
The sealing method also differs from traditional air 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 in the FPG design, and installation requires no tools.
Core 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 Replacement | 2000 hours or 3 months |
Technical Parameters
Filtration Performance
| Parameter | Value / Notes |
|---|---|
| Filtration Rating | 5 μm class (main element) |
| Filtration Efficiency | 99.9% (per ISO 5011) |
| Pre-cleaner Efficiency | Up to 85% coarse dust removal (tangential pre-cleaner stage) |
| Filter Class | Two-stage: centrifugal pre-cleaner + cellulose main element; not classified under EN 779 HVAC standards |
| Dust Holding Capacity | Approx. 1200 g |
The practical difference of the two-stage structure: a single-stage filter's media must handle both coarse and fine particles, so coarse dust builds up quickly on the surface, resistance rises fast, and life is short. By transferring the coarse-dust burden to the centrifugal pre-cleaner, the FPG10 improves the main element's load profile — which is why it is widely adopted on construction machinery, generator sets, and other dusty-duty equipment.
Flow and Resistance
| Parameter | Value / Notes |
|---|---|
| Rated Airflow | ≤346 cfm / 9.8 m³/min (air filter assembly rated intake) |
| Filtration Face Velocity | Approx. 0.038 m/s |
| Initial Pressure Drop | Approx. 0.5–1.0 kPa (approx. 50–100 mmH₂O) |
| Operating Differential Range | From new-element initial resistance to blockage alarm value |
| Alarm / Final Resistance | Per the unit's intake 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; to maintain set discharge pressure and flow, the unit must do more work, and specific power rises. Based on 0.7 MPa discharge pressure and 101.3 kPa atmospheric pressure, theoretical compression ratio calculation:
| 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 about 6% over the interval. This ongoing electricity cost usually far exceeds the price of one filter element — which is why the OEM provides a restriction indicator port on the FPG10 housing: replacement timing should be decided by actual resistance, not calendar estimation.
Dimensions and Installation
| Parameter | Value / Notes |
|---|---|
| Dimensions | 208 mm OD x 106 mm ID x 409 mm length |
| Configuration | 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, installed inside the primary element as backup protection |
Materials
| Parameter | Value / Notes |
|---|---|
| Filter Media | Cellulose paper, per FPG10 specification |
| Media Weight | Approx. 130 g/m² |
| Inner/Outer Support | Galvanized steel perforated support (inner cage + outer screen) |
| 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 |
Operating Tolerance
| Parameter | Value / Notes |
|---|---|
| Operating Temperature | Continuous 83 °C |
| Relative Humidity | ≤80% RH, no condensation |
| Burst Strength | Media burst strength approx. 200–400 kPa (per ISO 2758 paper burst test) |
| 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 Characteristic | FPG housing is injection-molded plastic, corrosion-resistant, vibration-resistant |
Life and Maintenance
| Parameter | Value / Notes |
|---|---|
| Service Life | 2000 hours or 3 months, whichever comes first |
| High-Dust Environment | Follow restriction indicator reading; schedule replacement when in 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 per this standard |
| Structural Standard | Donaldson FPG / FRG series air filter specification (RadialSeal sealing system) |
| Commonly Cited Test Standards | ISO 2941 / 2942 / 2943 / 3723 / 3724 / 3968 |
| Standard Applicability Note | The above ISO 29xx / 37xx series are actually general test methods for hydraulic transmission filter elements. If a supplier can only provide hydraulic filter standards, request ISO 5011 or the OEM specification sheet. |
Standard Maintenance and Installation Steps
A major feature of the FPG design is tool-free maintenance; a single service takes about 15 minutes.
Shut down, confirm 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 air filter service cover. Release the cover latches; the FPG design uses two spring latches or a twist-off cover, requiring no tools. Criterion: latches unbroken, cover not deformed.
Remove the old element. Grip the polyurethane end cap and pull straight out. Criterion: note that the RadialSeal design has no gasket to peel off; if a residual gasket is found on the housing outlet tube, a non-genuine part was previously installed and must be cleaned off.
Check the Vacuator dust valve. Inspect the Vacuator valve (rubber duckbill) at the bottom of the housing. Criterion: valve opens and closes freely, no caked dust, no obstruction. This is the most easily skipped step in FPG maintenance and the most serious if neglected — a blocked dust valve disables the pre-cleaner stage, transferring all dust load to the main element and greatly shortening its life.
Inspect the pre-cleaner stage and housing for dust traces. Look for dust bypass tracks inside the housing and abnormal accumulation in the pre-cleaner swirl area. Criterion: no dust track bands 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 the outlet tube; no gasket is needed or permitted.
Reinstall the service cover and check the restriction indicator. Refit the cover and secure the latches. Confirm the intake restriction indicator is in the green zone; if resettable, press to reset and verify it returns normally. Criterion: green zone reading, indicator operates correctly.
Start up and record. Start the unit, run to operating temperature, and read intake restriction. Criterion: resistance within the new-element baseline range; record date, running hours, and resistance reading.
Installation rule: do not start the unit before the element is 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 are defeated, equivalent to no filter installed.
FAQ
What specification is the 49164395 filter?
A two-stage RadialSeal primary element manufactured to the Donaldson FPG10 specification. The integrated tangential pre-cleaner removes about 85% of coarse dust first, and the main element handles fine filtration.
Is it interchangeable with 49101637?
No. 49101637 is FPG09, with different dimensions and rated airflow. Confirmation is simple: 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 filter have no gasket?
Because it uses RadialSeal radial sealing. The polyurethane end cap body seals directly against the housing outlet tube, requiring no additional glued gasket or separate seal ring. Fewer parts, fewer failure points, and less chance of incorrect installation.
What is the Vacuator dust valve for?
It is the dust discharge port of the pre-cleaner stage. Coarse dust separated by the swirling airflow falls by gravity to the bottom of the housing and is automatically discharged through the Vacuator valve. Once the valve is blocked, the pre-cleaner stage is completely defeated and all dust presses directly onto the main element. Check it at every filter change — this is the key maintenance action for the FPG design.
How often should it be replaced?
The 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 the indicator reading.
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, letting unfiltered air pass directly through — more dangerous than not replacing it.
Can a gasket be added to improve sealing?
No, and it is unnecessary. RadialSeal relies on radial compression of the end cap body to seal; adding a gasket would push the element away from the outlet tube and actually break the sealing fit, causing bypass.
The intake restriction indicator never moves — is that normal?
No. A stuck indicator is a common failure point; it gives a "clean" reading even when the element is actually clogged. Check at every service by pressing to verify it returns normally; if it has failed, replace the element on a conservative time interval until 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 makes on-site maintenance faster. 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 end cap of the currently installed element and confirm it is FPG10; (2) measure the old part's OD and length to verify 208 mm and 409 mm; (3) if the old part has been discarded, provide the model marking on the air filter housing and we will cross-reference by FPG specification.
Compatible Equipment
This part is supplied to the Donaldson FPG10 specification and is suitable for Ingersoll Rand screw air compressors equipped with an FPG10 air filter.
FPG10 is a Donaldson finished air filter assembly specification, adopted by OEMs as a standard intake filtration unit. Key identification points:
| Identification Item | Specification |
|---|---|
| Air Filter Specification | Donaldson FPG10 (element interchangeable with FRG10 series) |
| Air Filter Rated Intake | ≤346 cfm / 9.8 m³/min |
| Role in Assembly | Primary Element |
| Other Specification in Series | FPG09; corresponding 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 end cap of the currently installed element. FPG10 means this part fits; 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 air filter housing or a photo of the unit nameplate, and we will cross-reference by FPG specification.
Note on Model Coverage
Donaldson FPG10 is a universal air filter adopted by multiple OEMs, so this part's compatibility is not fully defined by any specific model list. The determining factor should be the fact of whether the air filter specification is FPG10, not the unit model itself. If the unit nameplate does not state the air filter specification, confirm using any of the three steps above.
Related Parts
The FPG10 air filter is a complete system; besides the primary element, there are 7 components maintained together with this part. Listed by component — function — inspection point:
| Component | Function | Inspection Point |
|---|---|---|
| Safety Element | Backup element inside the primary element, protecting downstream if the primary is damaged or during change intervals | Generally replaced on the same interval as the primary or every other change; check media for damage |
| Vacuator Dust Valve | Pre-cleaner automatic dust discharge port, expelling centrifugally separated coarse dust from the housing | Must check at every element change: valve must open and close freely, no caked dust, no obstruction |
| Restriction Indicator | Indicates element blockage level; the authoritative basis for replacement timing | Check needle returns normally; connecting line must be clear |
| Service Cover and Latches | Tool-free opening structure of the FPG housing | Check latches for breakage and cover for deformation; no air leak when secured |
| FPG Housing Assembly | Injection-molded plastic housing with tangential inlet and pre-cleaner swirl area | Check inner walls for dust bypass tracks; check plastic parts for cracks |
| Intake Hose and Clamps | Connects air filter to the main unit intake duct | Check for cracks, aging, looseness; bypass leakage is as harmful as no filter installed |
| Other Series Primary Element | FPG09; corresponding part number 49101637 | Different dimensions and airflow, not interchangeable; distinguish when stocking |
Companion replacement advice: the maintenance value of the FPG10 system centers on whether the pre-cleaner stage is working properly. When changing the primary element, also check the Vacuator valve and restriction indicator. If either small part fails, the primary element's life is noticeably shortened. Their cost is far lower than the primary element, yet they determine how long it lasts.