Product
Ingersoll Rand 49164395 Air Filter Element | Donaldson FPG10 RadialSeal
Ingersoll Rand 49164395 air filter element built to Donaldson FPG10 two-stage RadialSeal specifications. 99.9% filtration efficiency (ISO 5011), 208 mm OD x 106 mm ID x 409 mm length, 2000-hour service interval. Export-ready for compressor distributors and OEM procurement.
- Export packaging & documentation support
- OEM / ODM customization available
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Product Overview
49164395 is the intake air filter element used on Ingersoll Rand rotary screw air compressors, manufactured to Donaldson FPG10 specifications.
Unlike a conventional single-stage air filter, FPG10 is a two-stage intake filtration system. Air first passes through an integrated tangential pre-cleaner, where the tangential airflow spins at high speed and centrifugal force drives coarse particles to the housing wall. Approximately 85% of coarse dust is separated before reaching the primary element and is automatically discharged through the Vacuator dust valve at the base of the housing. Pre-cleaned air then enters the primary element, where cellulose filter media performs fine filtration. This architecture matters most in dusty environments: the primary element carries only fine-particle load, maintaining longer service life under high-dust conditions.
The sealing method also differs from traditional air filters. FPG uses Donaldson's 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 means fewer failure points — gasket aging, detachment, and installation misalignment are eliminated in the FPG design, and no tools are required for removal or installation.
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 Type | 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 | Up to 346 cfm / 9.8 m3/min |
| Recommended Service Interval | 2000 hours or 3 months |
Technical Specifications
Filtration Performance
| Parameter | Value / Notes |
|---|---|
| Filtration Rating | 5 micron class (primary element) |
| Filtration Efficiency | 99.9% (tested per ISO 5011) |
| Pre-Cleaner Efficiency | Up to 85% coarse dust removal (tangential pre-cleaner stage) |
| Filter Class | Two-stage: centrifugal pre-cleaner + cellulose primary element; HVAC filter classification (EN 779) does not apply |
| Dust Holding Capacity | Approx. 1200 g |
Practical difference of the two-stage design: in a single-stage filter, the media must handle both coarse and fine particles; coarse dust accumulates rapidly on the surface, resistance rises quickly, and service life is short. FPG10 transfers the coarse-dust burden to the centrifugal pre-cleaner stage, significantly improving the load profile of the primary element — a key reason it is widely adopted on construction machinery and generator sets operating in dusty conditions.
Flow and Resistance
| Parameter | Value / Notes |
|---|---|
| Rated Airflow | Up to 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 (approx. 50-100 mmH2O) |
| Operating Differential Range | From new-element initial resistance to clogging alarm threshold |
| Alarm / Final Resistance | Per the machine's restriction indicator yellow/red zone |
| Pressure Drop vs. Energy | Each 1 kPa increase in intake resistance adds roughly 1% to machine energy consumption |
Pressure drop and energy consumption
Rising intake resistance lowers intake pressure and density; the machine must do more work to maintain set discharge pressure and flow, and specific power rises. Calculated at 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% |
Engineering implication: as an element progresses from new to heavily clogged (0 to 6 kPa), machine energy consumption rises by roughly 6%. The cumulative electricity cost typically far exceeds the price of an element — which is why the FPG10 housing provides a restriction indicator port: replacement timing is driven by actual resistance, not calendar estimates.
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, mounted inside the primary element as backup protection |
Procurement note: when cross-checking 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, with no additional gasket. Do not attempt to add a gasket, as it will break the radial seal fit.
Material Construction
| Parameter | Value / Notes |
|---|---|
| Filter Media | Cellulose filter paper, per FPG10 specification |
| Media Weight | Approx. 130 g/m2 |
| Inner/Outer Support | Galvanized steel perforated support (inner core + outer screen) |
| End Cap | One-piece molded polyurethane (PU) end cap, encapsulating both media ends and sealing surface |
| Sealing Element | RadialSeal formed by the polyurethane end cap itself; no separate O-ring or gasket |
| Bonding | Molded integrally with end cap; no additional adhesive layer |
Construction note: a traditional axial element comprises three parts — metal end cap, glued gasket, and separate seal ring — any of which can age and cause bypass. FPG encapsulates the end cap, sealing surface, and media ends in a single polyurethane body, reducing part count and improving seal reliability, which is also the basis for tool-free installation.
Operating Tolerance
| Parameter | Value / Notes |
|---|---|
| Operating Temperature | Continuous 83 C |
| Relative Humidity | Up to 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 Characteristics | FPG housing is injection-molded plastic; corrosion-resistant and vibration-resistant |
Service Life and Maintenance
| Parameter | Value / Notes |
|---|---|
| Service Life | 2000 hours or 3 months, whichever comes first |
| High-Dust Environments | Follow the restriction indicator reading; schedule replacement when resistance enters the yellow zone |
| Shelf Life | Approx. 2-3 years (unopened, dry, ventilated storage) |
Applicable Standards
| Item | Content |
|---|---|
| Product Standard | ISO 5011 (intake air filters for internal combustion engines and compressors — performance testing); efficiency figures are tested to this standard |
| Design 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
A key 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 machine, 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 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.Inspect the Vacuator dust valve
Check the Vacuator valve (rubber duckbill) at the base of the housing. Criterion: valve opens and closes freely, no compacted dust, no obstruction. This is the most commonly skipped step in FPG maintenance and the most consequential — a clogged dust valve disables the pre-cleaner stage, shifting the full dust load to the primary element and sharply reducing service life.Check the pre-cleaner stage and interior dust traces
Look for dust bypass tracks inside the housing and abnormal accumulation in the pre-cleaner swirl zone. Criterion: no dust tracks on the inner wall; if tracks are present, inspect the sealing surfaces.Install the new element
Push 49164395 into the housing until the polyurethane end cap contacts the outlet tube. Criterion: end cap seated 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 restriction indicator is in the green zone; if resettable, press to reset and verify it returns properly. Criterion: green-zone reading, indicator functioning.Start up and record
Start the machine, run to operating temperature, and read intake resistance. Criterion: resistance within the new-element baseline range; record date, running hours, and resistance reading.
Installation rule: do not start the machine before the element is seated. If the RadialSeal is not pushed fully into place, air bypasses directly through the gap between end cap and outlet tube, disabling both the pre-cleaner stage and the primary element — equivalent to running with no filter at all.
Frequently Asked Questions
What specification is 49164395?
A two-stage RadialSeal primary element manufactured to Donaldson FPG10 specifications. The integrated tangential pre-cleaner removes approximately 85% of coarse dust first, with the primary element handling 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 installed element's end cap — FPG10 means order this part; FPG09 means order 49101637.
Why does this element have no gasket?
Because it uses RadialSeal radial sealing. The polyurethane end cap itself forms the seal against the housing outlet tube, with 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 discharge port for the pre-cleaner stage. Coarse dust separated by the swirling airflow falls by gravity to the base of the housing and discharges automatically through the Vacuator valve. Once the valve clogs, the pre-cleaner stage fails completely, and all dust is forced 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?
The 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 locations, 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 media fiber structure and creates invisible channels that let unfiltered air pass through, which is more dangerous than not replacing it.
Can a gasket be added to improve sealing?
No, and it is unnecessary. RadialSeal forms its seal through radial compression of the end cap body; adding a gasket pushes the element away from the outlet tube and breaks the seal fit, causing bypass.
The restriction indicator never moves — is that normal?
No. A stuck indicator is a common failure point that can show a "clean" reading when the element is actually clogged. Check at every service that it returns properly when pressed; if it has failed, replace the element on a conservative time-based interval until it is repaired.
How does the FPG plastic housing compare with metal housings?
The FPG injection-molded housing is corrosion-resistant, lightweight, and vibration-resistant, and will not rust in coastal salt-spray or humid environments. The tool-free design also speeds up on-site 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 to confirm FPG10; (2) measure the old element's outer diameter and length to verify 208 mm and 409 mm; (3) if the old element has been discarded, provide the model marking on the filter housing and we will cross-reference against FPG specifications.
Compatible Equipment
This part is supplied to Donaldson FPG10 specifications and fits Ingersoll Rand rotary screw air compressors equipped with the FPG10 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 Housing Specification | Donaldson FPG10 (element interchangeable with FRG10 series) |
| Rated Intake Airflow | Up to 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 fitment
- 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 element's outer diameter and length to verify 208 mm x 409 mm.
- Fallback: provide the model marking on the filter housing or a photo of the machine nameplate, and we will cross-reference against FPG specifications.
Note on model coverage
Donaldson FPG10 is a universal filter adopted by multiple OEMs, so the fitment range of this part is not limited to a specific machine model list. The determining factor is whether the filter housing is FPG10, not the machine model itself. If the machine nameplate does not state the filter specification, confirm using any of the three methods above.
Related Components
The FPG10 filter is a complete system; besides the primary element, 7 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, protecting downstream if the primary is damaged or during change intervals | Typically replaced on the same interval or every other interval; check media for damage |
| Vacuator Dust Valve | Automatic discharge port for the pre-cleaner stage, expelling centrifugally separated coarse dust | Check at every element change: valve must open and close freely, no compacted dust, no obstruction |
| Restriction Indicator | Indicates element clogging level; the authoritative basis for replacement timing | Check that the needle returns properly; connection line must be clear |
| Service Cover and Latches | Tool-free opening structure of the FPG housing | Check latches for cracks and cover for deformation; no air leaks when secured |
| FPG Housing Assembly | Injection-molded plastic housing with tangential inlet and pre-cleaner swirl zone | Check inner wall for dust bypass tracks; check plastic for cracks |
| Intake Hose and Clamps | Connect the filter to the machine intake duct | 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; keep separate in stock |
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, inspect the Vacuator valve and restriction indicator at the same time. Failure of either small part will noticeably shorten primary element life — their cost is far lower than the primary element, yet they determine how long it lasts.