Product
Ingersoll Rand 49164395 Air Filter Element | Donaldson FPG10 RadialSeal
Ingersoll Rand 49164395 primary air filter element built to Donaldson FPG10 two-stage RadialSeal specification. 208 mm OD × 106 mm ID × 409 mm length, 99.9% efficiency to ISO 5011, tangential pre-cleaner removes up to 85% of coarse dust. Export-ready for compressor OEM and MRO buyers.
- Export packaging & documentation support
- OEM / ODM customization available
- Sample and bulk order workflow
Product Overview
49164395 is the intake air filter element used on Ingersoll Rand rotary screw air compressors, manufactured to the Donaldson FPG10 specification.
Unlike a conventional single-stage element, FPG10 is a two-stage intake filtration system. Air first passes through an integral tangential pre-cleaner: entering at high velocity, the airflow spins and centrifugal force throws coarse particles against the housing wall. Roughly 85% of coarse dust is separated before it reaches the main element and is discharged automatically through the Vacuator dust valve at the base of the housing. Pre-cleaned air then enters the main element, where cellulose media performs fine filtration. This architecture pays off most in dusty environments: the main element carries only the fine-particle load, so service life stays long even under heavy dust.
The sealing method also differs from traditional elements. FPG uses Donaldson RadialSeal technology: an integrally molded polyurethane end cap seals radially against the housing outlet tube, eliminating the glued gasket of older axial elements. Fewer parts means fewer failure points — gasket aging, detachment and misalignment are simply not possible with the FPG design, and no tools are required for installation or removal.
Key Specifications
| Item | Value |
|---|---|
| Part number | 49164395 |
| Description | Air filter element |
| Brand | Ingersoll Rand |
| Specification source | Donaldson FPG10 (two-stage RadialSeal) |
| Role in assembly | Primary element |
| Dimensions | 208 mm OD × 106 mm ID × 409 mm length |
| Sealing | RadialSeal (polyurethane end cap, gasket-free) |
| Net weight | Approx. 1.88 kg |
| Filtration efficiency | 99.9% (ISO 5011) |
| Pre-cleaner efficiency | Up to 85% of coarse dust |
| Rated intake flow | ≤346 cfm / 9.8 m³/min |
| Recommended change interval | 2,000 hours or 3 months |
Technical Parameters
Filtration Performance
| Parameter | Value / Notes |
|---|---|
| Filtration rating | 5 μm class (primary element) |
| Filtration efficiency | 99.9% (tested to ISO 5011) |
| Pre-cleaner efficiency | Up to 85% coarse dust (tangential pre-cleaner stage) |
| Filter class | Two-stage: centrifugal pre-cleaning + cellulose main element; EN 779 HVAC classification does not apply |
| Dust holding capacity | Approx. 1,200 g |
What the two-stage design changes in practice: a single-stage element forces the media to handle both coarse and fine particles, so coarse dust builds up on the surface, restriction rises quickly and life is short. By shifting the coarse load to the centrifugal stage, FPG10 markedly improves the main element's loading profile — one reason it is widely used on construction machinery and generator sets operating in dusty conditions.
Flow and Restriction
| Parameter | Value / Notes |
|---|---|
| Rated flow | ≤346 cfm / 9.8 m³/min (filter assembly rated intake) |
| 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 restriction to blockage alarm value |
| Alarm / final restriction | Per the machine's restriction indicator yellow/red zone |
| Restriction vs. energy | Each 1 kPa rise in intake restriction increases machine energy consumption by roughly 1% |
Restriction and energy consumption
Rising intake restriction lowers intake pressure and density, so the machine must work harder to hold discharge pressure and flow, and specific power increases. Calculated on a theoretical compression ratio basis at 0.7 MPa discharge and 101.3 kPa atmospheric:
| Intake restriction | 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 goes from new to heavily loaded (0 → 6 kPa), machine energy consumption rises by roughly 6% along the way. That ongoing electricity cost normally far exceeds the price of an element — which is why the OEM provides a restriction indicator port on the FPG10 housing: change timing should be driven by actual restriction, not by the calendar.
Dimensions and Installation
| Parameter | Value / Notes |
|---|---|
| Dimensions | 208 mm OD × 106 mm ID × 409 mm length |
| Construction | Pleated cylindrical element, two-stage RadialSeal primary |
| 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 — integrally molded polyurethane end cap forms the radial seal, no separate gasket |
| Companion element | Safety element, fitted inside the primary as backup protection |
Purchasing note: when cross-checking a replacement, compare all three dimensions — 208 mm OD, 106 mm ID, 409 mm length. The FPG design seals radially; push the element in until the end cap contacts the outlet tube. No additional gasket is needed — do not attempt to add one, as it will break the radial seal fit.
Materials
| Parameter | Value / Notes |
|---|---|
| Media | Cellulose filter paper to FPG10 specification |
| Media weight | Approx. 130 g/m² |
| Inner / outer support | Galvanized steel perforated core (inner core + outer screen) |
| End cap | Integrally molded polyurethane (PU) end cap, encapsulating both media ends and sealing face |
| Seal | RadialSeal formed by the polyurethane end cap itself; no separate seal ring or gasket |
| Bonding | Molded integrally with the end cap; no additional adhesive layer |
Construction note: a traditional axial element consists of three parts — metal end cap, glued gasket and separate seal ring — and aging in any one of them causes bypass. FPG encapsulates the end cap, sealing face and media ends in a single polyurethane body, reducing part count and improving seal reliability. That is also what makes tool-free installation possible.
Operating Conditions
| 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 strength) |
| Collapse resistance | Element withstands intake alarm differential without collapse (RadialSeal construction supports layer by layer) |
| Special function | Two-stage filtration (integral tangential pre-cleaner) + Vacuator automatic dust valve |
| Housing | FPG housing is injection-molded plastic — corrosion resistant and vibration tolerant |
Service Life and Maintenance
| Parameter | Value / Notes |
|---|---|
| Service life | 2,000 hours or 3 months, whichever comes first |
| High-dust environments | Follow the restriction indicator; schedule replacement once it enters the yellow zone |
| Storage shelf life | Approx. 2–3 years (unopened, dry, ventilated storage) |
Applicable Standards
| Item | Details |
|---|---|
| Product standard | ISO 5011 (inlet air cleaning equipment for internal combustion engines and compressors — performance testing); efficiency figures are measured to this standard |
| Construction standard | Donaldson FPG / FRG series filter specification (RadialSeal sealing system) |
| Commonly cited test standards | ISO 2941 / 2942 / 2943 / 3723 / 3724 / 3968 |
| Note on applicability | The ISO 29xx / 37xx series above are in fact general test methods for hydraulic fluid power filter elements. If a supplier can only provide hydraulic element standards, request ISO 5011 or the OEM specification sheet as well. |
Standard Maintenance and Installation 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, isolate the 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 a RadialSeal element has no gasket to peel off — if you find a residual gasket on the housing outlet tube, a non-genuine part was fitted previously 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 caked dust, no foreign-object obstruction. This is the most commonly skipped step in FPG maintenance and the most consequential — a blocked valve disables the pre-cleaner stage, shifting the entire dust load onto the main element and sharply shortening its life.Inspect the pre-cleaner stage and housing for dust traces
Look for dust bypass tracks inside the housing and abnormal build-up in the pre-cleaner swirl zone. Criterion: no dust tracks on the inner wall; if tracks are present, inspect the sealing surfaces.Fit 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 and none should be added.Refit 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 confirm it returns correctly. Criterion: green-zone reading, indicator functioning.Start up and record
Start the machine, run to operating temperature and read intake restriction. Criterion: restriction within the new-element baseline range; record date, running hours and restriction reading.
Non-negotiable rule: do not start the machine before the element is fully seated. If a RadialSeal element is not pushed home, air bypasses directly through the gap between end cap and outlet tube — the pre-cleaner and main element are both ineffective, equivalent to running with no element at all.
Frequently Asked Questions
What specification is 49164395?
A two-stage RadialSeal primary element built to the Donaldson FPG10 specification. The integral tangential pre-cleaner removes roughly 85% of coarse dust first, leaving fine filtration to the main element.
Is it interchangeable with 49101637?
No. 49101637 is FPG09, with different dimensions and rated flow. Confirmation is simple: read the specification marking on the end cap of the element currently fitted — 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 seals against the housing outlet tube, so no glued gasket or separate seal ring is required. Fewer parts, fewer failure points and less chance of incorrect installation.
What does the Vacuator dust valve do?
It is the dust discharge point for the pre-cleaner stage. Coarse dust separated by the swirling airflow falls to the base of the housing and is ejected automatically through the Vacuator valve. Once the valve blocks, the pre-cleaner stage fails completely and all dust is pushed onto the main 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 2,000 hours or 3 months, whichever comes first. More accurately, follow the restriction indicator: schedule replacement once it enters the yellow zone. In high-dust sites, replace earlier according to the indicator reading.
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 fibre structure and creates invisible channels that let unfiltered air pass, which is more dangerous than not changing the element at all.
Can a gasket be added to improve sealing?
No, and it is unnecessary. RadialSeal relies on radial compression of the end cap itself; adding a gasket lifts the element off 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 and will show a "clean" reading even when the element is actually loaded. Press and check that it returns correctly at every service; if it has failed, change the element on the conservative time interval until it is repaired.
How does the FPG plastic housing compare with a metal housing?
The FPG injection-molded housing is corrosion resistant, lightweight and vibration tolerant, and will not rust in coastal salt-spray or humid conditions. Tool-free access also makes field maintenance faster. This is one reason 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 fitted element and confirm FPG10; (2) measure the old element's outside diameter and length against 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-check against the FPG specification.
Compatible Equipment
This part is supplied to the Donaldson FPG10 specification and fits Ingersoll Rand rotary screw air compressors equipped with an FPG10 air filter.
FPG10 is a Donaldson off-the-shelf filter assembly specification, adopted by OEMs as a standard intake filtration unit. The determining factors are:
| Check item | Specification |
|---|---|
| Filter specification | Donaldson FPG10 (elements interchangeable with the FRG10 series) |
| Filter rated intake flow | ≤346 cfm / 9.8 m³/min |
| Role in assembly | Primary element |
| Other specification in series | FPG09 — part number 49101637, different dimensions and flow, not interchangeable |
| Sealing system | RadialSeal (polyurethane end cap radial seal) |
How to confirm fitment
- Preferred: read the specification marking on the end cap of the fitted element. FPG10 means this part applies; FPG09 means order 49101637.
- Alternative: measure the old element's outside diameter and length against 208 mm × 409 mm.
- Fallback: provide the model marking on the filter housing or a photo of the machine nameplate, and we will cross-check against the FPG specification.
Note on model coverage
Donaldson FPG10 is a general-purpose filter assembly used by several OEMs, so the fitment scope of this part is not strictly equivalent to a single list of machine models. The determining factor is the fact that the filter specification is FPG10, not the machine model itself. If the machine nameplate does not state the filter specification, confirm using any one of the three methods above.
Related Components
The FPG10 filter is a complete system; besides the primary element there are seven components serviced together with it. Listed below by component — function — inspection point:
| Component | Function | Inspection point |
|---|---|---|
| Safety element | Backup element inside the primary, protecting downstream if the primary is damaged or during change intervals | Usually changed on the same interval as the primary or every other change; check media for damage |
| Vacuator dust valve | Automatic dust discharge for the pre-cleaner stage, ejecting centrifugally separated coarse dust | Check at every element change: valve must open and close freely, no caked dust, no obstruction |
| Restriction indicator | Indicates element loading and is the authoritative basis for change timing | Check that the needle returns correctly; connecting 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 leakage once 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 filter to machine intake duct | Check for cracks, aging and looseness — bypass leakage is as harmful as no element at all |
| Other primary elements in series | FPG09 — part number 49101637 | Different dimensions and flow, not interchangeable; keep separate in stock |
Companion replacement advice: the service value of the FPG10 system centres 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 — if either small part fails, primary element life is noticeably shortened. They cost far less than the primary element but determine how long it lasts.