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% of coarse dust, tool-free installation.
- 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 screw air compressors, manufactured to the Donaldson FPG10 specification.
Its structure differs notably from a conventional single-stage air filter. FPG10 is a two-stage intake filtration system. Air first passes through an integrated tangential pre-cleaner; entering tangentially at high speed, centrifugal force throws coarse particles against 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 bottom of the housing. Pre-cleaned air then enters the primary element, where cellulose filter media performs fine filtration. The value of this design is most evident in dusty environments: the primary element carries only the fine-particle load, maintaining a longer service life under high dust conditions.
Sealing also differs from traditional air filters. FPG uses Donaldson RadialSeal technology: an integrally 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 installation misalignment are eliminated in the FPG design, and no tools are required for installation or removal.
Key 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 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 Air Flow | ≤346 cfm / 9.8 m³/min |
| Recommended Replacement | 2000 hours or 3 months |
Technical Specifications
Filtration Performance
| Parameter | Value / Notes |
|---|---|
| Filtration Rating | 5 μm (primary element) |
| Filtration Efficiency | 99.9% (tested to 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; EN 779 HVAC classification does not apply |
| Dust Holding Capacity | Approx. 1200 g |
The practical difference of the two-stage design: a single-stage filter's media must handle both coarse and fine particles, so coarse dust builds rapidly on the surface, resistance rises quickly, and service life is short. By shifting the coarse dust load to the centrifugal pre-cleaner, FPG10 significantly improves the primary element's load profile — a key reason it is widely adopted on construction machinery, generator sets, and other dusty-duty equipment.
Flow and Pressure Drop
| Parameter | Value / Notes |
|---|---|
| Rated Air Flow | ≤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% |
Rising intake resistance lowers intake pressure and density; the unit must do more work to maintain set discharge pressure and flow, raising specific power. 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 heavily clogged (0 → 6 kPa), unit energy consumption rises by roughly 6% over the interval. This ongoing electricity cost typically far exceeds the price of a filter element — which is why the OEM provides a restriction indicator port on the FPG10 housing: replacement timing is determined by actual resistance, not by 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; integrally molded polyurethane end cap forms radial seal, no separate gasket |
| Companion Element | Safety element, mounted inside 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. No additional gasket is required — adding one will actually break the radial seal fit.
Material Construction
| Parameter | Value / Notes |
|---|---|
| Media | Cellulose filter paper, to FPG10 specification |
| Media Weight | Approx. 130 g/m² |
| Inner/Outer Support | Galvanized steel perforated cage (inner cage + outer guard) |
| End Cap | Integrally molded polyurethane (PU) end cap, encapsulating media ends and sealing surface |
| Seal | RadialSeal formed by the polyurethane end cap body, no separate seal ring or gasket |
| Bonding | Integrally molded with end cap, no additional adhesive layer |
Construction note: Traditional axial elements consist of three parts — metal end cap, glued gasket, and separate seal ring — any one of which aging causes 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 the basis for tool-free installation and removal.
Operating Conditions
| Parameter | Value / Notes |
|---|---|
| Operating Temperature | Continuous 83 ℃ |
| 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 | FPG housing is injection-molded plastic, corrosion-resistant and 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; replace when entering 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 tested to this standard |
| Structural Standard | Donaldson FPG / FRG series air filter specification (RadialSeal sealing system) |
| Industry-Referenced 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. |
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 unit, disconnect main power, and apply lockout/tagout. Criterion: controller shows system pressure at 0.
- Open the FPG air filter service cover. Release the service cover latches; FPG is designed with two spring latches or a twist-off cover, no tools required. Criterion: latches unbroken, cover undeformed.
- Remove the old element. Grip the polyurethane end cap and pull straight out. Criterion: note that the RadialSeal design has no gasket to peel — if you find a residual gasket on the housing outlet tube, a non-genuine part was previously installed and must be cleaned off.
- Inspect the Vacuator dust valve. Check the rubber duckbill valve at the bottom of the housing. Criterion: valve opens and closes freely, no caked 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 entire dust load to the primary 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 accumulation 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 seated against outlet tube; no gasket needed or permitted.
- Reinstall the service cover and check the restriction indicator. Refit the cover and secure latches. 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 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 seated. If the RadialSeal element is not pushed fully home, air bypasses directly through the gap between end cap and outlet tube — both the pre-cleaner and primary element become ineffective, equivalent to running with no filter at all.
Frequently Asked Questions
What specification is the 49164395 element?
A two-stage RadialSeal primary element manufactured to the Donaldson FPG10 specification. The integrated tangential pre-cleaner removes approximately 85% of coarse dust first, while the primary element handles fine filtration.
Is it interchangeable with 49101637?
No. 49101637 is FPG09, with different dimensions and rated air flow from FPG10. Confirmation is simple: read the specification marking on the installed element's end cap — 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 forms the seal directly against the housing outlet tube, requiring no 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 pre-cleaner stage discharge port. Coarse dust separated by the swirling airflow in the pre-cleaner falls by gravity to the bottom of the housing and is automatically discharged through the Vacuator valve. If the valve clogs, the pre-cleaner stage fails completely and all dust loads directly onto the primary element. Check it at every element 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 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, creating invisible channels that let unfiltered air pass straight through — more dangerous than not changing it at all.
Can a gasket be added to improve sealing?
No, and it is unnecessary. RadialSeal relies on radial compression of the end cap body to form the seal. Adding a gasket pushes the element away from the outlet tube, actually breaking 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 to confirm it returns properly; if it has failed, replace the element on a conservative time interval 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 service design also makes field 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 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 model marking on the air filter housing — we will cross-reference by FPG specification to confirm.
Compatible Equipment
This part is supplied to the Donaldson FPG10 specification and fits Ingersoll Rand screw air compressors equipped with the FPG10 air filter.
FPG10 is a Donaldson finished air filter assembly specification, adopted by OEMs as a standard intake filtration unit. Identification points:
| Check Item | Specification |
|---|---|
| Air Filter Specification | Donaldson FPG10 (element interchangeable with FRG10 series) |
| Air Filter Rated Flow | ≤346 cfm / 9.8 m³/min |
| Role in Assembly | Primary Element |
| Other Specification in Series | FPG09; corresponding part number 49101637, different dimensions and flow, not interchangeable |
| Sealing System | RadialSeal (polyurethane end cap radial seal) |
How to Confirm Fitment
- First choice: read the specification marking on the installed element's end cap. If it reads FPG10, this part applies; if FPG09, order 49101637.
- Second choice: measure the old part's OD and length to verify 208 mm x 409 mm.
- Fallback: provide the model marking on the air filter housing or a photo of the unit nameplate; we will cross-reference by FPG specification to confirm.
Note on Model Coverage
The Donaldson FPG10 is a universal air filter adopted by multiple OEMs, so this part's fitment range does not correspond exactly to any single list of machine models. The determining factor should be the fact of whether the air filter specification is FPG10, not the machine model itself. If the unit nameplate does not show the air filter specification, confirm using any of the three steps above.
Related Components
The FPG10 air filter is a complete system. In addition to the primary element, there are 7 components serviced together with this part. Listed below 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 or every other change; inspect media for damage |
| Vacuator Dust Valve | Pre-cleaner automatic discharge port, expelling centrifugally separated coarse dust from the housing | Must check at every element change: valve must open/close freely, no caked dust, no obstruction |
| Restriction Indicator | Indicates element clogging level; the authoritative basis for replacement timing | Check whether the needle returns properly; connecting line must be unobstructed |
| Service Cover and Latches | Tool-free opening/closing structure of the FPG housing | Check latches for breakage, cover for deformation; no air leak after securing |
| FPG Housing Assembly | Injection-molded plastic housing with tangential inlet and pre-cleaner swirl zone | Check inner walls for dust bypass tracks; check plastic parts for cracks |
| Intake Hose and Clamps | Connects air filter to main unit intake duct | Check for cracks, aging, looseness; bypass leakage is as harmful as no filter |
| Other Series Primary Elements | FPG09; corresponding part number 49101637 | Different dimensions and flow, 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, 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.