Product
Ingersoll Rand 49164395 Air Filter Element | Donaldson FPG10 RadialSeal
Two-stage RadialSeal primary air filter element for Ingersoll Rand screw compressors, built to Donaldson FPG10 specification. Integral tangential pre-cleaner removes up to 85% of coarse dust; main element rated 99.9% efficiency (ISO 5011). OD 208 mm, ID 106 mm, length 409 mm, gasket-free tool-free fitment. OEM/ODM and bulk supply available — request a quotation or datasheet.
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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 construction differs clearly from a conventional single-stage element: FPG10 is a two-stage intake filtration system. Air first passes through an integral tangential pre-cleaner — entering tangentially and spinning at high speed so centrifugal force throws coarse particles against the housing wall. Roughly 85% of coarse dust is separated before reaching 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 filter media performs fine filtration. The benefit is most obvious on dusty sites: the main element carries only the fine-particle load and maintains a longer service life 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 means fewer failure points — gasket ageing, detachment and misalignment are no longer possible with the FPG design, and no tools are required for removal or installation.
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 | OD 208 mm × ID 106 mm × length 409 mm |
| Sealing | RadialSeal (polyurethane end cap, no gasket) |
| Net weight (each) | Approx. 1.88 kg |
| Filtration efficiency | 99.9% (ISO 5011) |
| Pre-cleaner efficiency | Up to 85% coarse dust removal |
| Rated intake flow | ≤346 cfm / 9.8 m³/min |
| Recommended replacement | 2,000 hours or 3 months |
Technical Parameters
Filtration Performance
| Parameter | Value / Note |
|---|---|
| Filtration rating | 5 μm class (main 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 main element; HVAC filter classification (EN 779) 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 rapidly on the surface, restriction rises quickly and service life is short. By moving the coarse-dust burden to the centrifugal pre-cleaner, FPG10 substantially improves the load profile of the main element — a key reason it is widely used on construction machinery, generator sets and other dusty-duty equipment.
Flow and Restriction
| Parameter | Value / Note |
|---|---|
| Rated air flow | ≤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 restriction to blockage alarm value |
| Alarm / final restriction | Per the unit's intake restriction indicator (yellow / red zone) |
| Restriction vs. energy | Each 1 kPa increase in intake restriction raises unit energy consumption by approx. 1% |
Restriction and energy consumption
Rising intake restriction lowers intake pressure and density; to hold the set discharge pressure and flow the unit must do more work, and specific power rises. Based on a theoretical compression-ratio calculation at 0.7 MPa discharge pressure and 101.3 kPa atmospheric pressure:
| Intake restriction | Compression ratio | Relative energy increase vs. baseline |
|---|---|---|
| 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 blocked (0 → 6 kPa), unit energy consumption gradually rises by about 6%. That ongoing electricity cost typically far exceeds the price of one filter element — which is why the OEM provides an intake restriction indicator port on the FPG10 housing: replacement timing should be decided by actual restriction, not by a calendar estimate.
Dimensions and Installation
| Parameter | Value / Note |
|---|---|
| Dimensions | OD 208 mm × ID 106 mm × length 409 mm |
| 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 the radial seal, no separate gasket |
| Companion element | Safety element, fitted inside the primary element as backup protection |
Procurement note: when cross-checking a replacement, compare all three dimensions — OD 208 mm, ID 106 mm, length 409 mm. The FPG design seals radially; push the element in until the end cap contacts the outlet tube. No additional gasket is required — do not attempt to add one, as it will break the radial seal fit.
Material Construction
| Parameter | Value / Note |
|---|---|
| Media | Cellulose filter paper, to FPG10 specification |
| Media basis weight | Approx. 130 g/m² |
| Inner / outer support | Galvanized steel perforated core (inner cage + outer screen) |
| End cap | One-piece molded polyurethane (PU) end cap, encapsulating both the media ends and the sealing surface |
| Seal | RadialSeal formed by the polyurethane end cap itself; no separate O-ring or gasket |
| Bonding | Molded integrally with the end cap; no additional adhesive layer |
Construction note: a traditional axial element consists of a metal end cap, a glued gasket and a separate seal ring. Ageing at any one of these points causes bypass. FPG encapsulates the end cap, sealing surface and media ends in a single polyurethane body, reducing part count and improving seal reliability — the basis for its tool-free service.
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 paper burst test) |
| Collapse resistance | Element withstands intake alarm differential without collapse (RadialSeal structure supports layer by layer) |
| Special function | Two-stage filtration (integral tangential pre-cleaner) + Vacuator automatic dust valve |
| Housing | FPG housing is molded plastic — corrosion-resistant and vibration-resistant |
Service Life and Maintenance
| Parameter | Value / Note |
|---|---|
| Service life | 2,000 hours or 3 months, whichever comes first |
| High-dust environment | Follow the intake restriction indicator; schedule replacement once restriction enters the yellow zone |
| Storage shelf life | Approx. 2–3 years (unopened, dry, ventilated conditions) |
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 |
| Construction 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 above are in fact general test methods for hydraulic fluid power filter elements. If a supplier can only provide hydraulic filter standards, request ISO 5011 or the OEM specification sheet. |
Standard Installation and Maintenance Procedure
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, isolate the main power and apply lockout/tagout. Criterion: controller shows system pressure at 0.Open the FPG filter service cover
Release the service cover latches — FPG is designed with two spring latches or a twist-off cover and requires no tools. Criterion: latches unbroken, cover undistorted.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 a residual gasket is found on the housing outlet tube, a non-genuine part was previously fitted and must be cleaned away.Inspect the Vacuator dust valve
Check the Vacuator valve (rubber duckbill) at the base of the housing. Criterion: valve lips open and close freely, no caked dust, no foreign-object obstruction. This is the most frequently skipped step in FPG maintenance and the most consequential — a blocked dust 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 dust traces inside the housing
Look for dust bypass tracks inside the housing and abnormal build-up in the pre-cleaner swirl zone. Criterion: no dust track bands 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 and none may be added.Refit 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 confirm it returns normally. Criterion: green-zone reading, indicator functioning.Start up and record
Start the unit, run to operating temperature and read intake restriction. Criterion: restriction within the new-element baseline range; record date, running hours and restriction reading.
Installation rule: never start the unit before the element is fully seated. If a RadialSeal element is not pushed fully home, air bypasses directly through the gap between end cap and outlet tube, disabling both the pre-cleaner and the main element — equivalent to running with no filter at all.
Frequently Asked Questions
What specification is 49164395?
A two-stage RadialSeal primary element manufactured to the Donaldson FPG10 specification. The integral tangential pre-cleaner removes roughly 85% of coarse dust first; the main element handles fine filtration.
Is it interchangeable with 49101637?
No. 49101637 is FPG09, with different dimensions and rated flow from FPG10. 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; 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 discharge port of the pre-cleaner stage. Coarse dust separated by the swirl in the pre-cleaner falls by gravity to the base of the housing and is expelled 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 intake restriction indicator: schedule replacement once restriction enters the yellow zone. On high-dust sites, replace earlier based on indicator readings.
Can the element be blown clean and reused?
No. This is a dry, single-use element — it must not be washed or reverse-blown with compressed air. Reverse blowing damages the media fibre structure and creates invisible channels that let unfiltered air pass straight through, 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 body; adding a gasket lifts the element off the outlet tube and breaks the seal fit, causing bypass.
The intake restriction indicator never moves — is that normal?
No. A stuck indicator is a common failure point; it will show a "clean" reading even when the element is actually blocked. Press-check it at every service to confirm it returns normally; if it has failed, replace elements on a conservative time-based schedule until it is repaired.
How does the FPG plastic housing compare with a metal housing?
The FPG 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 service. This is a key reason the FPG series is widely used on construction machinery and mobile equipment.
How can I be 100% certain 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 part's outside diameter and length against 208 mm and 409 mm; ③ if the old part 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 screw air compressors equipped with the FPG10 air filter housing.
FPG10 is a finished Donaldson filter assembly specification, adopted by OEMs as a standard intake filtration unit. The key criteria are:
| Criterion | 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 part's outside diameter and length against 208 mm × 409 mm.
- Fallback: provide the model marking on the filter housing or a photo of the unit nameplate and we will cross-check against the FPG specification.
Note on model coverage
Donaldson FPG10 is a universal air filter assembly used by several OEMs, so the fitment scope of this part is not strictly limited to one specific machine model list. The deciding factor is the fact that the filter specification is FPG10, not the machine model itself. If the unit nameplate does not state the filter specification, confirm using any one of the three methods above.
Related Components
The FPG10 air filter is a complete system; besides the primary element, seven components are serviced together with it. Listed below as 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 cycle as the primary or every second change; check media for damage |
| Vacuator dust valve | Automatic dust discharge port of the pre-cleaner stage, expelling centrifugally separated coarse dust from the housing | Check at every element change: lips must open and close freely, no caked dust, no obstruction |
| Restriction indicator | Indicates element blockage level; the authoritative basis for replacement timing | Check that the needle returns normally; connecting line must be clear |
| Service cover and latches | Tool-free opening and closing structure of the FPG housing | Check latches for cracks and cover for distortion; no air leak when secured |
| FPG housing assembly | 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, ageing and looseness — bypass leakage is as harmful as no element at all |
| Other elements in the series | FPG09 — part number 49101637 | Different dimensions and flow, not interchangeable; keep separate in stock |
Companion replacement advice: the maintenance value of the FPG10 system centres on whether the pre-cleaner stage is working. When changing the primary element, inspect the Vacuator valve and the restriction indicator at the same time. Failure of either small part noticeably shortens primary element life — yet both cost far less than the element and determine how long it lasts.