Product
Ingersoll Rand 49164395 Air Filter Element | Donaldson FPG10 RadialSeal
Ingersoll Rand 49164395 air filter element built to Donaldson FPG10 two-stage RadialSeal specification. 208 mm OD x 106 mm ID x 409 mm length, 99.9% efficiency (ISO 5011), tangential pre-cleaner removing up to 85% of coarse dust. Gasket-free, tool-free installation with a 2000-hour or 3-month service interval.
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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 architecture differs from a conventional single-stage air filter, and that difference is worth stating clearly: FPG10 is a two-stage intake filtration system. Air first passes through the integrated tangential pre-cleaner, where it enters at a tangent and spins at high velocity; centrifugal force throws coarse particles against the housing wall, so 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. The pre-cleaned air then enters the main element, where cellulose filter media performs fine filtration. The value of this architecture is most visible in dusty sites: the main element carries only the fine-particle load and still achieves a long service life in high-dust environments.
Sealing also differs from traditional air filters. FPG uses Donaldson's RadialSeal technology: a one-piece molded polyurethane end cap seals radially and directly against the housing outlet tube, eliminating the glued gasket of older axial elements. One fewer part means one fewer failure point — gasket aging, detachment and misalignment during installation simply do not exist in the FPG design, and no tools are required for removal or refitting.
Key Specifications at a Glance
| Item | Value |
|---|---|
| Part number | 49164395 |
| Product name | Air Filter Element |
| Brand | Ingersoll Rand |
| Specification source | Donaldson FPG10 (two-stage RadialSeal design) |
| Role in assembly | Primary element |
| Dimensions | 208 mm OD x 106 mm ID x 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 service interval | 2000 hours or 3 months |
Technical Parameters
1. Filtration Performance
| Parameter | Value / Notes |
|---|---|
| Filtration rating | 5 μm class (main element) |
| Filtration efficiency | 99.9% (tested to ISO 5011) |
| Pre-cleaner efficiency | Up to 85% of coarse dust (tangential pre-cleaner stage) |
| Filter class | Two-stage: centrifugal pre-cleaning plus cellulose main element; EN 779 ventilation filter classification does not apply |
| Dust holding capacity | Approx. 1200 g |
What the two-stage design changes in practice: in a single-stage filter, the media must handle both coarse and fine particles, so coarse dust builds up quickly on the surface, restriction rises fast and service life is short. By shifting the coarse-dust load to the centrifugal pre-cleaner stage, FPG10 substantially improves the load profile of the main element — one reason it is widely adopted on construction machinery, generator sets and other dusty-duty equipment.
2. Flow and Restriction
| Parameter | Value / Notes |
|---|---|
| Rated air flow | ≤346 cfm / 9.8 m³/min (rated intake flow of the complete filter assembly) |
| 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 the clogging alarm value |
| Alarm / final restriction | Per the machine's intake restriction indicator (yellow / red zone) |
| Restriction vs. energy | Every 1 kPa increase in intake restriction raises machine energy consumption by roughly 1% |
Restriction and energy consumption
Rising intake restriction lowers intake pressure and density; to hold the set discharge pressure and flow, the machine must do more work and specific power rises. Calculated on a theoretical compression-ratio basis at 0.7 MPa discharge pressure and 101.3 kPa atmospheric pressure:
| 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 takeaway: as an element goes from new to heavily clogged (0 → 6 kPa), machine energy consumption climbs by roughly 6% along the way. That ongoing electricity cost normally far exceeds the price of an element — which is why the FPG10 housing provides an intake restriction indicator port, so replacement timing is set by actual restriction rather than by calendar estimate.
3. Dimensions and Installation
| Parameter | Value / Notes |
|---|---|
| Dimensions | 208 mm OD x 106 mm ID x 409 mm length |
| 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 the 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 |
Sourcing note: when cross-checking a replacement, compare all three dimensions: 208 mm OD, 106 mm ID and 409 mm length. The FPG design seals radially; push the element in until the end cap contacts the outlet tube, with no additional gasket. Do not attempt to add a gasket — it will break the radial seal fit.
4. Materials of Construction
| Parameter | Value / Notes |
|---|---|
| Media | Cellulose filter paper, to FPG10 specification |
| Media grammage | Approx. 130 g/m² |
| Inner / outer support | Galvanized steel perforated support (inner cage plus 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 conventional 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 surface and media ends in a single polyurethane body, reducing part count and improving seal reliability; this is also what makes tool-free servicing possible.
5. Operating Conditions
| Parameter | Value / Notes |
|---|---|
| Operating temperature | Continuous 83 °C |
| Relative humidity | ≤80% RH, without condensation |
| Burst strength | Media burst strength approx. 200–400 kPa (per ISO 2758 paper burst test) |
| Collapse resistance | Element withstands intake alarm differential without collapsing (RadialSeal construction with layered support) |
| Special features | Two-stage filtration (integrated tangential pre-cleaner) plus Vacuator automatic dust valve |
| Housing | FPG housing is injection-molded plastic: corrosion-resistant and vibration-resistant |
6. Service Life and Maintenance
| Parameter | Value / Notes |
|---|---|
| Service life | 2000 hours or 3 months, whichever comes first |
| High-dust environments | Follow the intake restriction indicator; schedule replacement once restriction enters the yellow zone |
| Storage shelf life | Approx. 2–3 years (unopened, dry and ventilated conditions) |
7. Applicable Standards
| Item | Content |
|---|---|
| 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 |
| 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, ask for ISO 5011 or the OEM specification sheet. |
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 supply and apply lockout/tagout. Criterion: controller shows system pressure at 0.Open the FPG filter service cover
Release the cover latches — the FPG design uses two spring latches or a twist-off cover, and no tools are needed. Criterion: latches unbroken, 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-original part was previously fitted and must be cleaned off.Inspect the Vacuator dust valve
Check the Vacuator valve (rubber duckbill) at the base of the housing. Criterion: the valve opens and closes freely, with no caked dust and no foreign-object obstruction. This is the step most often skipped in FPG maintenance and the one with the most serious consequences — a blocked dust valve disables the pre-cleaner stage, shifting the full 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 buildup in the pre-cleaner swirl zone. Criterion: no dust track on the inner wall; if a track is present, check 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 or permitted.Refit the service cover and check the restriction indicator
Refit the cover and secure the latches. Confirm the intake restriction indicator reads in the green zone; if the indicator is resettable, press to reset and confirm it returns correctly. Criterion: green-zone reading, indicator operating normally.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.
Installation rule: never start the machine before the element is seated. If a RadialSeal element is not pushed fully home, air bypasses directly through the gap between end cap and outlet tube; both the pre-cleaner stage and the main element are then ineffective — equivalent to running with no filter at all.
Frequently Asked Questions
What specification is 49164395?
A two-stage RadialSeal primary element built to the Donaldson FPG10 specification. The integrated tangential pre-cleaner removes roughly 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 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 directly against the housing outlet tube, with no glued gasket or separate seal ring. Fewer parts, fewer failure points and less chance of incorrect installation.
What does the Vacuator dust valve do?
It is the dust discharge port of the pre-cleaner stage. Coarse dust separated by the swirling airflow falls by gravity to the base of the housing and is discharged automatically through the Vacuator valve. Once the valve blocks, the pre-cleaner stage fails completely and all dust is pushed onto the main element. Inspect it at every element change — this is the critical maintenance action on 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 once restriction 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, 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 — more dangerous than not changing the element at all.
Can a gasket be added to improve sealing?
No, and it is unnecessary. RadialSeal seals by radial compression of the end cap body; adding a gasket lifts the element away from the outlet tube and actually breaks the seal fit, causing bypass.
The intake restriction indicator never moves — is that normal?
No. A stuck indicator is a common failure point and will keep showing a “clean” reading even when the element is in fact clogged. Press-check it at every service to confirm it returns correctly; if it has failed, change the element on a conservative time-based 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-resistant, and will not rust in coastal salt-spray or humid environments; the tool-free design also makes on-site 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 element currently fitted and confirm it is FPG10; (2) measure the old element's outer 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 Machines
This element is supplied to the Donaldson FPG10 specification and fits Ingersoll Rand screw air compressors equipped with an FPG10 air filter housing.
FPG10 is a finished Donaldson air cleaner assembly specification, adopted by OEMs as a standard intake filtration unit. The decision points are as follows:
| Check item | Specification |
|---|---|
| Air cleaner specification | Donaldson FPG10 (element interchangeable with the FRG10 series) |
| 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 element currently fitted. FPG10 means this part fits; FPG09 means order 49101637.
- Alternative: measure the old element's outer diameter and length against 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-check against the FPG specification.
Note on model coverage
The Donaldson FPG10 is a universal air cleaner adopted by several OEMs, so the fitment scope of this element is not fully equivalent to any single list of machine models. The correct basis for the decision is the fact of whether the air cleaner specification is FPG10, not the machine model itself. If the machine nameplate does not state the air cleaner specification, confirm using any one of the three methods above.
Related Components
The FPG10 air cleaner 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 interval as the primary or every other 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: valve must open and close freely, with no caked dust and no obstruction |
| Intake restriction indicator | Indicates element clogging and is the authoritative basis for replacement timing | Check that the needle returns correctly; connecting line must be clear |
| Service cover and latches | Tool-free opening and closing of the FPG housing | Check latches for breakage 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 parts for cracks |
| Intake hose and clamps | Connect the air cleaner to the machine intake duct | Check for cracks, aging and looseness — bypass leakage is as harmful as running with no filter |
| Other primary element in series | FPG09 — part number 49101637 | Different dimensions and flow from this part, not interchangeable; keep separate in stock |
Recommended companion replacement: 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 intake restriction indicator at the same time — failure of either small part will noticeably shorten primary element life. Their cost is far below that of the primary element, yet they determine how long it lasts.