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 removes up to 85% of coarse dust. Tool-free fitment, 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 and manufactured to the Donaldson FPG10 specification.
Its structure differs clearly from a conventional single-stage filter. FPG10 is a two-stage intake filtration system. Air first passes through an integrated tangential pre-cleaner: entering tangentially at high velocity, the airflow spins and 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 dump 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 sites: the main element carries only the fine-particle load and still delivers long service life in high-dust environments.
Sealing also differs from traditional 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. One less part means one less failure point — gasket aging, detachment and misalignment no longer apply, and no tools are needed for removal or installation.
Key Specifications at a Glance
| 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 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 removed |
| Rated intake flow | Up to 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 micron class (main element) |
| Filtration efficiency | 99.9% (tested to ISO 5011) |
| Pre-cleaner efficiency | Up to 85% of coarse dust removed (tangential stage) |
| Filter class | Two-stage: centrifugal pre-cleaner plus cellulose main element; HVAC filter classes (EN 779) do not apply |
| Dust holding capacity | Approx. 1200 g |
What the two-stage design changes: in a single-stage filter, the media must handle both coarse and fine particles, so coarse dust builds quickly on the surface, restriction rises fast and life is short. By moving the coarse load to the centrifugal pre-cleaner, FPG10 markedly improves the loading profile of the main element — one reason it is widely used on construction machinery and generator sets in dusty conditions.
2. Flow and Restriction
| 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 restriction to blockage alarm value |
| Alarm / final restriction | Per the machine restriction indicator yellow / red zone |
| Restriction vs. energy | Each 1 kPa rise in intake restriction increases package energy consumption by about 1% |
Restriction and energy consumption
Rising intake restriction lowers intake pressure and density; to hold the set discharge pressure and flow, the package must do more work and specific power increases. Using 0.7 MPa discharge pressure and 101.3 kPa atmospheric pressure as the base for a theoretical compression-ratio calculation:
| 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 blocked (0 to 6 kPa), package energy consumption rises by roughly 6% over the interval. The extra electricity cost typically far exceeds the price of an element — which is why the FPG10 housing provides a restriction indicator port: change-out timing is set by actual restriction rather than calendar estimates.
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 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 replacements, verify all three dimensions: 208 mm OD, 106 mm ID, 409 mm length. FPG is a radial seal; push 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 weight | Approx. 130 g/m2 |
| Inner / outer support | Galvanized steel perforated cage (inner cage plus outer guard) |
| End cap | One-piece molded polyurethane (PU) end cap, encapsulating media ends and sealing surface |
| Sealing component | RadialSeal formed by the PU end cap body; 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 a metal end cap, glued gasket and separate seal ring - aging of any one leads to bypass. FPG encapsulates end cap, sealing surface and media ends in a single polyurethane body, reducing part count and improving seal reliability, which is what makes tool-free service possible.
5. 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 structure supports layer by layer) |
| Special function | Two-stage filtration (integrated tangential pre-cleaner) plus Vacuator automatic dump valve |
| Housing characteristics | FPG housing is injection-molded plastic: corrosion-resistant and vibration-tolerant |
6. Service Life and Maintenance
| Parameter | Value / Notes |
|---|---|
| Service life | 2000 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 conditions) |
7. Applicable Standards
| Item | Content |
|---|---|
| Product standard | ISO 5011 (inlet air cleaning equipment for internal combustion engines and compressors - performance testing); efficiency figures measured to this standard |
| Construction standard | Donaldson FPG / FRG series filter specification (RadialSeal system) |
| Commonly cited test standards | ISO 2941 / 2942 / 2943 / 3723 / 3724 / 3968 |
| Standard applicability note | The ISO 29xx / 37xx series 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 Maintenance and Installation Steps
A key feature of the FPG design is tool-free maintenance; a single job takes about 15 minutes.
- Shut down, confirm zero pressure, lock out / tag out. Stop the package, 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 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 the RadialSeal design has no gasket to peel off - if you find a gasket left on the outlet tube, a non-genuine part was fitted previously and must be cleaned off.
- Inspect the Vacuator dump valve. Check the rubber duckbill valve at the base 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 blocked dump valve disables the pre-cleaner, shifting the full dust load onto the main element and sharply shortening its life.
- Inspect the pre-cleaner stage and dust traces in the housing. 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.
- Install the new element. Push 49164395 into the housing until the polyurethane end cap contacts the outlet tube. Criterion: end cap fully seated against the outlet tube; no gasket is needed or permitted.
- Refit the service cover and check the restriction indicator. Replace the cover and lock the latches. Confirm the intake restriction indicator reads green; if resettable, press to reset and confirm it returns correctly. Criterion: green-zone reading, indicator functioning.
- Start up and record. Start the package, 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 package 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 and main element are then ineffective - equivalent to running with no element at all.
FAQ
What specification is 49164395?
A two-stage RadialSeal primary element built to the Donaldson FPG10 specification. The integrated tangential pre-cleaner removes about 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 airflow 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 body seals directly 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 dump 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 is fully ineffective and all dust is pushed onto the main element. Check it at every element change - it 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 intake restriction indicator: schedule replacement once it 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, single-use 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 - more dangerous than not replacing it.
Can a gasket be added to improve sealing?
No, and it is unnecessary. RadialSeal seals through radial compression of the end cap body; adding a gasket lifts the element off the outlet tube and actually 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 blocked. Press-check it for correct return at every service; if it has failed, replace the element on a conservative time 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-tolerant, and will not rust in coastal salt-spray or humid conditions; the tool-free design also makes field service 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 end cap of the fitted element and confirm FPG10; (2) measure the old part's OD 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 Machines
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 filter assembly specification that OEMs install as a standard intake filtration unit. Key checks:
| Check item | Specification |
|---|---|
| Filter specification | Donaldson FPG10 (elements interchangeable with the FRG10 series) |
| Filter rated intake | 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 end cap of the fitted element. FPG10 means this part applies; FPG09 means order 49101637.
- Alternative: measure the old part's OD 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
Donaldson FPG10 is a universal filter used by several OEMs, so the fitment range of this part is not identical to any single machine model list. The correct basis for judgment is the fact of whether the filter specification 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 there are 7 components serviced together with it. Listed below as component - function - check point:
| Component | Function | Check 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 dump valve | Automatic dust discharge for the pre-cleaner stage, expelling separated coarse dust from the housing | Must be checked at every element change: valve must open and close freely, no caked dust, no obstruction |
| Restriction indicator | Indicates element blockage and is the authoritative basis for change timing | Check 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 distortion; no leakage once locked |
| FPG housing assembly | Injection-molded plastic housing with tangential inlet and pre-cleaner swirl zone | Inspect inner wall for dust bypass tracks; check plastic parts for cracks |
| Intake hose and clamps | Connect filter to the 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 | Dimensions and airflow differ, not interchangeable; keep separate in stock |
Companion replacement advice: the service value of the FPG10 system centers on whether the pre-cleaner stage is working. 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 below that of the primary element, yet they determine how long it lasts.