Product
Ingersoll Rand 49164395 Air Filter | Donaldson FPG10 RadialSeal
Ingersoll Rand 49164395 air filter element built to Donaldson FPG10 two-stage RadialSeal specification. 208 mm OD, 106 mm ID, 409 mm length; 99.9% efficiency per ISO 5011, pre-cleaner removes up to 85% of coarse dust. Tool-free fitment, 2,000-hour 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 construction differs from a conventional single-stage filter in a way worth stating plainly: FPG10 is a two-stage intake system. Air first passes through an integrated tangential pre-cleaner — entering at a tangent, the airstream spins at high speed and centrifugal force throws coarse particles against the housing wall. Roughly 85% of coarse dust is separated before it reaches the primary element and is discharged automatically through the Vacuator dust valve at the base of the housing. Pre-cleaned air then enters the primary element, where cellulose media performs fine filtration. The benefit is most visible on dusty sites: the primary element carries only the fine-particle load, so service life holds up even in high-dust environments.
Sealing also differs from traditional filters. FPG uses Donaldson's RadialSeal design: a one-piece molded polyurethane end cap seals radially directly against the housing outlet tube, eliminating the glued gasket of older axial elements. Fewer parts means fewer failure points — gasket ageing, detachment and installation misalignment no longer apply, and no tools are required for removal or refitting.
Core 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 | 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 removed |
| Rated intake flow | ≤346 cfm / 9.8 m³/min |
| Recommended service 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% (per ISO 5011) |
| Pre-cleaner efficiency | Up to 85% of coarse dust removed (tangential pre-cleaner stage) |
| Filter class | Two-stage: centrifugal pre-cleaning + cellulose primary element; HVAC filter classifications (EN 779) do 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 quickly on the surface, restriction rises fast and life is short. By shifting the coarse load to the centrifugal stage, FPG10 materially improves the load profile on the primary element — a key reason it is widely used on construction machinery and generator sets working in dusty conditions.
Flow and Restriction
| Parameter | Value / Notes |
|---|---|
| Rated air flow | ≤346 cfm / 9.8 m³/min (rated intake of the complete filter assembly) |
| Media 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 baseline to blockage alarm point |
| Alarm / final restriction | Per the machine's intake 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. To hold the set discharge pressure and flow, the machine must do more work and specific power rises. Calculated on compression ratio theory 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 takeaway: from new to heavily blocked (0 → 6 kPa), machine energy consumption climbs by roughly 6% along the way. That ongoing electricity cost usually far exceeds the price of one element — which is why the FPG10 housing provides a restriction indicator port, letting actual restriction rather than a calendar decide when to change.
Dimensions and Installation
| Parameter | Value / Notes |
|---|---|
| Dimensions | 208 mm OD × 106 mm ID × 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 | 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 |
Procurement note: when cross-checking replacements, verify all three dimensions — 208 mm OD, 106 mm ID, 409 mm length. FPG seals radially; push the element in until the end cap contacts the outlet tube, with no additional gasket. Do not add a gasket — it will disturb the radial seal fit.
Materials
| Parameter | Value / Notes |
|---|---|
| Media | Cellulose filter paper to FPG10 specification |
| Media weight | Approx. 130 g/m² |
| Support | Galvanized perforated steel (inner cage + outer mesh) |
| 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 |
Design note: a traditional axial element consists of three parts — metal end cap, glued gasket and separate seal ring — and ageing at 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 service 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 test) |
| Collapse resistance | Element withstands intake alarm differential without collapse (RadialSeal construction supports layer by layer) |
| Special function | Two-stage filtration (integrated tangential pre-cleaner) + Vacuator automatic dust valve |
| Housing characteristics | FPG housing is 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 and ventilated conditions) |
Standards
| Item | Details |
|---|---|
| Applicable 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 are general test methods for hydraulic fluid power filter elements. If a supplier can only cite hydraulic element standards, request ISO 5011 data or the original specification sheet. |
Standard Maintenance and Installation Steps
A defining 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 the RadialSeal design has no gasket to peel off — if you find a gasket residue on the housing outlet tube, a non-genuine part was fitted previously and must be cleaned off.Check the Vacuator dust valve
Inspect the Vacuator valve (rubber duckbill) at the base of the housing. Criterion: valve lips open and close freely, no caked dust, no obstruction. This is the most commonly skipped step in FPG maintenance and the most consequential — a blocked dust valve disables the pre-cleaner stage, shifting the full dust load onto the primary 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 swirl zone. Criterion: no dust track on the inner wall; if a track is 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 is 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 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 and primary element become 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 roughly 85% of coarse dust first; the primary 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 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 dust valve do?
It is the discharge point for the pre-cleaner stage. Coarse dust separated by the swirling airflow falls 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 loads the primary element directly. Check it at every element change — it is the critical maintenance action on 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 very dusty sites, replace earlier based on indicator readings.
Can it 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 straight through, which is more dangerous than not changing it 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 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: it can read "clean" even when the element is actually blocked. Press-check that it returns correctly at every service; if it has failed, change elements on a conservative time-based interval until it is repaired.
How does the FPG plastic housing compare with metal housings?
The FPG molded housing is corrosion-resistant, lightweight and vibration-tolerant, and will not rust in coastal salt-spray or humid conditions. Tool-free service also makes field maintenance faster — 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 OD 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.
Machine Compatibility
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 Donaldson finished filter assembly specification, adopted by OEMs as a standard intake filtration unit. Key identification points:
| Identification item | Specification |
|---|---|
| Filter specification | Donaldson FPG10 (elements 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 fitted element. FPG10 means this part fits; FPG09 means order 49101637.
- Alternative: measure the old element's OD 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
The Donaldson FPG10 is a universal filter assembly adopted by several OEMs, so coverage for this part is not strictly equivalent to a fixed list of machine models. The deciding factor should be 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, seven components are serviced alongside it. Listed below as component — function — inspection point:
| Component | Function | Inspection point |
|---|---|---|
| Safety Element | Backup element inside the primary element; protects downstream if the primary is damaged or during the change interval | Generally replaced on the same interval or every other change; check media for damage |
| Vacuator dust valve | Automatic discharge for 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 | Shows element blockage level; the authoritative basis for replacement timing | Check that the needle returns correctly; connection line must be clear |
| Service cover and latches | Tool-free open/close feature of the FPG housing | Check latches for cracks and cover for deformation; no air leakage once secured |
| FPG housing assembly | 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 | Connects filter housing to the machine intake duct | Check for cracks, ageing and looseness — bypass leakage is as harmful as no element at all |
| Other primary elements in the series | FPG09 — part number 49101637 | Different dimensions and flow, not interchangeable; keep stock clearly separated |
Companion replacement advice: the service value of the FPG10 system centres on whether the pre-cleaner stage is working. When changing the primary element, check the Vacuator valve and restriction indicator at the same time. If either small part fails, primary element life shortens noticeably — they cost far less than the primary element but determine how long it lasts.