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% filtration efficiency to ISO 5011, tangential pre-cleaner removes up to 85% of coarse dust. Export-ready for compressor parts distributors and OEM procurement.
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Product Overview
49164395 is the intake air filter element used on Ingersoll Rand screw air compressors equipped with the Donaldson FPG10 air cleaner assembly. It is supplied as the primary element within a two-stage RadialSeal filtration system.
The structural difference from a conventional single-stage element is worth stating first. Air enters through a built-in tangential pre-cleaner, where the tangential inlet spins the airflow at high speed and centrifugal force throws coarse particles against the housing wall. Roughly 85% of coarse dust is separated before it reaches the main element and is discharged automatically through the Vacuator dust valve at the bottom of the housing. Pre-cleaned air then passes into the main element, where cellulose filter media performs fine filtration. This architecture matters most on dusty sites: the main element carries only the fine-particle load and maintains a longer service life in high-dust environments.
Sealing also differs from traditional elements. 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 used on older axial elements. Fewer parts means fewer failure points, and the gasket aging, detachment and misalignment problems common to older designs do not exist in the FPG structure. No tools are required for installation or removal.
Key Specifications at a Glance
| Item | Value |
|---|---|
| Part number | 49164395 |
| Product name | Air Filter Element |
| Brand | Ingersoll Rand |
| Specification basis | 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, no gasket) |
| Net weight | Approx. 1.88 kg |
| Filtration efficiency | 99.9% (ISO 5011) |
| Pre-cleaner efficiency | Up to 85% coarse dust removal |
| Rated intake flow | Up to 346 cfm / 9.8 m3/min |
| Recommended change interval | 2000 hours or 3 months |
Technical Parameters
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% coarse dust removal (tangential stage) |
| Filter class | Two-stage: centrifugal pre-cleaner plus cellulose main element; HVAC filter classification (EN 779) does not apply |
| Dust holding capacity | Approx. 1200 g |
What the two-stage design changes in practice: a single-stage element forces the filter paper to handle both coarse and fine particles, so coarse dust builds quickly on the surface, pressure drop rises fast and service life is short. By shifting the coarse-dust load to the centrifugal pre-cleaner, FPG10 substantially improves the load profile on the main element. This is why the design is widely used on construction machinery, generator sets and other dust-exposed equipment.
Flow and Pressure Drop
| Parameter | Value / Notes |
|---|---|
| Rated air flow | Up to 346 cfm / 9.8 m3/min (air cleaner assembly rating) |
| 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 machine restriction indicator yellow/red zone |
| Pressure drop vs. energy | Each 1 kPa rise in intake resistance increases machine energy consumption by approximately 1% |
Pressure drop and energy consumption
Rising intake resistance lowers intake pressure and air 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 resistance | 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 moves from new to heavily blocked (0 to 6 kPa), machine energy consumption rises by roughly 6% over the interval. The cumulative electricity cost usually far exceeds the price of one element. This is why the original FPG10 housing provides an intake restriction indicator port: change timing is set by actual resistance rather than by calendar estimate.
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, mounted inside the primary element as backup protection |
Procurement note: when cross-checking a replacement, verify all three dimensions - 208 mm OD, 106 mm ID, 409 mm length. 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 a gasket - it will break the radial seal fit.
Material Composition
| Parameter | Value / Notes |
|---|---|
| Filter media | Cellulose filter paper, to FPG10 specification |
| Media basis weight | Approx. 130 g/m2 |
| Inner and outer support | Galvanized steel perforated cage (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 |
Structural note: a conventional axial element consists of a metal end cap, a glued gasket and a separate seal ring. Aging 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. This is also what makes tool-free servicing possible.
Operating Condition Tolerance
| Parameter | Value / Notes |
|---|---|
| Operating temperature | Continuous 83 deg C |
| Relative humidity | Up to 80% RH, no condensation |
| Burst strength | Filter paper 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 features | Two-stage filtration (built-in tangential pre-cleaner) plus Vacuator automatic dust valve |
| Housing characteristics | FPG housing is injection-molded plastic: corrosion-resistant and vibration-tolerant |
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 resistance 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 |
| Structural standard | Donaldson FPG / FRG series air cleaner 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 general test methods for hydraulic fluid power filter elements. If a supplier can only provide hydraulic element standards, request ISO 5011 or the original specification sheet as a supplement. |
Standard Maintenance and Installation Steps
A key feature of the FPG design is tool-free maintenance, with a single service job taking 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 air cleaner service cover
Release the service cover latches - the FPG design uses two spring latches or a twist-off cover and requires no tools. Criterion: latches not broken, 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 a residual gasket is found on the housing outlet tube, a non-original part was previously fitted and must be cleaned away.Inspect the Vacuator dust valve
Check the Vacuator valve (rubber duckbill) at the bottom of the housing. Criterion: the valve must open and close freely, with no caked dust and no 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.Check the pre-cleaner stage and dust traces inside the housing
Look for dust bypass tracks inside the housing and abnormal accumulation 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 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 resettable, press to reset and confirm it returns correctly. Criterion: green-zone reading and correct indicator movement.Start up and record
Start the machine, run to operating temperature and read intake restriction. Criterion: resistance within the new-element baseline range; record date, running hours and resistance reading.
Installation rule: do not start the machine 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 the main element then become ineffective, equivalent to running with no element at all.
Frequently Asked Questions
What specification is 49164395?
A two-stage RadialSeal primary element manufactured to Donaldson FPG10 specification. The built-in 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 from FPG10. Confirmation is straightforward: read the specification marking on the end cap of the element currently fitted. If it reads FPG10, order this part; if it reads FPG09, 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, 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 dust discharge port of the pre-cleaner stage. Coarse dust separated by the swirling airflow falls by gravity to the bottom 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 straight 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 2000 hours or 3 months, whichever comes first. A more accurate approach is to follow the intake restriction indicator: schedule replacement once resistance enters the yellow zone. On 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 filter media 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 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.
Is it normal for the intake restriction indicator never to move?
No. A stuck indicator is a common failure point and will keep giving a clean reading even when the element is actually blocked. Press and check that it returns correctly at every service; if it has failed, change the element on the conservative time interval until the indicator is repaired.
What are the pros and cons of the FPG plastic housing versus a metal housing?
The FPG injection-molded housing is corrosion-resistant, lightweight and vibration-tolerant, and will not rust in coastal salt-spray or humid environments. The tool-free servicing 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 end cap of the fitted element and confirm it is FPG10; (2) measure the old part's outer diameter and length against 208 mm and 409 mm; (3) if the old part has been discarded, provide the model marking on the air cleaner housing and we will cross-check against the FPG specification.
Compatible Equipment
This part is supplied to Donaldson FPG10 specification and fits Ingersoll Rand screw air compressors equipped with an FPG10 air cleaner.
FPG10 is a Donaldson finished air cleaner assembly specification, adopted by machine builders 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) |
| Air cleaner rated flow | Up to 346 cfm / 9.8 m3/min |
| Role in assembly | Primary element |
| Other specification in the series | FPG09 - part number 49101637, different dimensions and flow, not interchangeable |
| Sealing system | RadialSeal (polyurethane end cap radial seal) |
How to confirm fit
- Preferred: read the specification marking on the end cap of the fitted element. If it reads FPG10, this part applies; if it reads FPG09, order 49101637.
- Alternative: measure the old part's outer diameter and length against 208 mm x 409 mm.
- Fallback: provide the model marking on the air cleaner housing or a photo of the machine nameplate, and we will cross-check against the FPG specification.
On model coverage
The Donaldson FPG10 is a universal air cleaner adopted by multiple machine builders, so the fitment range of this part is not fully equivalent to any single list of machine models. The correct basis for judgement 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. In addition to the primary element, seven components are serviced alongside this part. They are listed below by component, function and inspection point:
| Component | Function | Inspection point |
|---|---|---|
| Safety element | Backup element mounted inside the primary element; protects downstream if the primary is damaged or during change intervals | Usually 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; expels 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 |
| Restriction indicator | Indicates element blockage level; the authoritative basis for change timing | Check that the needle returns correctly; connecting line must be clear |
| Service cover and latches | Tool-free opening structure of the FPG housing | Check latches for breakage and the cover for deformation; no air 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 without an element |
| Other primary 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 correctly. When changing the primary element, inspect the Vacuator valve and restriction indicator at the same time. If either small part fails, the service life of the primary element drops noticeably - their cost is far below that of the main element, yet they determine how long it lasts.