Product
Ingersoll Rand 49164395 Air Filter Element | Donaldson FPG10 Spec
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 (ISO 5011), 85% pre-cleaner dust removal. Export-ready for screw compressor OEM and aftermarket programs.
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- OEM / ODM customization available
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Product Overview
49164395 is the intake air filter element for Ingersoll Rand screw air compressors, manufactured to the Donaldson FPG10 specification.
FPG10 is a two-stage intake filtration system. Air first passes through an integrated tangential pre-cleaner: the airflow enters tangentially and spins at high speed, centrifugal force throws coarse particles against the housing wall, and approximately 85% of coarse dust is separated before reaching the main element, discharged automatically through a Vacuator dust valve at the housing base. Pre-cleaned air then enters the main element, where cellulose filter media performs fine filtration. This architecture matters most on dusty sites: the main element carries only fine-particle load, sustaining longer service life in high-dust environments.
Sealing differs from conventional 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 aging, detachment, and misalignment are eliminated, and no tools are required for installation or removal.
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 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% coarse dust removal |
| Rated Airflow | Up to 346 cfm / 9.8 m3/min |
| Recommended Replacement | 2,000 hours or 3 months |
Technical Parameters
1. Filtration Performance
| Parameter | Value / Notes |
|---|---|
| Filtration Rating | 5 micron class (main element) |
| Filtration Efficiency | 99.9% (per 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; EN 779 HVAC classification not applicable |
| Dust Holding Capacity | Approx. 1,200 g |
Practical difference of the two-stage design: a single-stage filter forces the media to handle both coarse and fine particles; coarse dust builds rapidly on the media surface, raising restriction quickly and shortening life. By shifting the coarse load to the centrifugal pre-cleaner, FPG10 markedly improves the main element's loading profile — a key reason it is widely adopted on construction machinery and generator sets working in dusty conditions.
2. Flow and Restriction
| Parameter | Value / Notes |
|---|---|
| Rated Airflow | Up to 346 cfm / 9.8 m3/min (air cleaner assembly rating) |
| Media Face Velocity | Approx. 0.038 m/s |
| Initial Pressure Drop | Approx. 0.5-1.0 kPa (approx. 50-100 mmH2O) |
| Operating Differential | From new-element baseline to blockage alarm value |
| Alarm / Final Restriction | Per the machine's intake restriction indicator (yellow/red zone) |
| Restriction vs. Energy | Each 1 kPa rise in intake restriction increases unit energy consumption by approx. 1% |
Restriction and energy consumption
Rising intake restriction lowers intake pressure and density; the unit must do more work to hold set discharge pressure and flow, raising specific power. Calculated on a theoretical compression-ratio basis 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 implication: from new to heavily blocked (0 to 6 kPa), unit energy consumption rises by roughly 6% over the interval. That ongoing electricity cost typically far exceeds the price of a filter element — which is why the FPG10 housing provides a restriction indicator port: replacement timing is set by actual restriction, not calendar estimates.
3. Dimensions and Installation
| Parameter | Value / Notes |
|---|---|
| Dimensions | 208 mm OD x 106 mm ID x 409 mm length |
| Configuration | Pleated cylindrical element, two-stage RadialSeal primary |
| 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 radial seal, no separate gasket |
| Companion Element | Safety element fitted inside the primary as backup protection |
Procurement note: when cross-checking replacements, verify all three dimensions — 208 mm OD, 106 mm ID, 409 mm length. The FPG design uses a radial seal; push in until the end cap contacts the outlet tube. Do not add a gasket — it will break the radial seal fit.
4. Materials of Construction
| Parameter | Value / Notes |
|---|---|
| Media | Cellulose filter paper, per FPG10 specification |
| Media Weight | Approx. 130 g/m2 |
| Inner/Outer Support | Galvanized steel perforated cage (inner core + outer screen) |
| End Cap | One-piece molded polyurethane (PU) end cap, encapsulating media ends and sealing face |
| Seal | RadialSeal formed by the polyurethane end cap body; no separate O-ring or gasket |
| Bonding | Molded integrally with the end cap; no additional adhesive layer |
Design note: a conventional axial element consists of three parts — metal end cap, glued gasket, and separate seal ring — and aging in any one causes bypass. FPG encapsulates the end cap, sealing face, and media ends in a single polyurethane body, reducing part count and improving seal reliability. This is also what enables tool-free service.
5. Operating Tolerance
| Parameter | Value / Notes |
|---|---|
| Operating Temperature | Continuous 83 deg C |
| Relative Humidity | Up to 80% RH, non-condensing |
| Burst Strength | Media burst strength approx. 200-400 kPa (per ISO 2758) |
| Collapse Resistance | Element withstands intake alarm differential without collapse (RadialSeal layer-by-layer support) |
| Special Function | Two-stage filtration (integrated tangential pre-cleaner) + Vacuator automatic dust valve |
| Housing Characteristics | FPG housing is injection-molded plastic: corrosion-resistant, vibration-resistant |
6. Service Life and Maintenance
| Parameter | Value / Notes |
|---|---|
| Service Life | 2,000 hours or 3 months, whichever comes first |
| High-Dust Environments | Follow restriction indicator reading; schedule replacement when 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 (intake air filters for internal combustion engines and compressors — performance testing); efficiency figures 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 are in fact general test methods for hydraulic 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 service; a single job takes about 15 minutes.
Shut down, confirm zero pressure, lock out/tag out
Stop the unit, disconnect main power, and apply lockout/tagout. Criterion: controller shows system pressure at 0.Open the FPG air cleaner service cover
Release the cover latches — FPG uses two spring latches or a twist-off cover, no tools required. Criterion: latches unbroken, cover undeformed.Remove the old element
Grip the polyurethane end cap and pull straight out. Criterion: note that the RadialSeal design has no gasket to peel — if a residual gasket is found on the housing outlet tube, a non-genuine part was previously fitted and must be cleaned off.Inspect the Vacuator dust valve
Check the Vacuator valve (rubber duckbill) at the housing base. Criterion: valve opens and closes freely, no caked dust, no obstruction. This is the most commonly skipped and most consequential step in FPG maintenance — a blocked dust valve disables the pre-cleaner, shifting the entire dust load to the main element and sharply shortening its life.Check the pre-cleaner stage and internal dust traces
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 present, inspect 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
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 correctly. Criterion: green-zone reading, indicator functioning.Start up and record
Start the unit, run to operating temperature, then read intake restriction. Criterion: restriction within the new-element baseline range; record date, running hours, and restriction reading.
Installation rule: do not start the unit 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, 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 built to the Donaldson FPG10 specification. The integrated tangential pre-cleaner removes about 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 airflow. Confirmation is simple: read the specification marking on the installed element's end cap — FPG10 means order this part; FPG09 means order 49101637.
Why does this element have no gasket?
Because it uses a RadialSeal radial seal. The polyurethane end cap body seals directly 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 pre-cleaner discharge port. Coarse dust separated by the swirling airflow falls to the housing base and is discharged automatically through the Vacuator valve. Once the valve blocks, the pre-cleaner is fully disabled and all dust loads 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 when 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, disposable element — it must not be washed or back-blown with compressed air. Back-blowing damages the media fiber structure and creates invisible channels that let unfiltered air pass, which is more dangerous than not replacing it.
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, breaking the seal fit and causing bypass.
The restriction indicator never moves — is that normal?
No. A stuck indicator is a common failure point; it can show a "clean" reading even when the element is actually blocked. Press-check it at every service to confirm it returns correctly; if it has failed, replace elements 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-resistant, and will not rust in coastal salt-spray or damp environments; tool-free service 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 installed element's end cap 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 air cleaner 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 an FPG10 air cleaner.
FPG10 is a Donaldson finished air cleaner assembly specification adopted by OEMs as a standard intake filtration unit. Key identification points:
| Identification Item | Specification |
|---|---|
| Air Cleaner Specification | Donaldson FPG10 (elements interchangeable with the FRG10 series) |
| Air Cleaner Rated Airflow | 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 fit
- Preferred: read the specification marking on the installed element's end cap. FPG10 means this part fits; FPG09 means order 49101637.
- Alternative: measure the old element's OD and length against 208 mm x 409 mm.
- Fallback: provide the model marking on the air cleaner housing or a photo of the unit nameplate and we will cross-check against the FPG specification.
Note on model coverage
The Donaldson FPG10 is a universal air cleaner used by multiple OEMs, so coverage is not strictly equivalent to a single fixed machine model list. The determining factor is whether the air cleaner specification is FPG10, not the machine model itself. If the unit nameplate does not state the air cleaner specification, confirm using any 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, protecting downstream if the primary is damaged or during change intervals | Generally replaced on the same interval or every other change; check media for damage |
| Vacuator Dust Valve | Automatic pre-cleaner discharge, expelling centrifugally separated coarse dust from the housing | Check at every element change: valve must open/close freely, no caked dust, no obstruction |
| Restriction Indicator | Indicates element blockage; the authoritative basis for replacement 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 cracks, cover for deformation; no air leak when 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 for cracks |
| Intake Hose and Clamps | Connect air cleaner to machine intake | Check for cracks, aging, looseness — bypass leakage is as harmful as no element |
| Other Primary Element in Series | FPG09 — part number 49101637 | Different dimensions and airflow, 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 — if either fails, primary element life drops noticeably. They cost far less than the primary element but determine how long it lasts.