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), tangential pre-cleaner removes up to 85% of coarse dust. Tool-free installation, 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.
FPG10 is a two-stage intake filtration system. Air first passes through an integrated tangential pre-cleaner: the tangential inlet spins the airflow at high speed, and centrifugal force drives coarse particles to the housing wall. Up to 85% of coarse dust is separated before reaching the main element and is discharged automatically through the Vacuator dust valve at the bottom of the housing. Pre-cleaned air then enters the main element, where cellulose filter media performs fine filtration. This structure matters most in dusty environments: the main element carries only fine-particle load, maintaining a longer service life under high dust conditions.
Sealing also differs from conventional air filters. FPG uses Donaldson RadialSeal technology: a one-piece molded polyurethane end cap seals radially against the housing outlet tube, eliminating the glued gasket of older axial elements. Fewer parts means fewer failure points, and gasket aging, detachment, and misalignment are eliminated. Installation and removal require no tools.
Key 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 radial seal, no gasket) |
| Net Weight | Approx. 1.88 kg |
| Filtration Efficiency | 99.9% (ISO 5011) |
| Pre-Cleaner Efficiency | Up to 85% of coarse dust removed |
| Rated Airflow | ≤346 cfm / 9.8 m³/min |
| Recommended Service Interval | 2000 hours or 3 months |
Technical Parameters
Filtration Performance
| Parameter | Value / Note |
|---|---|
| Filtration Rating | 5 μm 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-cleaning + cellulose main element; not rated under EN 779 HVAC classification |
| Dust Holding Capacity | Approx. 1200 g |
In a single-stage filter, the media carries both coarse and fine particles, so coarse dust accumulates rapidly on the surface, pressure drop rises quickly, and service life is shortened. FPG10 transfers the coarse-dust load to the centrifugal pre-cleaner, significantly improving the load profile of the main element. This is why the design is widely used on construction machinery and generator sets operating in dusty conditions.
Flow and Pressure Drop
| Parameter | Value / Note |
|---|---|
| Rated Airflow | ≤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 mmH&sub2;O) |
| Operating Pressure Differential | From new-element initial resistance to blockage alarm value |
| Alarm / Final Resistance | Per the intake restriction indicator yellow/red zone |
| Pressure Drop vs. Energy | Each 1 kPa increase in intake resistance raises unit energy consumption by approx. 1% |
Rising intake resistance reduces intake pressure and density. To maintain set discharge pressure and flow, the unit must do more work, and specific power increases. Based on a compression ratio calculation at 0.7 MPa discharge pressure and 101.3 kPa atmospheric pressure:
| Intake Resistance | 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% |
As an element goes from new to severely blocked (0 → 6 kPa), unit energy consumption gradually rises by about 6%. This ongoing electricity cost typically far exceeds the price of one filter element. This is why the original FPG10 housing includes a restriction indicator port: replacement timing is determined by actual resistance, not by calendar estimates.
Dimensions and Installation
| Parameter | Value / Note |
|---|---|
| Dimensions | 208 mm OD x 106 mm ID x 409 mm length |
| Configuration | 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 radial seal, no separate gasket |
| Companion Element | Safety element, mounted inside the primary element as backup protection |
Procurement note: When cross-checking replacements, verify all three dimensions: 208 mm OD, 106 mm ID, and 409 mm length. The FPG design uses a radial seal; push the element in until the end cap contacts the outlet tube. Do not add a gasket—it will break the radial seal fit.
Materials
| Parameter | Value / Note |
|---|---|
| Filter Media | Cellulose, per FPG10 specification |
| Media Weight | Approx. 130 g/m² |
| Inner/Outer Support | Galvanized steel perforated support (inner cage + outer guard) |
| End Caps | One-piece molded polyurethane (PU), encapsulating media ends and sealing surface |
| Seal | RadialSeal formed by the polyurethane end cap body; no separate O-ring or gasket |
| Bonding | Molded integrally with end cap; no additional adhesive layer |
Conventional axial elements consist of a metal end cap, glued gasket, and separate seal ring. Any one of these aging can cause bypass. FPG encapsulates the end cap, sealing surface, and media ends in a single polyurethane body, reducing part count and improving seal reliability—the basis for tool-free installation.
Operating Conditions
| Parameter | Value / Note |
|---|---|
| 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 collapsing (RadialSeal layered support) |
| Special Functions | Two-stage filtration (integrated tangential pre-cleaner) + Vacuator automatic dust valve |
| Housing | FPG housing is injection-molded plastic, corrosion-resistant, vibration-resistant |
Service Life and Maintenance
| Parameter | Value / Note |
|---|---|
| Service Life | 2000 hours or 3 months, whichever comes first |
| High-Dust Environments | Follow restriction indicator reading; schedule replacement when resistance enters yellow zone |
| Shelf Life | Approx. 2–3 years (unopened, dry, ventilated storage) |
Standards
| Item | Content |
|---|---|
| Product Standard | ISO 5011 (inlet air filters for internal combustion engines and compressors—performance testing); efficiency figures measured per this standard |
| Configuration 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 above ISO 29xx / 37xx series are general test methods for hydraulic fluid power filter elements. If a supplier can only provide hydraulic filter standards, request ISO 5011 or the original specification sheet. |
Installation and Maintenance Steps
FPG design enables tool-free maintenance; a single service takes about 15 minutes.
Shut down, verify 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 filter 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-original part was previously installed; clean it off completely.
Inspect the Vacuator dust valve. Check the rubber duckbill valve at the bottom 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 dust valve disables the pre-cleaner stage, transferring the full dust load to the main element and sharply reducing service life.
Check the pre-cleaner stage and housing for dust traces. Look for dust bypass tracks inside the housing and abnormal accumulation in the pre-cleaner swirl zone. Criterion: no dust tracks on inner walls; if tracks are 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 seats fully against the outlet tube; no gasket is needed or permitted.
Reinstall the service cover and check the restriction indicator. Refit the cover and secure latches. Confirm the intake restriction indicator is in the green zone; if resettable, press reset and verify it returns properly. Criterion: green zone reading, indicator operates normally.
Start up and record. Start the unit, run to operating temperature, and read intake restriction. Criterion: resistance within new-element baseline range; record date, running hours, and resistance reading.
Installation rule: Do not start the unit before the element is fully 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 main element—equivalent to running with no filter.
FAQ
What specification is 49164395?
A two-stage RadialSeal primary element built to Donaldson FPG10 specification. The integrated tangential pre-cleaner removes up to 85% of coarse dust first; the main element handles fine filtration.
Is it interchangeable with 49101637?
No. 49101637 is FPG09; dimensions and rated airflow differ from FPG10. To confirm: read the specification marking on the end cap of the currently installed element. If it reads FPG10, order this part; if FPG09, 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, 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 bottom of the housing and is discharged automatically through the Vacuator valve. If the valve becomes blocked, the pre-cleaner stage fails completely and all dust loads the main element. Check it at every element change—this is the key maintenance action for the FPG design.
How often should it be replaced?
Recommended interval is 2000 hours or 3 months, whichever comes first. More accurately, follow the intake restriction indicator: schedule replacement when resistance 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 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 changing the filter.
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 and breaks the seal fit, causing bypass.
The restriction indicator never moves—is that normal?
No. A stuck indicator is a common failure point and can show a "clean" reading when the element is actually blocked. Press and check it returns properly at every service; if it has failed, replace the element on a conservative time interval until the indicator is repaired.
How does the FPG plastic housing compare with metal housings?
The FPG injection-molded housing is corrosion-resistant, lightweight, and vibration-resistant. It does not rust in coastal salt-spray or humid environments. The tool-free 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 currently installed element and confirm it is FPG10. (2) Measure the old element's OD and length to verify 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 FPG specifications.
Compatible Equipment
This element is supplied to 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 used by multiple OEMs as a standard intake filtration unit. Identification points:
| Item | Specification |
|---|---|
| Filter Assembly | Donaldson FPG10 (element interchangeable with FRG10 series) |
| Rated Airflow | ≤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 end cap of the currently installed element. FPG10 means this part fits; FPG09 means order 49101637.
- Alternative: Measure the old element's OD and length to verify 208 mm x 409 mm.
- Fallback: Provide the model marking on the filter housing or a photo of the unit nameplate; we will cross-check against FPG specifications.
Note on model coverage: Donaldson FPG10 is a general-purpose filter assembly used by several OEMs, so its fitment is not limited to one specific model list. The deciding factor is whether the filter assembly is FPG10, not the unit model itself. If the unit nameplate does not state the filter specification, confirm using any of the three steps above.
Related Components
The FPG10 air filter is a complete system. Beyond the primary element, seven components are maintained together with this part. Listed by component—function—inspection point:
| Component | Function | Inspection Point |
|---|---|---|
| Safety Element | Backup element inside the primary; protects downstream if the primary is damaged or during change intervals | Generally replaced on the same interval or every other interval; check media for damage |
| Vacuator Dust Valve | Automatic dust discharge port of the pre-cleaner stage, expels centrifugally separated coarse dust | Check at every element change: valve must open/close freely, no caked dust, no obstruction |
| Restriction Indicator | Indicates element blockage; authoritative basis for replacement timing | Check needle returns properly; 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 leaks after securing |
| FPG Housing Assembly | Injection-molded plastic housing with tangential inlet and pre-cleaner swirl zone | Check inner walls for dust bypass tracks; check plastic for cracks |
| Intake Hose and Clamps | Connects filter housing to machine intake | Check for cracks, aging, looseness; bypass leakage is as harmful as no filter |
| Other Primary Element in Series | FPG09; part number 49101637 | Different dimensions and airflow, not interchangeable; distinguish when stocking |
Companion replacement advice: The maintenance value of the FPG10 system centers on whether the pre-cleaner stage is working properly. When changing the primary element, inspect the Vacuator valve and restriction indicator at the same time. If either fails, primary element life is significantly shortened. Their cost is far lower than the primary element, yet they determine how long it lasts.