Product
Ingersoll Rand 49164395 Air Filter Element | Donaldson FPG10
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. Export-ready, OEM/ODM supply and bulk orders supported.
- Export packaging & documentation support
- OEM / ODM customization available
- Sample and bulk order workflow
Product Overview
49164395 is the intake air filter element used on Ingersoll Rand screw air compressors, manufactured to the Donaldson FPG10 specification.
The FPG10 is a two-stage intake filtration system, not a conventional single-stage element. Incoming air first passes through an integrated tangential pre-cleaner: the airstream enters tangentially at high speed, centrifugal force drives coarse particles to the housing wall, and roughly 85% of coarse dust is separated before it reaches the main element. Separated dust falls to the housing base and discharges automatically through the Vacuator dust valve. Pre-cleaned air then enters the main element, where cellulose filter media performs fine filtration. The benefit is greatest in dusty environments: the main element carries only the fine-particle load and retains a longer service life.
Sealing also differs from older designs. FPG uses Donaldson's RadialSeal technology: a one-piece molded polyurethane end cap forms a radial seal directly against the housing outlet tube, eliminating the glued gasket found on older axial elements. Fewer parts means fewer failure points, and no tools are required for installation or removal.
| 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% of coarse dust removed |
| Rated intake flow | Up to 346 cfm / 9.8 m3/min |
| Recommended replacement | 2,000 hours or 3 months |
Technical Specifications
Filtration Performance
| Parameter | Value |
|---|---|
| Filtration rating (main element) | 5 micron class |
| Filtration efficiency | 99.9% (tested per ISO 5011) |
| Pre-cleaner efficiency | Up to 85% coarse dust removal (tangential stage) |
| Filter class | Two-stage: centrifugal pre-cleaner + cellulose main element; EN 779 HVAC classification does not apply |
| Dust holding capacity | Approx. 1,200 g |
A single-stage element forces the filter media to handle both coarse and fine particles at once, so coarse dust builds up on the surface, restriction rises quickly and service life shortens. By transferring the coarse-dust load to the centrifugal pre-cleaner, the FPG10 improves the loading profile of the main element. This is why the design is widely adopted on construction machinery and generator sets operating in dusty conditions.
Flow and Restriction Data
| Parameter | Value |
|---|---|
| Rated air flow | Up to 346 cfm / 9.8 m3/min (filter assembly rating) |
| Filtration face velocity | Approx. 0.038 m/s |
| Initial pressure drop | Approx. 0.5-1.0 kPa (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 machine energy consumption by approx. 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 increases. Based on a 0.7 MPa discharge pressure and 101.3 kPa atmospheric pressure, theoretical compression-ratio calculation gives:
| 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% |
Practical implication: as an element moves from new to heavily loaded (0 to 6 kPa), machine energy consumption rises by roughly 6% along the way. That ongoing electricity cost typically exceeds the price of a filter element. This is why the FPG10 housing provides a restriction indicator port, so replacement timing can be based on actual restriction rather than a calendar estimate.
Dimensions and Installation
| Parameter | Value |
|---|---|
| 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 installed inside the primary element as backup protection |
Procurement note: when cross-checking a replacement, verify all three dimensions: 208 mm OD, 106 mm ID and 409 mm length. The FPG design seals radially; push the element in until the end cap contacts the outlet tube. Do not add a gasket - it will interfere with the radial seal fit.
Materials
| Parameter | Value |
|---|---|
| Media | Cellulose filter paper to FPG10 specification |
| Media basis weight | Approx. 130 g/m2 |
| Inner / outer support | Galvanized perforated steel (inner cage + outer screen) |
| End cap | One-piece molded polyurethane (PU) end cap, enclosing media ends and 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 |
Construction note: a conventional axial element consists of a metal end cap, a glued gasket and a separate seal - any one of which can age and cause bypass. The FPG design encapsulates the end cap, sealing surface and media ends in a single polyurethane body. Fewer components improve sealing reliability and make tool-free servicing possible.
Operating Conditions
| Parameter | Value |
|---|---|
| Operating temperature | Continuous 83 C |
| Relative humidity | Up to 80% RH, no condensation |
| Burst strength | Media burst approx. 200-400 kPa (per ISO 2758 paper burst test) |
| Collapse resistance | Element withstands intake alarm differential without collapse (layered RadialSeal support) |
| Special function | Two-stage filtration (integrated tangential pre-cleaner) + Vacuator automatic dust valve |
| Housing | FPG housing is molded plastic - corrosion-resistant and vibration-tolerant |
Service Life and Storage
| Parameter | Value |
|---|---|
| Service life | 2,000 hours or 3 months, whichever comes first |
| High-dust environments | Follow the restriction indicator; schedule replacement once restriction enters the yellow zone |
| Storage shelf life | Approx. 2-3 years (unopened, dry, ventilated conditions) |
Applicable Standards
| Item | Detail |
|---|---|
| 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 filter elements. If a supplier can only provide hydraulic element standards, request ISO 5011 data or the OEM specification sheet. |
Installation and Maintenance Procedure
The FPG design is tool-free to service; a single job 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 - the FPG design uses two spring latches or a twist-off cover and requires no tools. 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 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 rubber duckbill valve at the housing base. Criterion: valve opens and closes freely, no caked dust, no obstruction. This is the most commonly skipped step in FPG maintenance and the most damaging - a blocked dust valve disables the pre-cleaner, shifting the entire dust load onto 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 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 seated against the outlet tube; no gasket is needed or permitted.
Refit the service cover and check the restriction indicator. Replace the cover and secure the latches. Confirm the intake restriction indicator reads in the green zone; if resettable, press reset and confirm it returns correctly. Criterion: green-zone reading, indicator functions 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.
Non-negotiable rule: do not start the machine before the element is fully seated. If the RadialSeal is not pushed 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.
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 roughly 85% of coarse dust before the main element handles fine filtration.
Is it interchangeable with 49101637?
No. 49101637 is the FPG09, with different dimensions and rated flow. Confirmation is straightforward: 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 itself seals against the housing outlet tube, so no glued gasket or separate seal is required. Fewer components, 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 housing base and discharges automatically through the Vacuator valve. Once the valve blocks, the pre-cleaner stage fails completely and all dust loads the main element directly. Check it at every element change - it is the key 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. A more accurate approach is to follow the intake restriction indicator: schedule replacement once restriction 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 - back-blowing damages the media fibre structure and creates invisible channels that let unfiltered air pass, which is more dangerous than not changing the element.
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 away from 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. Check at every service that it returns correctly when pressed; if it has failed, replace the element on a conservative time-based interval until the indicator is repaired.
How does the FPG plastic housing compare with metal housings?
The FPG molded housing resists corrosion, is lightweight and tolerates vibration; it will not rust in coastal salt-spray or humid conditions. The tool-free design also speeds up on-site servicing. 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 element's outside diameter 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 element is supplied to the Donaldson FPG10 specification and fits Ingersoll Rand screw air compressors equipped with an FPG10 air filter housing.
FPG10 is a Donaldson finished filter assembly specification used by OEMs as a standard intake filtration unit. Verification points:
| Check item | Specification |
|---|---|
| Filter housing specification | Donaldson FPG10 (element interchangeable with the FRG10 series) |
| Housing rated intake flow | Up to 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 outside diameter 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
The Donaldson FPG10 is a universal filter assembly adopted by several OEMs, so fitment for this element is not defined by any single machine model list. The deciding factor is whether the filter housing 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 assembly is a complete system. Besides the primary element, seven service components are relevant. Listed by part - function - inspection point:
| Component | Function | Inspection point |
|---|---|---|
| Safety element | Backup element fitted inside the primary element; protects 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 discharge point for the pre-cleaner stage, expelling centrifugally separated coarse dust | Check 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 replacement timing | Check the needle returns correctly; ensure the connecting line is clear |
| Service cover and latches | Tool-free opening and closing of the FPG housing | Check latches for cracks and cover for deformation; no air leaks when secured |
| FPG housing assembly | 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 the filter housing to the machine intake duct | Check for cracks, ageing and looseness - bypass leakage is as harmful as no element |
| Other primary element in series | FPG09 - part number 49101637 | Different dimensions and flow, not interchangeable; keep stock separated |
Recommended companion replacement: 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, the primary element's service life drops noticeably - they cost far less than the primary element but determine how long it lasts.