Ingersoll Rand 49164395 Air Filter Element | Donaldson FPG10 Spec

Product Overview

49164395 is the intake air filter element used on Ingersoll Rand rotary screw air compressors, manufactured to the Donaldson FPG10 specification.

Unlike a conventional single-stage air filter, FPG10 is a two-stage intake filtration system. Air first passes through an integrated tangential pre-cleaner: entering at high velocity, the airstream rotates and centrifugal force drives coarse particles to the housing wall. Up to 85% of coarse dust is separated before it reaches the main element and is discharged automatically through the Vacuator dust valve at the base of the housing. Pre-filtered air then enters the main element, where cellulose filter media performs fine filtration. This architecture pays off most clearly in dusty environments: the main element carries only the fine-particle load, so service life stays long even under heavy dust.

Sealing differs from traditional air filters as well. The FPG design 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. One less component means one less failure point — gasket aging, detachment, and misalignment are no longer possible with the FPG design, 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 design)
Role in Assembly	Primary Element
Dimensions	208 mm OD × 106 mm ID × 409 mm length
Sealing	RadialSeal (polyurethane end cap radial seal, 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	≤346 cfm / 9.8 m³/min
Recommended Service Interval	2,000 hours or 3 months

Technical Parameters

1. Filtration Performance

Parameter	Value / Notes
Filtration Rating	5 μm class (main element)
Filtration Efficiency	99.9% (tested 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 does not apply.
Dust Holding Capacity	Approx. 1,200 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 up quickly on the surface, restriction rises fast, and service life is short. By shifting the coarse-dust burden to the centrifugal pre-cleaner, FPG10 substantially improves the load profile of the main element — one reason the platform is widely adopted on construction machinery and generator sets operating in dusty conditions.

2. Flow and Restriction

Parameter	Value / Notes
Rated Airflow	≤346 cfm / 9.8 m³/min (air cleaner assembly rated intake)
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 restriction to blockage alarm value
Alarm / Final Restriction	Per the unit's intake restriction indicator (yellow / red zone)
Restriction vs. Energy	Each 1 kPa increase in intake restriction raises unit 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 unit must do more work, and specific power rises. Calculated on compression-ratio theory at 0.7 MPa discharge pressure and 101.3 kPa atmospheric pressure:

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: as an element goes from new to heavily loaded (0 → 6 kPa), unit energy consumption rises by roughly 6% along the way. The accumulated electricity cost typically far exceeds the price of one filter element — which is why the FPG10 air cleaner body includes a restriction indicator port: replacement timing is driven by actual restriction, not calendar estimates.

3. 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 Interface	Radial push-in; end cap seals against housing outlet tube
Sealing	RadialSeal — one-piece molded polyurethane end cap forms the radial seal directly, no separate gasket
Companion Element	Safety element installed inboard of the primary element as backup protection

Purchasing 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. Do not add a gasket — doing so will break the radial seal fit.

4. Materials

Parameter	Value / Notes
Filter Media	Cellulose filter paper, to FPG10 specification
Media Basis Weight	Approx. 130 g/m²
Inner / Outer Support	Galvanized steel perforated core (inner core + outer guard)
End Cap	One-piece molded polyurethane (PU) end cap, encapsulating both the media ends and the sealing surface
Sealing Element	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

Construction note: a conventional axial element consists of three parts — metal end cap, glued gasket, and separate seal ring — and aging in 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. That is also what makes tool-free service possible.

5. Operating Tolerance

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 provides layered support)
Special Function	Two-stage filtration (integrated tangential pre-cleaner) + Vacuator automatic dust valve
Housing Characteristics	FPG housing is injection-molded plastic — corrosion-resistant and vibration-tolerant

6. 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 restriction enters the yellow zone
Shelf Life	Approx. 2–3 years (unopened, dry, ventilated storage)

7. Applicable Standards

Item	Details
Product Standard	ISO 5011 (inlet air cleaning equipment for internal combustion engines and compressors — performance testing); efficiency figures are tested to this standard
Construction 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 hydraulic filter element test methods. If a supplier can only provide hydraulic filter standards, request ISO 5011 or the OEM specification sheet as a supplement.

Standard Maintenance and Installation Steps

A key feature of the FPG design is tool-free maintenance; a single service takes about 15 minutes.

1. 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.

2. Open the FPG air cleaner service cover
   Release the cover latches — the FPG design uses two spring latches or a twist-off cover, no tools required. Criterion: latches intact, cover not deformed.

3. 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 outlet tube, a non-genuine part was previously fitted and must be cleaned away.

4. Inspect the Vacuator dust valve
   Check the Vacuator valve (rubber duckbill) at the base 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 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.

5. Inspect 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.

6. 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 and none is permitted.

7. 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 the indicator is resettable, press to reset and confirm it returns normally. Criterion: green-zone reading, indicator functioning.

8. Start up and record
   Start the unit, 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 unit 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 the main element become ineffective, equivalent to running with no filter at all.

FAQ

What specification is 49164395?
A two-stage RadialSeal primary element manufactured to the Donaldson FPG10 specification. The integrated tangential pre-cleaner removes up to 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 airflow from FPG10. Confirmation is simple: read the specification marking on the end cap of the element currently installed — 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 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 rotating airflow in the pre-cleaner falls by gravity to the base of the housing and is discharged automatically through the Vacuator valve. Once the valve is blocked, the pre-cleaner stage fails completely and all dust is forced onto the main element. That is why it must be checked at every element change — a critical step in FPG maintenance.

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 — reverse blowing damages the fiber structure of the media 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 relies on radial compression of the end cap body to seal; adding a gasket pushes 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: it can keep showing a "clean" reading even when the element is actually blocked. Press and check that it returns normally at every service; if it has failed, use a conservative time-based replacement 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-tolerant, and will not rust in coastal salt-spray or humid environments. The tool-free service design also makes field maintenance faster. This is 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 installed element and confirm it reads FPG10; ② measure the old part's outer diameter and length and verify 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-reference against the FPG specification to confirm.

Compatible Equipment

This part is supplied to the Donaldson FPG10 specification and fits Ingersoll Rand rotary 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	≤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

1. Preferred: read the specification marking on the end cap of the installed element. If it reads FPG10, this part applies; if it reads FPG09, order 49101637.
2. Alternative: measure the old part's outer diameter and length and verify 208 mm × 409 mm.
3. Fallback: provide the model marking on the air cleaner housing or a photo of the unit nameplate, and we will cross-reference against the FPG specification to confirm.

Note on model coverage

The Donaldson FPG10 is a universal air cleaner adopted by multiple OEMs, so the fitment range of this part is not strictly equivalent to any single list of machine models. The correct basis for judgment is the fact of whether the air cleaner specification is FPG10, not the machine model itself. If the air cleaner specification is not marked on the unit nameplate, confirm using any 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 together with this part. They are listed below as component — function — inspection point:

Component	Function	Inspection Point
Safety Element	Backup element inboard of the primary element; protects downstream if the primary is damaged or during change intervals	Generally 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	Must be checked at every element change: valve must open and close freely, no caked dust, no obstruction
Restriction Indicator	Indicates element blockage level; the authoritative basis for replacement timing	Check that the needle returns normally; connecting line must be clear
Service Cover and Latches	Tool-free opening and closing structure of the FPG housing	Check latches for cracks and 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 engine intake duct	Check for cracks, aging, and looseness — bypass leakage is as harmful as running with no filter
Other Primary Element in Series	FPG09 — part number 49101637	Different dimensions and airflow from this part, not interchangeable; keep separate in stock

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 — failure of either small part will noticeably shorten the life of the primary element. Both cost far less than the primary element, yet they determine how long it lasts.