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 (ISO 5011), 85% pre-cleaner dust removal, 2000-hour or 3-month service interval. Export-ready for screw compressor OEM and aftermarket programs.
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Product Overview
49164395 is the intake air filter element used on Ingersoll Rand rotary screw air compressors, manufactured to the Donaldson FPG10 specification.
Its construction differs from a conventional single-stage element, and that difference is worth stating first: FPG10 is a two-stage intake filtration system. Air enters through an integrated tangential pre-cleaner, where the tangential inlet spins the airflow at high velocity and centrifugal force drives coarse particles against the housing wall. Roughly 85% of coarse dust is separated before reaching the primary element and is discharged automatically through the Vacuator dust valve at the base of the housing. Pre-cleaned air then passes to the primary element, where cellulose filter media performs fine filtration. The benefit is most visible in dusty sites: the primary element carries only the fine-particle load, so service life stays long even in high-dust environments.
Sealing also differs from traditional elements. FPG uses Donaldson's RadialSeal technology: a one-piece molded polyurethane end cap seals radially against the housing outlet tube, eliminating the glued gasket used on older axial elements. Fewer parts means fewer failure points — gasket aging, detachment, and misalignment during installation do not exist in the FPG design, and no tools are required for removal or installation.
Core Specifications at a Glance
| Item | Value |
|---|---|
| Part Number | 49164395 |
| Product Name | Air Filter Element |
| Brand | Ingersoll Rand |
| Specification Source | Donaldson FPG10 (two-stage RadialSeal construction) |
| Role in Assembly | Primary Element |
| Dimensions | 208 mm OD x 106 mm ID x 409 mm length |
| Sealing Type | 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% coarse dust removal |
| Rated Intake Airflow | ≤346 cfm / 9.8 m³/min |
| Recommended Service Interval | 2000 hours or 3 months |
Basic Parameters
| Parameter | Detail |
|---|---|
| Part Number | 49164395 |
| Brand | Ingersoll Rand |
| Product Name | Air Filter Element |
| Product Category | Intake filtration (air filter), two-stage RadialSeal construction |
| Specification System | Donaldson FPG10 |
| Application | Ingersoll Rand rotary screw compressors fitted with Donaldson FPG10 air cleaner housings |
| Installation Position | Inside FPG10 air cleaner housing, as primary element |
| Quantity per Machine | 1 piece |
| Service Interval | 2000 hours or 3 months |
Fitment confirmation: This element is supplied to the Donaldson FPG10 specification. To confirm, read the specification marking or part number on the end cap of the element currently installed — if it reads FPG10, this element applies; if it reads FPG09, order 49101637 (different dimensions and airflow rating). The two specifications in this series are not interchangeable.
Technical Specifications
1. Filtration Performance
| Parameter | Value / Notes |
|---|---|
| Filtration Rating | 5 μm class (primary element) |
| Filtration Efficiency | 99.9% (tested to ISO 5011) |
| Pre-Cleaner Efficiency | Up to 85% coarse dust removal (tangential pre-cleaner stage) |
| Filter Class | Two-stage construction: first-stage centrifugal pre-cleaner plus second-stage cellulose primary element; HVAC filter classification (EN 779) does not apply |
| Dust Holding Capacity | Approx. 1200 g |
Practical difference of the two-stage design: A single-stage element forces the filter media to handle both coarse and fine particles, so coarse dust builds quickly on the media surface and restriction rises fast, shortening service life. FPG10 shifts the coarse-dust burden to the centrifugal pre-cleaner stage, materially improving the load profile of the primary element — a key reason it is widely used on construction machinery, generator sets, and other dusty-duty equipment.
2. Flow and Restriction Parameters
| Parameter | Value / Notes |
|---|---|
| Rated Airflow | ≤346 cfm / 9.8 m³/min (air cleaner assembly rated intake airflow) |
| Filtration Face Velocity | Approx. 0.038 m/s |
| Initial Pressure Drop | Approx. 0.5–1.0 kPa (approx. 50–100 mmH&sub2;O) |
| Operating Differential Range | From new-element initial restriction to clogging alarm value |
| Alarm / Final Restriction | Per the machine intake restriction indicator yellow/red zone |
| Restriction vs. Energy | Each 1 kPa increase in intake restriction raises machine energy consumption by roughly 1% |
Restriction and energy relationship
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 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 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 clogged (0 to 6 kPa), machine energy consumption climbs by roughly 6% along the way. That ongoing electricity cost typically far exceeds the price of an element — which is why the original FPG10 air cleaner body includes a restriction indicator port: change timing should be driven by actual restriction, not by a calendar estimate.
3. Dimensions and Installation Parameters
| 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 Type | RadialSeal — one-piece molded polyurethane end cap forms the radial seal directly, 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 uses a radial seal; during installation the element must be pushed in until the end cap contacts the outlet tube, with no additional gasket. Do not attempt to add a gasket — it will disrupt the radial seal fit.
4. Material Composition
| Parameter | Value / Notes |
|---|---|
| Filter Media | Cellulose filter paper, to FPG10 specification |
| Media Basis Weight | Approx. 130 g/m² |
| Inner/Outer Support | Galvanized steel perforated support (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 body itself; no separate seal ring or gasket |
| Bonding Layer | Molded integrally with the end cap; no additional adhesive layer |
Construction note: A traditional axial element consists of three parts — metal end cap, glued gasket, and separate seal ring — and aging at 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. This is also what makes tool-free service possible.
5. Operating Condition Tolerance
| Parameter | Value / Notes |
|---|---|
| Operating Temperature | Continuous 83 °C |
| Relative Humidity | ≤80% RH, non-condensing |
| 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 construction provides layered support) |
| Special Feature | Two-stage filtration (integrated tangential pre-cleaner) plus Vacuator automatic dust valve |
| Housing Characteristic | FPG housing is molded plastic: corrosion-resistant and vibration-resistant |
6. Service Life and Maintenance Parameters
| Parameter | Value / Notes |
|---|---|
| Service Life | 2000 hours or 3 months, whichever comes first |
| High-Dust Environment | Follow the intake restriction indicator; schedule replacement once restriction enters the yellow zone |
| Storage Shelf Life | Approx. 2–3 years (unopened, dry, ventilated conditions) |
7. 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 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 in fact general test methods for hydraulic fluid power filter elements. If a supplier can only provide hydraulic element standards, request ISO 5011 data or the original specification sheet. |
Standard Maintenance and Installation Steps
A key characteristic of the FPG design is tool-free maintenance; a single service takes about 15 minutes.
Shut down, confirm zero pressure, lock out/tag out
Stop the machine, disconnect 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 unbroken, cover not deformed.Remove the old element
Grip the polyurethane end cap and pull straight out. Criterion: note that a RadialSeal element has no gasket to peel off — if you find a gasket residue on the housing outlet tube, a non-original part was previously fitted and must be cleaned off.Inspect the Vacuator dust valve
Check the Vacuator valve (rubber duckbill valve) at the base of the housing. Criterion: valve lips open and close freely, no caked dust, no foreign-object obstruction. This is the most frequently skipped step in FPG maintenance and the most consequential — a blocked dust valve disables the pre-cleaner stage, shifting the full dust load onto the primary element and sharply shortening its life.Inspect the pre-cleaner stage and dust traces inside the housing
Look for dust bypass tracks inside the housing and unusual buildup in the pre-cleaner swirl zone. Criterion: no dust track bands 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 tighten the latches. Confirm the intake restriction indicator is in the green zone; if the indicator is resettable, press to reset and confirm it returns properly. Criterion: green-zone reading, indicator functioning normally.Start up and record
Start the machine and read intake restriction after reaching operating temperature. Criterion: restriction within the new-element baseline range; record date, running hours, and restriction reading.
Installation rule: Do not start the machine 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 stage and the primary 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 manufactured to the Donaldson FPG10 specification. The integrated tangential pre-cleaner removes roughly 85% of coarse dust first, and the primary 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 installed element — 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 body 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 base of the housing and discharges automatically through the Vacuator valve. Once the valve is blocked, the pre-cleaner stage is fully ineffective and all dust loads the primary element directly. Check it at every element change — it 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 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, single-use 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 through, 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 itself; 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 can give a “clean” reading even when the element is actually clogged. Press-check it at every service to confirm it returns properly; if it has failed, replace elements on a conservative time-based interval until it is repaired.
How does the FPG plastic housing compare with metal housings?
The FPG molded housing is corrosion-resistant, lightweight, and vibration-resistant; it will not rust in coastal salt-spray or humid environments. Combined with tool-free service, 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 end cap and confirm it is FPG10; (2) measure the old element's outer diameter 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.
Machine Compatibility
This element is supplied to the Donaldson FPG10 specification and applies to Ingersoll Rand rotary screw air compressors fitted with an FPG10 air cleaner.
FPG10 is a Donaldson finished air cleaner assembly specification, adopted by OEMs as a standard intake filtration unit. The determining points are as follows:
| Checkpoint | Specification |
|---|---|
| Air Cleaner Specification | Donaldson FPG10 (element 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 fitment
- Preferred: read the specification marking on the installed element end cap. FPG10 means this element applies; FPG09 means order 49101637.
- Alternative: measure the old element'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.
Note on model coverage
The Donaldson FPG10 is a universal air cleaner adopted by multiple OEMs, so the fitment scope of this element is not strictly equivalent to a specific machine model list. The deciding factor should be the fact that 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 of the three methods above.
Related Components
The FPG10 air cleaner is a complete system; beyond 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 element; protects downstream if the primary element 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; ejects centrifugally separated coarse dust from the housing | Check at every element change: valve lips must open and close freely, no caked dust, no obstruction |
| Restriction indicator | Indicates element clogging level; the authoritative basis for change timing | Check that the pointer resets properly; connection line must be clear |
| Service cover and latches | Tool-free opening and closing structure of the FPG housing | Check latches for breakage and cover for deformation; no air leakage when locked |
| FPG housing assembly | 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 air cleaner to machine intake duct | Check for cracks, aging, looseness — bypass leakage is as harmful as running with no element |
| Other primary element in series | FPG09 — part number 49101637 | Different dimensions and airflow from FPG10, not interchangeable; keep separate in stock |
Companion replacement advice: maintenance value in 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 primary element life — they cost far less than the primary element but determine how long it lasts.