Ingersoll Rand 49164395 Air Filter Element | Donaldson FPG10 RadialSeal

Product Overview

49164395 is the intake air filter element used on Ingersoll Rand screw air compressors, manufactured to Donaldson FPG10 specifications. It is the primary element in a two-stage RadialSeal filtration system.

Unlike conventional single-stage filters, the FPG10 system uses a built-in tangential pre-cleaner. Incoming air rotates at high speed, and centrifugal force throws coarse particles against the housing wall. Approximately 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 passes through the cellulose main element for fine filtration. This two-stage design keeps the main element focused on fine particles, extending service life in high-dust environments.

Sealing also differs from traditional 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 found on older axial elements. Fewer parts mean fewer failure points — gasket aging, detachment, and installation misalignment are eliminated, and no tools are required for replacement.

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
Seal Type	RadialSeal (polyurethane end cap, no gasket)
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 Change Interval	2,000 hours or 3 months

Technical Specifications

Filtration Performance

Parameter	Value / Notes
Filtration Rating	5 μm (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; not classified under EN 779 HVAC standards
Dust Holding Capacity	Approx. 1,200 g

Practical difference of two-stage design: A single-stage filter forces the media to handle both coarse and fine particles. Coarse dust builds up rapidly on the surface, causing fast pressure rise and short life. By transferring the coarse load to the centrifugal pre-cleaner, the FPG10 significantly improves the main element's loading profile — a key reason it is widely used in construction machinery, generator sets, and other dusty applications.

Flow and Pressure Drop

Parameter	Value / Notes
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 (50–100 mmH&sub2;O)
Operating Differential Range	From new element initial resistance to clogging alarm value
Alarm / Final Resistance	Per unit's restriction indicator (yellow/red zone)
Pressure Drop vs. Energy	Each 1 kPa increase in intake resistance raises unit energy consumption by approx. 1%

Pressure drop and energy relationship: Rising intake resistance lowers intake pressure and density. The unit must work harder to maintain discharge pressure and flow, increasing specific power. Based on 0.7 MPa discharge pressure and 101.3 kPa atmospheric pressure (theoretical compression ratio):

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%

Engineering implication: As the element goes from new to severely clogged (0 → 6 kPa), unit energy consumption gradually rises by about 6%. This ongoing electricity cost typically far exceeds the price of a filter element — which is why the OEM provides a restriction indicator port on the FPG10 housing: replacement timing should be based on actual resistance, not calendar estimates.

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
Pleat Spacing	Approx. 4.8 mm
Mounting Interface	Radial push-in; end cap seals against housing outlet tube
Seal Type	RadialSeal — one-piece molded polyurethane end cap forms radial seal, no separate gasket
Companion Element	Safety element (inner backup filter)

Procurement note: When cross-referencing 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 disrupt the radial seal fit.

Materials

Parameter	Value / Notes
Media	Cellulose filter paper, FPG10 specification
Media Weight	Approx. 130 g/m²
Inner/Outer Support	Galvanized steel perforated cage (inner + outer mesh)
End Cap	One-piece molded polyurethane (PU) end cap, encapsulating media ends and sealing surface
Sealing Element	RadialSeal formed by PU end cap; no separate O-ring or gasket
Bonding	Molded integrally with end cap; no additional adhesive layer

Design note: Traditional axial elements use three components: metal end cap + glued gasket + separate seal ring. Failure of any one causes bypass. FPG encapsulates the end cap, sealing surface, and media ends in a single polyurethane body, reducing part count and improving seal reliability — which also enables tool-free replacement.

Operating Conditions

Parameter	Value / Notes
Operating Temperature	Continuous 83°C
Relative Humidity	≤80% RH, non-condensing
Burst Strength	Media burst approx. 200–400 kPa (per ISO 2758 paper burst test)
Collapse Resistance	Element withstands intake alarm differential without collapse (RadialSeal layered support)
Special Features	Two-stage filtration (integrated tangential pre-cleaner) + Vacuator automatic dust valve
Housing Characteristics	FPG housing is injection-molded plastic; corrosion-resistant, vibration-resistant

Service Life and Maintenance

Parameter	Value / Notes
Service Life	2,000 hours or 3 months, whichever comes first
High-Dust Environments	Follow restriction indicator readings; schedule replacement when in yellow zone
Shelf Life	Approx. 2–3 years (unopened, dry, ventilated conditions)

Standards

Item	Details
Product Standard	ISO 5011 (Intake air filters for internal combustion engines and compressors — performance testing); efficiency figures measured to this standard
Design Standard	Donaldson FPG / FRG series filter specifications (RadialSeal sealing system)
Commonly Cited Test Standards	ISO 2941 / 2942 / 2943 / 3723 / 3724 / 3968
Standard Applicability Note	The above ISO 29xx / 37xx series are actually hydraulic filter element test methods. If a supplier can only provide hydraulic filter standards, request ISO 5011 or OEM specification sheets.

Standard Maintenance and Installation Steps

A key feature of the FPG design is tool-free maintenance, with each service taking approximately 15 minutes.

1. Shut down, confirm zero pressure, lockout/tagout
   Stop the unit, disconnect main power, and apply lockout/tagout. Criterion: controller shows system pressure at 0.

2. 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 intact, cover undeformed.

3. Remove 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-OEM part was previously installed and must be cleaned off.

4. Inspect the Vacuator dust valve
   Check the Vacuator valve (rubber duckbill) at the housing bottom. Criterion: valve opens and closes freely, no caked dust, no obstruction. This is the most commonly skipped step in FPG maintenance and has the most serious consequences — a blocked dust valve disables the pre-cleaner, transferring the full dust load to the main element and sharply reducing its life.

5. Inspect pre-cleaner stage and internal 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 present, inspect seal mating surfaces.

6. Install new element
   Push 49164395 into the housing until the polyurethane end cap contacts the outlet tube. Criterion: end cap seats fully against outlet tube; no gasket is needed or permitted.

7. Reinstall service cover and check restriction indicator
   Replace 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 functions correctly.

8. Start up and record
   Start the unit, run to operating temperature, and read intake restriction. Criterion: restriction within new-element baseline range; record date, running hours, and restriction reading.

Installation rule: Do not start the unit before the element is fully seated. If the RadialSeal is not pushed fully into position, air bypasses directly through the gap between end cap and outlet tube, rendering both the pre-cleaner and main element ineffective — equivalent to running with no filter at all.

Frequently Asked Questions

What specification is 49164395?
A two-stage RadialSeal primary element built to Donaldson FPG10 specifications. The integrated tangential pre-cleaner removes up to 85% of coarse dust before the main element handles fine filtration.

Is it interchangeable with 49101637?
No. 49101637 is FPG09, with different dimensions and rated airflow. To confirm: read the specification marking on the installed element's end cap — if marked FPG10, order this part; if marked FPG09, order 49101637.

Why does this element have no gasket?
Because it uses RadialSeal radial sealing. The polyurethane end cap itself forms the seal against the housing outlet tube, eliminating the need for a 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 pre-cleaner dust discharge port. Coarse dust separated by centrifugal force in the pre-cleaner stage falls by gravity to the housing bottom and is automatically discharged through the Vacuator valve. If the valve becomes blocked, the pre-cleaner stage fails completely, and all dust is forced onto the main element. Inspect 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. A more accurate method is to monitor the restriction indicator: schedule replacement when resistance enters the yellow zone. In high-dust environments, replace earlier based on indicator readings.

Can the element be blown clean and reused?
No. This is a dry, disposable element. It cannot be washed or reverse-blown with compressed air — reverse blowing damages the media fiber structure and creates invisible channels that allow unfiltered air to pass, which is more dangerous than not replacing it.

Can I add a gasket to improve sealing?
No, and it is unnecessary. RadialSeal relies on radial compression of the end cap itself. Adding a gasket pushes the element away from the outlet tube, disrupting the seal fit and causing bypass.

The restriction indicator never moves — is that normal?
No. A stuck indicator is a common failure point that can give a "clean" reading even when the element is actually clogged. Check at every service by pressing to verify it returns properly; if it has failed, replace the element on a conservative time-based schedule until the indicator is repaired.

What are the pros and cons of FPG's plastic housing versus metal?
The FPG injection-molded housing is corrosion-resistant, lightweight, and vibration-resistant. It does not rust in coastal salt-spray or humid environments, and the tool-free design speeds up field maintenance. This is why the FPG series is widely used in 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 to confirm FPG10; 2) Measure the old part's OD and length to verify 208 mm and 409 mm; 3) If the old part is discarded, provide the model marking on the filter housing, and we will cross-reference by FPG specification.

Compatible Equipment

This part is supplied to Donaldson FPG10 specifications and is suitable for Ingersoll Rand screw air compressors equipped with FPG10 filter housings.

FPG10 is a Donaldson complete filter assembly specification used by OEMs as a standard intake filtration unit. Key identification points:

Item	Specification
Filter Assembly Spec	Donaldson FPG10 (elements interchangeable with FRG10 series)
Filter Assembly Rated Airflow	≤346 cfm / 9.8 m³/min
Role in Assembly	Primary Element
Other Specs in Series	FPG09 — part number 49101637, different dimensions and airflow, not interchangeable
Sealing System	RadialSeal (polyurethane end cap radial seal)

How to confirm compatibility

1. Preferred: Read the specification marking on the installed element's end cap. Marked FPG10 means this part fits; marked FPG09 means order 49101637.
2. Alternative: Measure the old part's OD and length to verify 208 mm x 409 mm.
3. Fallback: Provide the model marking on the filter housing or a photo of the unit nameplate, and we will cross-reference by FPG specification.

Note on model coverage

Donaldson FPG10 is a universal filter assembly used by multiple OEMs, so this part's compatibility is not limited to a specific machine model list. The determining factor is whether the filter assembly specification is FPG10, not the machine model itself. If the unit nameplate does not show the filter specification, confirm using any of the three methods above.

Related Components

The FPG10 filter assembly is a complete system. In addition to the primary element, there are 7 components maintained together with this part. Listed by component — function — inspection point:

Component	Function	Inspection Point
Safety Element	Inner backup filter protecting downstream if the primary element is damaged or during change intervals	Typically replaced on the same or alternating schedule as the primary; check media for damage
Vacuator Dust Valve	Pre-cleaner automatic dust discharge port, expelling centrifugally separated coarse dust from the housing	Must check at every element change: valve must open/close freely, no caked dust, no obstruction
Restriction Indicator	Indicates element clogging level; authoritative basis for replacement timing	Check needle returns properly; connecting line must be clear
Service Cover and Latches	Tool-free opening/closing structure of the FPG housing	Check latches for cracks, cover for deformation; no air leaks after locking
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 assembly to engine intake	Check for cracks, aging, looseness — bypass leakage is as harmful as no filter
Other Primary Elements 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 small component fails, the primary element's life will be significantly shortened — their cost is far lower than the primary element, yet they determine how long it lasts.