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. Unlike conventional single-stage elements, the FPG10 is a two-stage intake filtration system: air first passes through an integrated tangential pre-cleaner, where high-speed rotation throws coarse particles against the housing wall. Approximately 85% of coarse dust is separated before reaching the primary element and discharged automatically through the Vacuator dust valve at the housing base. Pre-cleaned air then enters the primary element, where cellulose filter media performs fine filtration. This architecture is most valuable in dusty environments: the primary element carries only fine-particle load, extending service life under high-dust conditions.

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

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
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 Replacement	2,000 hours or 3 months

Technical Specifications

Filtration Performance

Parameter	Value / Notes
Filtration Rating	5 µm class (primary element)
Filtration Efficiency	99.9% (per ISO 5011)
Pre-Cleaner Efficiency	Up to 85% coarse dust removal (tangential stage)
Filter Class	Two-stage: centrifugal pre-cleaner + cellulose primary element; not classified under EN 779 HVAC standards
Dust Holding Capacity	Approx. 1,200 g

Practical difference of two-stage design: A single-stage element forces the filter media to handle both coarse and fine particles, causing rapid surface loading, faster pressure rise, and shorter life. By transferring coarse dust load to the centrifugal pre-cleaner, the FPG10 significantly improves the primary element's loading profile — a key reason it is widely adopted on construction machinery and generator sets in dusty conditions.

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 (approx. 50–100 mmH&sub2;O)
Operating Differential Range	From new-element initial resistance to clogging alarm value
Alarm / Final Resistance	Per unit intake 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, forcing the unit to work harder to maintain set discharge pressure and flow, increasing specific power. Based on 0.7 MPa discharge pressure and 101.3 kPa atmospheric pressure, theoretical compression ratio calculations show:

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 an element goes from new to severely clogged (0 to 6 kPa), unit energy consumption rises by approximately 6%. This ongoing electricity cost typically far exceeds the price of an element — which is why the original FPG10 housing includes a restriction indicator port, allowing replacement timing to be based on actual resistance rather than 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 pleats
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 element) as backup protection

Procurement note: When cross-referencing replacements, verify all three dimensions: 208 mm OD, 106 mm ID, 409 mm length. FPG design uses radial sealing; push in until the end cap contacts the outlet tube. Do not attempt to add a gasket — it will compromise the radial seal fit.

Materials of Construction

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

Design note: Traditional axial elements consist of metal end cap + glued gasket + separate seal ring — any one aging can cause bypass. FPG encapsulates end cap, sealing surface, and media ends in a single polyurethane body, reducing part count and improving seal reliability, which also enables tool-free installation and removal.

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	FPG housing is injection-molded plastic, corrosion-resistant and 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; replace when indicator enters yellow zone
Shelf Life	Approx. 2–3 years (unopened, dry, ventilated storage)

Applicable Standards

Item	Details
Product Standard	ISO 5011 (intake air filter performance testing for engines and compressors); efficiency figures measured per this standard
Configuration Standard	Donaldson FPG / FRG series filter specifications (RadialSeal sealing system)
Commonly Referenced Test Standards	ISO 2941 / 2942 / 2943 / 3723 / 3724 / 3968
Applicability Note	The ISO 29xx / 37xx series are general test methods for hydraulic filter elements. If a supplier can only provide hydraulic filter standards, request ISO 5011 or original specification documentation.

Standard Maintenance and Installation

The FPG design enables 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 clips 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 RadialSeal has no gasket to peel — if a residual gasket is found on the housing outlet tube, a non-original part was previously installed and must be cleaned off.

4. Inspect the Vacuator dust valve
   Check the Vacuator valve (rubber duckbill) at the housing base. Criterion: valve opens and closes freely, no dust caking, no obstruction. This is the most commonly skipped step in FPG maintenance and the most costly: a blocked valve disables the pre-cleaner, transferring all dust load to the primary element and drastically shortening its life.

5. Inspect pre-cleaner 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.

6. Install the 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 cover and check restriction indicator
   Replace the service cover and secure latches. Confirm the intake restriction indicator is in the green zone; if resettable, press to reset and verify it returns properly. Criterion: green zone reading, indicator functions normally.

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

Installation rule: Do not start the unit before the element is seated. If the RadialSeal is not fully pushed in, air will bypass directly through the gap between end cap and outlet tube, rendering both the pre-cleaner and primary element ineffective — equivalent to running without a filter.

Frequently Asked Questions

What specification is 49164395?
A two-stage RadialSeal primary element manufactured to Donaldson FPG10 specifications. The integrated tangential pre-cleaner removes approximately 85% of coarse dust first, with the primary element handling fine filtration.

Is it interchangeable with 49101637?
No. 49101637 is FPG09, with different dimensions and rated airflow. Verification is simple: 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. The polyurethane end cap body forms the seal directly 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 action falls to the housing base by gravity and is discharged automatically through the Vacuator valve. Once the valve is blocked, the pre-cleaner becomes completely ineffective, and all dust loads the primary element directly. Inspect it at every element change — this is the critical maintenance step for FPG systems.

How often should it be replaced?
Recommended interval is 2,000 hours or 3 months, whichever comes first. A more accurate method is to monitor the intake restriction indicator: schedule replacement when it 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 that cannot be washed or reverse-blown with compressed air — reverse blowing damages the filter 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 body to form the seal; adding a gasket pushes the element away from the outlet tube and actually compromises the seal, causing bypass.

The restriction indicator never moves. Is that normal?
No. A stuck indicator is a common failure point, giving 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 the element on a conservative time 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, with no rusting in coastal salt-spray or humid environments. The tool-free design also speeds up field maintenance. 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'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 per FPG specifications.

Compatible Equipment

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

FPG10 is a Donaldson finished filter assembly specification, adopted by OEMs as a standard intake filtration unit. Key identification points:

Identification Item	Specification
Filter Housing Specification	Donaldson FPG10 (element interchangeable with FRG10 series)
Filter Housing Rated Airflow	≤346 cfm / 9.8 m³/min
Role in Assembly	Primary Element
Other Specifications 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. If marked FPG10, this part applies; if FPG09, 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 per FPG specifications.

Note on model coverage: Donaldson FPG10 is a universal filter housing adopted by multiple OEMs, so this part's compatibility is not strictly equivalent to a specific machine model list. The determining factor should be whether the filter housing specification is FPG10, not the machine model itself. If the unit nameplate does not indicate the filter housing specification, use any of the three methods above to confirm.

Related Components

The FPG10 filter housing is a complete system with 7 additional components serviced alongside the primary element. Listed below by component — function — inspection point:

Component	Function	Inspection Point
Safety Element	Backup element inside the primary element, protecting downstream during primary element damage or changeover	Typically replaced on the same interval or every other interval; inspect media for damage
Vacuator Dust Valve	Pre-cleaner automatic dust discharge, expelling centrifugally separated coarse dust from the housing	Inspect at every element change: valve must open and close freely, no dust caking, no obstruction
Restriction Indicator	Indicates element clogging level; authoritative basis for replacement timing	Check that the needle returns properly; connecting line must be clear
Service Cover and Latches	Tool-free opening structure of the FPG housing	Check latches for breakage, cover for deformation; no air leakage after securing
FPG Housing Assembly	Injection-molded plastic housing with tangential inlet and pre-cleaner swirl zone	Inspect inner walls for dust bypass tracks; check plastic for cracks
Intake Hose and Clamps	Connects filter housing to main intake duct	Check for cracks, aging, looseness — bypass leakage is as harmful as no element
Other Series Primary Elements	FPG09 — part number 49101637	Different dimensions and airflow, not interchangeable; distinguish when stocking

Companion replacement recommendation: The maintenance value of the FPG10 system centers on whether the pre-cleaner 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 will be significantly shortened — their cost is far lower than the primary element, yet they determine how long it lasts.