Ingersoll Rand 49164395 Air Filter | Donaldson FPG10 RadialSeal

Product Overview

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

Unlike conventional single-stage filters, the FPG10 uses a built-in tangential pre-cleaner. Incoming air spins at high speed, and centrifugal force drives coarse particles to the housing wall — approximately 85% of coarse dust is separated before reaching the main element and discharged automatically through the Vacuator dust valve at the housing base. The pre-cleaned air then passes through the cellulose media main element for fine filtration. This two-stage design is most valuable in dusty environments: the main element carries only fine-particle load and maintains a longer service life.

Sealing is also different. 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 of older axial elements. Fewer parts means 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	OD 208 mm × ID 106 mm × Length 409 mm
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	2000 hours or 3 months

Technical Parameters

Filtration Performance

Parameter	Value / Note
Filtration Rating	5 μm (main 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 main element; not classified under EN 779 HVAC standards
Dust Holding Capacity	Approx. 1200 g

Practical difference of the two-stage design: A single-stage filter forces the media to handle both coarse and fine particles, causing rapid surface loading, fast pressure rise, and short life. By shifting 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 on construction machinery and generator sets in dusty conditions.

Flow and Pressure Drop

Parameter	Value / Note
Rated Airflow	≤346 cfm / 9.8 m³/min (filter assembly rating)
Media Face Velocity	Approx. 0.038 m/s
Initial Pressure Drop	Approx. 0.5–1.0 kPa (50–100 mmH₂O)
Operating Differential	From new-element baseline to clogging alarm
Alarm / Final Resistance	Per the machine's intake restriction indicator (yellow/red zone)
Pressure Drop vs. Energy	Every 1 kPa increase in intake resistance raises machine energy consumption by approx. 1%

Pressure drop and energy consumption: Rising intake resistance lowers intake pressure and density, forcing the machine to work harder to maintain discharge pressure and flow, which increases specific power. Based on a 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 the element goes from new to heavily clogged (0 → 6 kPa), machine energy consumption rises by about 6%. The cumulative electricity cost typically far exceeds the price of a filter element. This is why the FPG10 housing includes a restriction indicator port — replacement timing should be based on actual resistance, not calendar estimates.

Dimensions and Installation

Parameter	Value / Note
Dimensions	OD 208 mm × ID 106 mm × Length 409 mm
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 (inside main element) as backup protection

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

Material Construction

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

Construction note: Traditional axial elements consist of a metal end cap, glued gasket, and separate seal ring — any one aging can cause 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 enables tool-free installation and removal.

Operating Tolerance

Parameter	Value / Note
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, vibration-resistant

Service Life and Maintenance

Parameter	Value / Note
Service Life	2000 hours or 3 months, whichever comes first
High-Dust Environments	Follow restriction indicator; schedule replacement when entering yellow zone
Shelf Life	Approx. 2–3 years (unopened, dry, ventilated storage)

Standards

Item	Detail
Product Standard	ISO 5011 (inlet air cleaning equipment for internal combustion engines and compressors — performance testing); efficiency figures measured per this standard
Construction Standard	Donaldson FPG / FRG series air cleaner specification (RadialSeal system)
Commonly Referenced Test Standards	ISO 2941 / 2942 / 2943 / 3723 / 3724 / 3968
Standard Applicability Note	The ISO 29xx / 37xx series are hydraulic filter test methods. If a supplier can only provide hydraulic filter standards, request ISO 5011 or the OEM specification sheet.

Installation and Maintenance Steps

The FPG design is tool-free; a complete service takes about 15 minutes.

1. Shut down, confirm zero pressure, lock out/tag out. Stop the machine, disconnect main power, and lock out/tag out. Criterion: controller shows system pressure at 0.

2. Open the FPG air cleaner service cover. Release the cover latches — FPG 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 — if a residual gasket is found on the outlet tube, a non-genuine part was previously installed and must be cleaned off.

4. 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 and most consequential step — a blocked valve disables the pre-cleaner, transferring all dust load to the main element and sharply reducing life.

5. Inspect the pre-cleaner and housing for dust tracks. 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 present, check sealing surfaces.

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

7. Reinstall the service cover and check the restriction indicator. Replace cover, secure latches. Confirm the restriction indicator is in the green zone; if resettable, press to reset and confirm it returns normally. Criterion: green zone reading, indicator functions.

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

Installation rule: Do not start the machine before the element is fully seated. If the RadialSeal is not pushed into place, air bypasses directly through the gap between end cap and outlet tube, disabling both the pre-cleaner and main element — equivalent to running without a filter.

Frequently Asked Questions

What specification is 49164395?
A two-stage RadialSeal primary element built to Donaldson FPG10 specification. The integrated tangential pre-cleaner removes about 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. Confirmation is simple: read the specification marking on the installed element's end cap — 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, 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 discharge port. Coarse dust separated by centrifugal action falls to the housing base and is automatically expelled through the Vacuator valve. If the valve clogs, the pre-cleaner is completely disabled and all dust loads the main element. Check it at every element change — this is a critical FPG maintenance action.

How often should it be replaced?
Recommended interval is 2000 hours or 3 months, whichever comes first. More accurately, follow the 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 — 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, 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. Adding a gasket lifts the element off 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 can give a "clean" reading when the element is actually clogged. Check it at every service by pressing to confirm it returns; if failed, replace the element on a conservative time schedule until repaired.

How does the FPG plastic housing compare with metal housings?
The FPG injection-molded housing is corrosion-resistant, lightweight, and vibration-resistant — it will not rust in coastal salt-spray or humid environments. The tool-free service 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 and confirm FPG10; ② Measure the old element's OD and length to verify 208 mm and 409 mm; ③ If the old element is discarded, provide the air cleaner housing model marking and we will cross-reference by FPG specification.

Compatible Equipment

This part is supplied to 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:

Item	Specification
Air Cleaner Specification	Donaldson FPG10 (elements interchangeable with 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
Seal System	RadialSeal (polyurethane end cap radial seal)

How to confirm compatibility

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

Note on model coverage: Donaldson FPG10 is a universal air cleaner used by multiple OEMs, so compatibility is not limited to a specific machine model list. The deciding factor is whether the air cleaner specification is FPG10, not the machine model itself. If the machine nameplate does not list the air cleaner specification, 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 maintained together with this part. Listed by component — function — inspection point:

Component	Function	Inspection Point
Safety Element	Backup element inside the primary; protects downstream if the primary is damaged or during change intervals	Typically replaced on the same cycle or every other cycle; check media for damage
Vacuator Dust Valve	Automatic discharge port for the pre-cleaner; expels centrifugally separated coarse dust	Check at every element change: valve must open and close freely, no caked dust, no obstruction
Restriction Indicator	Indicates element clogging level; authoritative basis for replacement timing	Check needle returns normally; 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 leak when locked
FPG Housing Assembly	Injection-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 air cleaner to machine intake duct	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 is working properly. When changing the primary element, also check the Vacuator valve and restriction indicator. If either fails, primary element life is significantly shortened — their cost is far lower than the primary element, yet they determine how long it lasts.