Field Service Bulletin
Pony Tank 87 PSI Regulator & Filter Upgrade Kit
Part Number 24409010
ENP-616
January 23, 2018

1. Introduction
Agility Fuel Solutions Pony Tanks made prior to 2017 supply 125 psi to the vehicle engine,
and is too high for Cummins Near Zero engines. The Near Zero 12L and possibly other
natural gas engines require lower fuel pressure to operate properly.
The Agility 24409010 Pony Tank retrofit kit includes a new pressure regulator and a high
pressure filter to improve existing and older Pony Tanks. The fuel pressure output is 85 psi
and is compatible with all Cummins 6.7L, 9L and 12L natural gas engines, including the
Near Zero 12L.
These instructions can be used for the entire 24400000 and 24401000 family of Agility
Pony Tank systems.

Warning Messages Used in this Bulletin

Personal injury or death may occur if procedures are not followed.

Damage to equipment, fuel system or vehicle is possible if instructions are not
followed.

2. Affected Units
This upgrade applies to 24400000 and 24401000 series of Agility Pony Tank systems.

3. Corrective Action
Not applicable.

4. Required Parts and Tools

Figure 1. Pony Tank 87 psi regulator and filter upgrade kit, part number 24409010.

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
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In addition to the information in this bulletin, the Pony Tank manual, ENP-005, Rev.
F and later, provides additional reference material.
Common CNG fuel system hand tools for leak detection and repair.
Pony Tank Retrofit Kit part number 24409010 consists of:
Qty.

Part
Number

Description

1

10200062 Connector, 3/8-in. tube x 9/16-18 male

1

10200176 Elbow, 1/4-in. tube x 7/16-20 male

3

10200180 Elbow, 1/4-in. tube x 7/16-20 male

1

10306975 Regulator, 87 psi outlet

1

10602021 Decal, “CNG Vent Line”

1

10602253 Decal, “WARNING, CNG Vent Hazard”

1

10602239 Decal, “Drain Filter”

1

20100466 Subassembly, filter

1

24409100 Bracket, regulator

1

24409101 Bracket, filter

1

24409104 Bracket, 3-way valve

1

24409400 Tube, formed, valve to filter

1

24409401 Tube, formed, filter to regulator

1

24409402 Tube, formed, regulator to low pressure gauge

1

30000410 Subassembly, regulator vent

2. Procedure

A. The Pony Tank should be depressurized before starting work.
B. This procedure requires drilling new holes for mounting brackets. DO
NOT allow the drill bit to contact the cylinder.
1. Depressurize the Pony Tank.
a.

Place the Pony Tank in a well ventilated area with no overhead spaces where gas
can be trapped.

b.

Close the cylinder valve to isolate pressure within the cylinder.

c.

Make sure the hose is securely tied to the frame to prevent movement and point it
away to a safe place when releasing gas.

d.

Turn the 3-way valve to the vent position to relieve pressure.

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2. Remove covers, bottom handle bracket and regulator bracket. See Figure 2.

Remove
regulator and
bottom handle
brackets

Figure 2. Remove covers and regulator bracket.
3. Next, remove the regulator, low pressure hose and regulator PRD vent as shown in
Figure 3. Clean and save all parts and fasteners for re-use.

Figure 3. Remove the old regulator and related parts. Clean and save the fittings and
fasteners for re-use.
4. Remove the tube from the regulator to the low pressure gauge and replace it with the
new tube regulator to low pressure gauge tube as shown in Figure 4.

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After
Before

Figure 4. Remove and replace the tube from the regulator outlet to the low pressure
gauge.
5.

See Figure 5. Drill the support to the right of the cylinder valve for the filter mounting
bracket. Refer to drawing 24409103 in Appendix A.

6.

Do not damage the cylinder with the drill bit.

Figure 5. Drill holes for the filter bracket as shown.
7.

Modify handle bottom bracket 24400008 to match the holes as the bottom handle
bracket 24409008. The new 3-way valve bracket will mount here. Refer to drawing
24409102, Appendix B for details.

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Bottom bracket 24400008
(View from below)

Bottom bracket 24409008
(View from below)

Figure 6. Modify bracket 24400008 to match the other bracket as shown.
8.

Refer to Figure 7. Install fittings into the new 85 psi regulator as shown. Re-use elbow
10240288, JIC elbow 20100403, regulator vent tube 30000409 and vent cap
10712383 from the old regulator.

1. 10240288, elbow, 9/16-18 male
SAE, 1/2-in. female NPT
2. 20100403, elbow, 1/4-in. female
NPT, -6 male JIC
3. 10240390, tube nut, -6
4. 30000409, regulator vent tube
5. 10712383, vent tube cap
6. 24409100, regulator bracket

Figure 7. New regulator and fittings, view 1.
9.

Refer to Figure 8. Add elbows 10200176 and 10200180.

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7. 10200176, elbow, 1/4-in. tube to
7/16-20 male
8. 10200180, positionable elbow, 3/8in. x 9/16-18

Figure 8. New regulator and fittings, view 2.
10. Install two elbows and the bleed valve into the high pressure filter assembly 20100466
as shown in Figure 9. Afffix the “Drain Filter” decal 10602437 to the filter housing so it
is visible to the operator. You may wish to attach the decal after the filter is installed to
make sure it is in the correct location.

1. 24409101, filter bracket
2. 10200180, elbow (2 each)
3. 10300172, bleed valve

Figure 9. Components installed into the high pressure filter assembly.
11. Attach the modified handle bottom bracket 24400008 to the Pony Tank frame and
install the regulator bracket 24409100 and filter bracket 24409101 as shown.

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Filter bracket
Regulator
bracket
Modified
bottom bracket

Figure 10. Install various mounting brackets to the Pony Tank frame.
12. Mount the regulator with parts on the regulator mounting bracket and install the low
pressure gauge tube 24409402 to the regulator outlet.

Low pressure
tube from
regulator outlet to
low pressure
gauge

Figure 11. Mount the regulator and attach the low pressure gauge tube.

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13. Mount the high pressure filter to the filter mounting bracket. If not done so already,
afffix the “Drain Filter” decal so it is visible to the operator.

Figure 12. Mount the filter and attach the decal in a visible location.
14. Next, install the U-shaped valve to filter tube 24409400 and the roughly J-shaped filter
to regulator tube 24409401 as shown in Figure 13.

Valve to filter
tube

Filter to regulator
tube

Figure 13. Install the high pressure lines as shown.

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15. Attach the low pressure hose to the 3-way outlet port and install the new valve bracket
24409104 as shown below.

3-way valve and
bracket

Figure 14. Attach the low pressure hose and install the new 3-way valve bracket
16. Pressure and leak test the assembly.
17. Repair any leaks.
18. Reassemble covers onto the system and replace any missing decals. Reference
24409000 system drawing or the Pony Tank Operation Manual, ENP-005, Rev F and
later, for other decal part numbers and their locations.

Maintenance Notes
Task

Frequency

Leak test with methane detector

Every month

Drain high pressure filter

After every 1 to 2 months*

Replace filter element

After every 6 to 12 months*

Component inspection

Every month

Cylinders

Inspect cylinders every 3 years or as required
by cylinder manufacturer

*Suggestions only. Intervals vary depending on actual use and must be determined
by the user.

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3. Warranty Information
Standard warranty terms apply.
Standard repair time (SRT) is 3 hours per Pony Tank system.
If you have any questions, contact Agility Fuel Solutions Customer Care: +1 949 267 7745,
toll free: +1 855 500 2445 or [email protected].

Proprietary Statement
The information provided within this document is proprietary and confidential. All prior
versions, including updates and revisions forwarded separately, are proprietary. The
information provided by Agility Fuel Solutions to its customers and clients is solely for the
use of those customers and clients. No portion of this manual may be reproduced or
distributed without express written consent of Agility Fuel Solutions. Agility Fuel Solutions
reserves the right to utilize the intellectual property contained within this publication as
content for any other publication produced by Agility Fuel Solutions.

Trademark Notice
Agility® and TUFFSHELL® are registered trademarks of Agility Fuel Solutions. Drop-NGo™ is a trademark of Agility Fuel Solutions. Trademarks of other manufacturers are the
property of their respective companies.
Agility Fuel Solutions
3335 Susan Street Suite 100
Costa Mesa, CA 92626 USA
www.agilityfuelsolutions.com

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Appendix A, 24409103

Existing serial number tag holes

Drill two new holes for the
filter bracket
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Appendix B, 24409102

Cut 2 new slots
for the 3-way
valve bracket
Drill 2 new holes
for the regulator
mounting bracket
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