HOW TO ASSEMBLE A BG4

PENN STATE MINE RESCUE

Adam Rodriguez
April 9th, 2015

[1]

Introduction
A BG4 is a self-contained breathing apparatus (SCBA), similar to the gear scuba divers wear. A
properly constructed BG4 will prevent the inhalation of harmful gases like carbon monoxide,
hydrogen sulfide and various forms of nitrous oxides. You can die if your BG4 is not properly
assemble. This instruction set will help you properly assemble your BG4.

Materials

Exhalation Hose
Inhalation Hose
Breathing Connector
CO2 Absorber
Breathing Bag
Breathing Bag Springs
Ice Container
O2 Valve
High Pressure Valve
CO2 Absorber Spring Clip
Computer
Drain Valve
Pressure Reducer
BG4 Case
BG4 Cover
Metal Clip

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Remove the components from the BG4

*Note lubricate all O-rings with the lubricating
oil before assembly. Leaks will occur otherwise.

Assemble the CO2 absorber

1.
2.
3.
4.
5.
6.
7.
8.

Insert one plastic screen (2) into the absorber container (1)
Insert one filter (3) on top of the plastic screen
Fill 80% of the absorber container with dragersorb
Place the remaining filter on top of the dragersorb
Place the remaining plastic screen on top of the filter
Place the lid (4) on the absorber container
Place the metal guard (5) on top of the lid
Secure the lid and metal guard to the absorber container
with the metal clips
9. Lock the clips

Attach the CO2 Absorber to the BG4

1. Slide the lip of the absorber container into the metal slot
2. Secure the absorber container to the BG4 case with the
spring assisted snap

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Assemble the Ice Container

1. Fill the ice container with crushed ice
2. Attach the lid to the container
The ice container cools the air before breathing. The air is hot due
to the exothermic reaction created by the CO2 absorber.

Attach the Ice Container to the BG4

1. Slide the indents of the ice container into the metal
dimples attached to the BG4
2. Secure the ice container to the BG4 case with the
spring assisted snap

Attach the Computer to the Ice Container

1. Snap the computer cable to the nipple on the ice
container
The computer analyzes the oxygen content of the air.

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Secure the Oxygen Nozzle to the BG4 case

1. Attach the oxygen nozzle to the white plastic with the
metal clip
This is the hardest step of the BG4 assembly. There is a groove etched
into the oxygen nozzle on the backside of the white plastic. The metal clip
snaps into the grove and secures the oxygen nozzle to the white plastic.
This step requires dexterity and patience.

Attach the Breathing Bag to the BG4

1. Slide the plastic rings of the breathing bag onto the
oxygen nozzle, CO2 absorber pipe and ice container pipe
Make sure the breathing bag is properly secured. There are grooves in
each of the pipes and the nozzle where the plastic rings will snuggly fit.

Attach the Blue Connector

1. Snap the blue connector to the buttons on the CO2
absorber and the breathing bag

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Assemble the Drain Valve

1. Place the valve pin (1) into the drain valve hole (2)
2. Place the spring (3) onto the valve pin
3. Screw the drain valve lid (4) onto the drain valve

Attach the Drain Valve to the BG4

1. Snap the drain valve onto the BG4
2. Attach the plastic ring on the breathing bag to the
drain valve
There is a groove on the drain valve which the plastic ring on
the breathing bag fits onto.

Assemble the High Pressure hose

1. Place the valve pin (1) into the hole on the high
pressure hose lid (2)
2. Snap the high pressure hose lid onto the high
pressure hose (3)
The spring is permanently attached to the high pressure hose

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Attach the High Pressure Hose to the BG4

1. Clip the high pressure hose to the black plastic
This step is tricky. The high pressure hose must be rotated
first in order to properly attach it to the plastic.

Snap the High Pressure Hose to the CO2 Absorber

Attach the Breathing Bag Springs

1. Place the two breathing bag springs between the
breathing bag and the black plastic
There are plastic stubs on the breathing bag and the black
plastic which the springs will fit onto.

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Check the O2 Gage Pressure

1. Verify that the O2 gage pressure is between 2500
psi and 3000 psi
If the pressure is below 2500 psi then the bottle needs to be
refilled.

Attach the O2 Bottle to the BG4

1. Remove the lid of the O2 nozzle
2. Screw the black seal onto the O2 nozzle
3. Strap the O2 bottle to the BG4

Assemble the Breathing Connector

1. Attach the intake valve (2) to the left side of the
breathing connector (1)
2. Attach the return valve (3) to the right side of the
breathing connector
3. Store the breathing connector cap (4) somewhere
safe

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Attach Hoses to the Breathing Connector

1. Attach the short end connection of the hose to the
left side of the breathing connector (Intake hose)
2. Attach the long end connection of the hose to the
right side of the breathing connector (Return hose)
3. Screw the breathing hose caps onto the breathing
connector
The two ends of the breathing hoses are different shapes. One end
is smaller than the other.

Connect the Breathing Hoses to the BG4

1. Attach the intake hose to the CO2 absorber pipe
2. Attach the return hose to the ice container pipe
3. Screw the breathing hose caps to their respective
pipes
4. Attach the BG4 lid to the BG4 case

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Trouble Shooting

What if my BG4 is leaking?

1. Lubricate the O-rings
2. Check for holes in the hoses and the breathing bag
3. Check to make sure the breathing bag rings are securely attached to the O2 nozzle, the
CO2 absorber pipe, the drain pipe and the ice container pipe

What if my BG4 is beeping?

1. Check the pressure in the oxygen bottle (should be above 2500 psi)
2. Replace the battery in the computer

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