Zeagle Flathead-7 User manual

This owner’s manual uses signal words recommended by the
American National Standards Institute (see ANSI Z535.4) to des-
ignate levels of hazard seriousness. These signal words and their
designations are as follows:
DANGER: Indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
This signal word is to be limited to the most extreme situ-
ations.
WARNING: Indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
CAUTION: Indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate injury.
It may also be used to alert against unsafe practices.

1
Introduction – Safety Information
Warranty Information
Disclaimer and Limitation of Remedy
Cold Water Diving Information
Nitrox Use / First Stage Features
Second Stage Features
Resistance Control Knob Dive / Pre-Dive Lever
Octopus Use
Wet Breathing
Pre-Dive Check
Post-Dive Care
Maintenance
Code Of The Responsible Diver
Specifications / Service Record
Pages
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3
4
6
8
9
10
11
11
11
13
14
14
15,16
Table of Contents:

2
Congratulations on your Zeagle Regulator Purchase!
Your Zeagle “Flathead” Regulator is the top of the Zeagle Regulator
line and has been designed and manufactured to the highest pos-
sible standards of performance and reliability. With the reasonable
care outlined in this manual it will provide you with many years of
diving enjoyment.
Since 1979, Zeagle Systems Inc. has been providing divers with
Scuba equipment and Buoyancy Control Devices. Zeagle Systems
and our worldwide network of authorized dealers are always ready
to serve you. For more information on our products, and for the
dealer nearest you, visit our web site at www.zeagle.com. Thank
you for choosing Zeagle!
Safety Information
Read these instructions carefully before using your regulator, and
keep this manual for future reference.
Following the care and maintenance section at the end of this book-
let will help ensure reliable service.
Model Differences
The primary difference between the Flathead-7 and Flathead-LT
models, involves the 1st stages. The Flathead-7 has a dry-sealed
first stage and a Heat-sink on the 2nd Stage to help prevent freezing
in cold water. The Flathead-LT has a wet spring chamber on the
1st stage and plastic spacer on the 2nd stage to make the LT lighter
while still maintaining the extremely high flow capacities.

Limited Lifetime Warranty To The Original Owner
1. Your Z / Flathead is guaranteed against defects in materials and work-
manship. This guarantee does not cover normal wear, or damage from
accident, abuse, neglect, alterations, improper usage, or failure to follow
reasonable care and maintenance as outlined in this manual. Under this
limited warranty, Zeagle will either repair or replace, at its sole option, any
original equipment or parts that fail to perform as intended. Shipping and
Labor charges are not included and must be paid by you. To validate your
warranty, you must fill out and return your warranty registration card within
30 days of purchase. This Limited Lifetime Warranty excludes filters,
hoses, O-rings, diaphragms and mouthpieces, which are warranted for two
years from the regulator’s date of purchase. Filling out the card requires
printing CLEARLY the serial numbers of both the first
and second stages. The first stage serial number is
stamped on the first stage on the top of the regulator
(fig. 1). The second stage serial number is stamped on
the mouthpiece tube (fig. 2). To read this serial number
you must fold back the flexible silicone mouthpiece to
expose the numbers. Each serial number consists of a
pre-fix letter followed by six numbers.
All of the digits of both the first and second stages must
be CLEARLY printed on your warranty registration card
for your warranty to be activated. You can also register
at www.zeagle.com.
2. For proof of original ownership,
It is your record of when and where the regulator was purchased.
It also lets you know when your annual service should be performed.
3. To keep the original-owner Limited Lifetime Warranty in effect, you
must have your regulator inspected and serviced annually, within 30
days before or after the anniversary of the purchase date. Failure to do
so will invalidate your warranty. This servicing must be performed by an
authorized Zeagle dealer. Save the receipts from this servicing for your
records.
3
Fig. 1
Fig. 2.
ID #

4
4. This limited warranty applies only to the original purchaser, and then
only to certified divers.
5. Sometimes products from other manufacturers are attached to Zeagle
Equipment. This warranty does not cover those other products or make
any claims as to the performance or suitability of those other products.
6. This limited warranty applies only to regulators sold in the USA through
authorized Zeagle Systems dealers.
7. This warranty gives you specific legal rights. You may also have other
rights that may vary from state to state.
8. This warranty applies only to regulators purchased from Authorized
Zeagle Dealers located within the United States. The regulator must be
picked up by the original owner at the dive store. Regulators shipped to
the customer in another location are not covered. Warranty coverage in
countries other than the US varies. Outside the US your dealer will be able
to get further Warranty information from the Authorized Zeagle Regional
Distributor.
Disclaimer And Limitation On Remedy
(Some states do not allow limitations on how long an implied warranty lasts
or do not allow exclusion of incidental or consequential damages, so the
following limitations or exclusions may not apply to you.)
Zeagle expressly limits any and all warranties, expressed or implied, to the
terms of the limited warranty as set forth above. Your remedies are limited
to those contained herein and are in lieu of all other remedies, whether
based on breach of warranty or contract, negligence, strict product liability
or other tort. Zeagle specifically disclaims liability for any consequential,
special or indirect damages arising out of the use of Zeagle Equipment.

5
CAUTION
Scuba products are subject to conditions of extreme wear and cor-
rosion. Inspection and maintenance are required to ensure contin-
ued performance. Zeagle recommends that you have your regulator
inspected and serviced once a year on the anniversary date of its
purchase at any authorized Zeagle dealer worldwide. Zeagle Scuba
equipment should be used by certified Scuba divers only.
WARNING
1. Scuba diving is an adventuresome activity that involves a degree
of risk. Zeagle Systems Inc. Self Contained Underwater Breathing
Apparatus (SCUBA) equipment is only to be used by those trained and
certified by a nationally recognized scuba training agency. Diving
without the necessary training in safe diving procedures, or without
observing the practices outlined by your training agency for your level
of certification, is extremely hazardous and could result in serious
personal injury or death. This owner’s manual is in no way meant
to be a substitute for the instruction received from a certified scuba
training agency.
2. Zeagle regulators must be serviced only by dealers or technicians
trained and authorized to service Zeagle Scuba equipment. At no
time should any unauthorized person attempt to repair the regulator
or adjust any nuts, bolts or screws other than those used to mount
the regulator to, or dismount it from the tank valve. Scuba equipment
that is not properly serviced might malfunction during use, putting the
diver at risk of serious personal injury or death.

Cold water is defined as water at a temperature of 50 degrees F (10°
C) or lower. In cold water there is a risk of the first or second stage
freezing. The risk of freezing is increased as the ambient tempera-
ture gets lower, the air flow increases, and/or the moisture content of
the air supply increases. Regulators for cold water use should have
environmentally sealed first stages to prevent water entry and lower
the chance of freezing. The second stages should have extra heat
absorbing features such as the metal Heat-sink. The Flathead-7
has these freeze resisting features and more, and is the best Zeagle
model for Cold Water. It is not possible to completely eliminate regu-
lator freezing under all conditions. In order to reduce the possibility
you should:
1. Start the dive with the regulators as warm as possible. If the air
temperature is far below freezing, try to warm the regulators by pour-
ing warm water over them or dunking them in warm water just before
entry.
2. If an Octopus regulator is put into the mouth underwater (IF safely
possible), try to start the breathing cycle with a long exhalation to get
the interior of the 2nd stage as warm as possible before the first breath
is drawn.
3. Avoid pushing the purge button in the second stage during cold
water diving operations.
4. Avoid high rates of breathing, and excessive inflation of buoyancy
devices or dry suits. The deeper the dive the greater the risk.
COLD WATER DIVING
6

7
CAUTION
1. The high-pressure outlets (HP Ports) are distinctly larger than the
low-pressure outlets. Only devices with fittings, hoses and com-
ponents designed for the full tank pressure that the regulator will
be mounted on, such as Submersible Pressure Gauges, are to be
installed in these ports.
2. During installation, the O-ring hose fittings will seal with hand-tight
pressure, but may come loose during use if not tightened carefully
with a small wrench. Proper torque for the hose fittings is 40-45 in
lbs. (4.5 - 5 N-m) Excessive tightening will not help the seal and may
damage the parts (see DEMA Guidelines No. 101, Low Pressure Hose
Installation Caution Statement; ANSI American National Standard for
Underwater Safety, paragraph 9.3.1).
5. Do not practice unnecessary buddy breathing, etc.
6. Do not use your regulator to fill lift bags, etc.
7. Keep YOUR regulator in YOUR mouth. In an emergency, offer
or take the spare regulator. When taking the spare regulator, do
not hit the purge button to clear the water (if possible). Clear the
regulator with as long a first exhalation as is safely possible.
8. If the physical gear set-up allows, use two 1st stages and utilize
one for breathing air and the other one for inflation air. This will
split the cooling effect between the two regulators.
COLD WATER DIVING (continued)

8
NITROX USE
Zeagle regulators are manufactured using materials suitable for use
with oxygen enriched gases (i.e., Nitrox, etc.) providing the oxygen
content does not exceed 40%. The regulator must be kept “Oxygen
Clean” and used only with certified clean air mixtures to maintain this
status. Once the regulator is used with air not certified to be clean
for enriched air use, the regulator will have to be cleaned again for
enriched air use by a certified technician.
FIRST STAGE FEATURES
The first stage reduces the high pressure air contained in the cyl-
inder to a constant intermediate pressure of approximately 135
p.s.i. (9.2 BAR). Zeagle first stages are designed to do this with
outstanding reliability.
Extreme cold water diving such as diving under ice requires specialized
training and procedures. Do not attempt these activities unless you are
fully qualified and properly equipped to do so safely.
WARNING
DANGER
Using nitrox (i.e., gas mixtures containing oxygen in excess of 21%)
requires special training and procedures. Improper use of nitrox can
lead to personal injury, convulsions, drowning, and death.
Use of gas mixtures containing oxygen in excess of 40% with this regu-
lator, can lead to fires and explosions, causing severe personal injury
and death.
DANGER

The Flathead First Stage may be attached to your Scuba cylinder
by means of the standard yoke assembly for cylinders using a “post”
type valve (fig. 3) or the optional DIN connector for cylinders utilizing
a DIN valve (fig. 4). Zeagle offers a DIN to Yoke Converter p/n 330-
0001 (fig. 5) that allows DIN fitted regulators to be converted for use
with a “post” type valve in a few seconds without using tools.
The use of advanced high-strength materials, has allowed Zeagle to
reduce the outside dimensions of the Flathead-7 and Flathead-LT
first (& 2nd) stages, making these models the lightest in the Zeagle
line.
SECOND STAGE FEATURES
Fig. 3
The Zeagle “Z” second stage is pneumatically balanced and is
among the most advanced diver adjustable breathing systems avail-
able. No fixed or “automatic” system can achieve an ideal level
of breathing performance under all conditions. Zeagle “Z” second
stages are equipped with separate diver controls for both cracking
resistance and venturi boost. This allows the diver to adjust the
complete range of breathing characteristics. By using a combination
of the two controls, it is possible to tune the regulator to give virtually
ideal performance.
Fig. 4 Fig. 5
9

10
Fig. 6
DIVE / PRE-DIVE VENTURI LEVER
This lever controls the sensitivity of the regulator.
The Plus and Minus Positions for the lever are
marked on the case beside the lever. To avoid
unexpected venturi free flows at the surface, or
when jumping into the water, the lever should
be set in the PRE-DIVE “-” (forward) position. As soon as the diver is
ready to descend, the lever should be moved to the DIVE “+” (back) posi-
tion.
NOTE: Ask your authorized Zeagle Scuba dealer for in-store instructions
and training on the use of the Resistence Control Knob and the Dive / Pre-
dive Venturi Lever. Your dealer will show you how to make adjustments
to get the desired breathing results. To actually experience the effects of
the adjustment range, the instruction should be conducted with the diver
breathing through a regulator attached to a full air supply. The feel of the
regulator breathing underwater is of course somewhat different from the
feel of breathing above the surface.
Clockwise
Counter Clockwise
This knob adjusts the spring load on the second stage valve and so var-
ies the initial inhalation effort. To adjust the Resistance Control Knob to
the easiest breathing setting, turn the knob fully counter-clockwise (fig. 6).
Sometimes a slight hissing flow of air may be heard at this setting. If this
occurs, turn the knob clockwise (fig. 7) just enough to stop the hissing.
RESISTANCE CONTROL KNOB
Fig. 7

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OCTOPUS (Alternate Second Stage)
The diver controls available on the Zeagle (p/n 320-8110) Z Octopus
second stage, make it an excellent choice for Octopus use. An Octopus
Regulator is often subjected to conditions that may cause a free-flow. For
example, jumping into the water or swimming in a strong current. To mini-
mize this, move the Dive / Pre-Dive Lever forward to the “-” Minus position.
When the Octopus Regulator is needed for delivering air to a diver, the
Dive / Pre-Dive Lever is moved back to the DIVE “+” position. Although
breathing resistance will be somewhat greater, the regulator will still deliver
ample air on demand if the Lever is accidentally left in the Pre-Dive posi-
tion. The 36” Yellow braided hose that comes with the Z Octopus, is
stronger, lighter and higher flow capacity than standard Scuba hoses.
WET BREATHING
The Z second stage is much “drier” than many other second stage designs
during use. However, it must be remembered that water (including the
diver’s own saliva) will always settle to the bottom of the case. If the diver
is in an unusual position (i.e. head down or upside down looking upwards)
the exhaust valve is no longer at the bottom of the case and the mouth
tube is. This means that water will settle in the mouth tube area and
sometimes is ingested by the diver. A tendency to wetness is aggravated
by slow exhalations while inverted. This is because the exhaust valve is
flapping open with little air velocity, thus letting water in. Of course a regu-
lator that begins breathing wetter than it has before, should be checked
out by a technician, but avoiding long periods of inversion, and using
shorter stronger exhalations if inverted, will keep the interior of the regula-
tor drier.
PRE-DIVE CHECK
1. Before mounting any Scuba regulator onto a tank valve, you must open
the valve briefly to blow out any water trapped in the outlet area of the
valve.

12
CAUTION
WARNING
If you hear any leaks, turn the tank valve off. Do not use the regulator
until the source of the leak has been found and corrected by an autho-
rized Zeagle Scuba service technician.
Lifting the tank by the regulator or hoses may loosen a previously tight
connection, which could cause unexpected air loss and put the diver at
risk during a subsequent dive. You could be physically injured by high
pressure air or parts that are propelled by high-pressure air.
Failing to perform this simple step will often result in water and con-
taminant’s being blown into the interior of the regulator, which in turn
will cause future mechanical problems in the regulator.
2. Prior to each dive always check to make certain your regulator has
no potential water leaks by inhaling on the regulator with the dust cap
properly installed or the tank with the air valve turned off. You should
be able to draw in very little if any air. If you can draw in any quantity
of air, either the exhaust valve is failing to seal properly, or there may
be a pinhole leak in the mouthpiece or second stage diaphragm.
3. Just before turning on the tank air valve, check to make sure that
the yoke nut or DIN connection is tight and that the regulator body
is aligned properly, with no kinks in the hoses. In the case of DIN
connections, check that the DIN connector O-ring on the regulator is
in place before installing the regulator into the valve. Always carry
spare DIN connection O-rings (Zeagle p/n 160-0111-N7).
4. Turn the tank valve on slowly, check for air leaks and proper
breathing function of the regulator.

13
4. The Valve Seal in the second stage will give longer service if the
Resistance Control Knob on the Z second stage is turned fully coun-
ter clockwise when the regulator is stored longer than a week.
1. After the dive, dry the dust cap and place it securely on the regula-
tor inlet. On multiple tank dives, keep water out of the regulator inlet
when changing the tanks. Neglect of these simple procedures is a
major cause of corrosion and wear in scuba regulators.
2. With the dust cap securely in place, rinse the first and second
stage in clean fresh water. DO NOT purge the regulator before or
during rinsing since this may introduce water into the second stage
and the low-pressure hose. After rinsing, reconnect the regulator to
an air supply and thoroughly shake all excess water from the second
stage. Press the Purge cover (with the regulator attached to a pres-
sure source) several times to blow the rinse water out of the inner
mechanism. Allow the entire regulator to air dry before storing. For
reasons of hygiene, equipment subjected to frequent use in training,
rental, etc. should finally rinsed in water containing a suitable steril-
izing agent. The best sterilizing solutions for your regulator are soap
based. If any stronger chemicals are used, make the immersion very
brief and rinse the regulator out again thoroughly. Failure to rinse
sterilizing chemicals out of the regulator will cause serious damage to
plastic parts of the regulator. This will result in cracking of hard plastic
parts and shrinking or swelling of soft plastic parts.
NOTE: DO NOT USE SOLVENT CHEMICALS TO CLEAN THE
REGULATOR
3. Store the clean dry regulator in a clean bag or storage box, away
from sunlight, excessive heat and humidity.
POST-DIVE CARE

14
The Code of the Responsible Diver
• As a responsible diver I understand the risks I may encounter while
diving. I will seek experience and knowledge from those with more
and will share mine with those who have less.
• “Superior divers use their superior knowledge to stay out of situations
that would require their superior skills.”
• “Your equipment can be excellent, but it is not responsible for you.”
• “Your training can be excellent, but it is not responsible for you.”
• “Your buddy can be excellent, but he is not responsible for you.”
• “You are responsible for you: Be excellent!”
• Zeagle BCD’s
• Zeagle Instruments, Computers
• Zeagle Alternate Air Sources
• Zeagle Drysuits
It is essential that your regulator is checked at least annually by an
authorized Zeagle regulator technician. Unusually heavy use, or use
in dirty or contaminated water may result in the need for more frequent
service. A service record has been provided at the end of this manual
to assist you in keeping your regulator’s service up to date.
Ask your Zeagle dealer for information on the following products to
use with your Zeagle Regulator, adding to your diving enjoyment and
safety.
MAINTENANCE

15
SPECIFICATIONS
MODEL: Flathead-7
FEATURES:
Balanced Diaphragm, Yoke or DIN Inlet available
Yoke or DIN inlet available.
A. FIRST STAGE REGULATOR
MODEL: Z
FEATURES:
Downstream valve, balanced diaphragm, Diver Adjustable Dive/Pre Dive Venturi Lever.
B. SECOND STAGE REGULATOR
WEIGHT (Flathead-7, Yoke)
WEIGHT (Flathead-LT, Yoke)
INTERMEDIATE PRESSURE
# LOW PRESSURE PORTS
# HIGH PRESSURE PORTS
MATERIALS:
Body
O-rings
Seat
HP Valve
1.82 lb. (.83 kg.)
1.80 lb. (.81 kg.)
120-150 psi (8-10 bar)
5
2
Brass
Buna-N
Advanced Polymer
Stainless Steel
HOSE WEIGHT
HOSE LENGTH
BODY WEIGHT
MATERIALS:
Cover
Case
Poppet Seat
O-Rings
Diaphragm
Exhaust Valve
Mouthpiece
.24 lb. (.11 kg)
30 in. (.76 mm)
.5 lb. (.23 kg)
Flexible Thermoplastic
Thermoplastic
Elastomer
Buna-N
Elastomeric Polymer
Elastomer
Silicone

16
Service Record
Date: Service:
Date Purchased:

17
Notes:
The date of purchase, dive store, and contact information at
the store should be written on this page. A copy of the receipt
could also be stapled to this page for future records.

Zeagle Systems Inc.
37150 Chancey Road,
Zephyrhills, FL, 33541
Phone: [phone]
Fax: [phone]
www.zeagle.com
07/2012
p/n 175-1653 Revision-
© 2012 Zeagle Systems, Inc.