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    Mossberg Training Manual 22-02-17 08-05-01 26 7421

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    Jonas Fernandes de Bom

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    © All Rights Reserved
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    O.F. MOSSBERG & SON: ARMORER , INC TRAINING MANUAL Mossberg® 500°, 590° & 590DA”™ Pump Action Shotguns TABLE OF CON Section 1.0 Introduction... . 1.1 General . 20 3.0 40 5.0 60 70 8.0 9.0 10.0 11.0 1.2 Technical Specifications - 1.3 Configurations ...| 1.4. Safety Declarations Design & Components , .. 2.1 Weapon Handling . 3.1 Functioning of Shoy 3.2 Loading ........ 3.3 Unloading 3.4 Firing the Shotgun |. General Disassembly & a - User Level 4.1 Disassembly - Seq 4.2. Assembly - Sequent ‘Weapon Inspection - Armorer / Instructor Level 5.1 General. 5.2 Function Inspection 5.3 Parts Inspection .. Cleaning & Lubrication 6.1 General ........ 6.2. Cleaning Equipment 63 Cleaning Procedures 6.4 Lubrication . 6.5. Reassembly . . 66 Requirement for Functional Inspection ..........s... Disassembly Instructions 71 General ..... 7.2. Tools Required . 7.3. Disassembly . Assembly Instructions - Armorer Level 8.1 General. 8.2 Assembly . Final Inspection / Certification for Duty 9.1 General : 9.2 Visual Inspection rice of Operations ...... of Operations -Armorer Level .... 9.3. Functional Inspection .. . 9.4 Log Book ........ Diagnostics and Troubleshooting . . Appendix/Exploded View: IHR RAVE O Figure Description aun 13 4 15 16 16a 7 18 19 20 2 23 24 25 25a 26 Za 29 Mode! 500° Ctuiser* Mode! 500° Model 590° with Ghost Ring® Sights Shoulder Stock Cruiser* Grip Stock Receiver with Action Slide ‘Assembly Removed Standard Barrel With Bead Barrel, Model 500°, with Bead Barrel, Model 500°, with Rifle Sights Barrel, Model 59, with Ghost Ring® Sights Receiver Assembly ‘Magazine Tube Style - Model 500° - Takedown Screw ‘Magazine Tube Style - ‘Mode! 590° - Magazine Cap Action Slide Components Bolt Assembly Trigger Group - Single Action - Hammer Cocked ‘rigger Group - Double Action - Hammer Partially Cocked Stock Assembly Action Assembly Action Lock Lever Location Action Lock Lever Operation Bolt Lock, Unlocking Bolt Lock, Unlocked Bolt Lock, Locked In Barre! Extension Safety Button Position Trigger/Scar Relationship at Rest - Single Action ‘Trigger/Sear Relationship at Rest - Double Action ‘Trigger/Sear Relationship, Pulling Trigger - Single Action ‘Trigger/Sear Relationship, Pulling Trigger - Double Action ‘Trigger/Sear Relationship, Firing - Single Action ‘Trigger/Sear Relationship, Firing - Double Action Receiver and Barrel Showing Chamber Ejector & Ejection Port in Receiver Loading the Chamber Figure Descriptio 31 32 33 35, 36 37 38 39) 41 2 43 45 41 48 49 50 50a,b.c 51 52 S2a,bc 53 55 BSASSRwSR 65 Loadibg the Magazine Tube Unloatiing the Magazine Tube Barrel|Removal - Bolt Position Barrel| Removal - Model 500° - Cartridge Stop & interrupter Assembly Bolt Side Removal from Receiver Bolt ahd Elevator Assembly Extractor Pins Removal are Removed Bolt Lock Pin Removal Bolt Lock Removed Firing Pin Retaining Pin Removal Firing Pin Removed Remoyal of Action Slide Tube Nut Action Slide Tube Nut Removed ‘Screw Removal Ejector Removed Safety Button Removal Stock Bolt Removal Cruiser® Grip Removal Disassembly of Magazine Tube Firing|Pin and Spring Installation Firing Pin Retaining Pin Installation Bolt Lock Pin Installation. Extractor Placement Bolt Assembly Ejector and Ejector Screw Action Bar Assembly to Receiver Bolt and Blevator Assembly Bolt Slide Assembly to Receiver - Step 1 Bolt Slide Assembly to Receiver - Step 2 Cartridge Stop & Interrupter Assembly to Receiver ‘Trigger Group Assembly to Receiver Receiver and Barrel Showing Barrel Seat Stock Bolt Installation 1.0 INTRODUCTION 11 GENERAL ‘The Mossberg® 500°, 590°, and 590DA™ combat shotguns have been developed to meet the exacting requirements of the world’s law enforcement and military agencies. All three are manufactured in the United States by state of the art production processes to provide uncompromised excellence in quality, dependability and operator safety. The 500®, 590° and S90DA" are superior close quarters combat and ‘squad support weapons that make use of both active and passive safeties, a single action trigger mecha- nism on the 500° and 590° and a double action trigger mechanism on the 590DA™. Various high visi ity sighting options allowing immediate deployment complete the package. All models are mechanically locked, manually cycled, 12 gauge pump action shotguns that will continue to fire with each depression of the trigger following movement of the forearm to the rear to extract and eject the empty shell and cock the hammer (590DA Hammer is partially cocked by rearward movement of the forearm.), then movement forward to chamber a new round. After firing, the shotgun may be easily disassembled for cleaning and maintenance without the use of specialized tools. 1.2 TECHNICAL SPECIFICATIONS Gauge: 12 System of Operation Manually operated, pump action Buttstock Model Receiver High Suength aluminum forging Boring of barrel Cylinder (Standard) ‘Chambered for shell length 2.75 and/or 3.00 inches Operation Manual, pump actuated ‘Type of action Slide Feed ‘Tubular magazine Ammunition capacity 6, 8 or 9 shot - includes one (1) round in the chamber cone (1) less if 3.00 inch shells are used. Barrel length 6 shot - 18.5 inches 8 shot and 9 shot - 20.75 inches Weight 6 shot w/wood 655 Ibs. (without ammunition) 8 shot wéwood & 9 shot 6.75 Ibs. Overall length 6 shot 37.75 inches 8 shot & 9 shot 39.75 inches ‘Type of firing mechanism Internal hammer ‘Type of stock Shoulder stock with pistol grip (standard) Safety ‘Top receiver mounted Cruiser” Model Armorer Note: Specifications are the same as for the Buttstock Model with the following exceptions: Weight 6 shot 5.75 Ibs. (without ammunition) 8 shot 6 Ibs. Overall length 6 shot 28.25 inches 8 shot 30.25 inches Type of stock ‘One hand molded nylon construction Armorer Note: Above specifications are subject to change without notice. Wor or broken parts are not subject to repair and must be replaced. Under no circumstances are triggers, hammers, hammer notches, seay, sear notches (or other trigger group or safety parts to be altered in any way. 13 CONFIGURATIONS Figure 1 Model 500° Figure 2 Cruiser® Model 500° Figure 3 ‘Model 590° with Ghost Ring® Sights 14 SAFETY DECLARATIONS + These declarations are designed to limit personal risk associated with the handling of firearms. For your pro- tection and the safety of others, read and understand the Owners Manual for your specific weapon before pro- ceeding. Disregarding these safety declarations may result in death, serious injury or property damage. + Mossberg shotguns are designed, manufactured and proof tested to SAAMI and Mil-Spec standards. Use only ammunition for which your shotgun is chambered and that meets these standards. O.F. Mossberg & Sons, Inc. ‘cannot assume responsibility for injury or damage caused by reloaded, non-SAAMI standard, or special pur- pose ammunition. + Load and unload in an area designated for these activities. Always point the muzzle in a safe direction iden- tified as that direction where ifa discharge did occur it would not result in death, personal injury, or prop- erty damage. Note the location of the safety and the action lock lever and understand their operation and the forces necessary to open and close the action and fire the shotgun. ‘The presence or use of a manual safety is not a substitute for safe weapon handling. + Do not make physical contact with the trigger or place your finger inside the trigger guard until you are on target and have actually decided (o fire. + Do not disengage the safety until you are on target and have actually decided to fire. + Prior to loading, visually and physically inspect the weapon to determine that the chamber and bore are free of obstructions and are clean. + Eye protection must be wom during all cleaning and maintenance processes. Hearing protection and eye protection must be wom while firing. DISCLAIMER ‘This Mossberg® Armorer Manual for the Mossberg® Model 500*, 590° and 590DA™ pump action shotguns is intended to be used as a reference guide for those attending formal training offered by O.F. Mossberg & ‘Sons, Inc. This manual contains instructions and procedures to be followed by trained, certified armorers for the inspection, maintenance and operation of these law enforcement/military weapons. It is not designed as a self-study guide for use by anyone not receiving formal training and certification from O.F. Mossberg and Sons, Inc. ‘Mossberg® shotguns are accompanied by an Owners Manual which outlines safety, operation and mainte- mance procedures for the end user. Information contained in the manual must be adhered to at ali times. All material is subject to change during revisions which may occur without notice. ‘The purpose ofthis Armorer manual is to educate and inform individuals assigned armorer responsibil within the law enforcement and military communities. O. F. Mossberg & Sons, Inc. accepts neither liabil- ity nor responsibility for any person with respect to any loss or damage caused, directly or indirectly by the information contained herein. This publication is copyrighted, is solely for the use of the attending armorer and may not be reproduced, copied or distributed in any form without the express, written consent of O.F. Mossberg & Sons, Inc. 2.0 DESIGN & COMPONENTS 2.1 WEAPON 24. OVERVIEW ‘The main components of the Mossberg* 500° & 590° model shotgun A. Stock B. Receiver, with Bolt, Trigger Group and Magazine Tube C. Barrel D. Bolt fy A ) Figure 4 A Shoulder Stock Figure 5 Cruiser® Grip Stock Figure 6 Receiver with Action Slide Assembly Removed ee Figure 7 Standard Barrel with Bead Sight Figure 7-1 Bolt 2.1.2 BARREL ASSEMBLY = Figure 8 6-Shot Barrel, Model 500°, with Bead Figure 9 8-Shot Barrel, Model 500°, with Rifle Sights Ib \, Figure 10 9-Shot Barrel, Model 590°, with Ghost Ring® Sights LEGEND 1. Bead Sight Ja. Rifle Sights (front & rear) 1b. Ghost Ring” Front Sight 24.3 RECEIVER ASSEMBLY Figure 11 Receiver Assembly LEGEND Receiver Ejector Ejector Screw Safety Button* Safety Button Screw* Safety Detent Plate* Safety Detent Ball* Safety Detent Spring* Safety Block* PRN AAS * Indicates items not field serviceable 21.4 MAGAZINE TUBE STYLES —¥ Figure 12 Model 500° 1, Takedown Screw D Figure 13 Model 590° 1. Magazine Cap 24.5 ACTION SLIDE COMPONENTS Figure 14 Action Slide Components LEGEND 1. Action Slide Assembly 2. Forearm 3. Action Slide Tube Nut 4, Left Hand Action Bar 5. Right Hand Action Bar 2.1.6 BOLT ASSEMBLY Figure 15 Bolt Assembly LEGEND 1. Bolt Body 7. Firing Pin Collar 2. Bolt Lock Pin 8. Right Hand Extractor 3. Bolt Lock 9. Left Hand Extractor 4, Firing Pin Spring 10. Extractor Springs 5. Firing Pin 11. Left Extractor Retaining Pins 6. Firing Pin Retaining Pin* _12. Right Extractor Retaining Pint * Note: Firing Pin Retaining Pin and Right Extractor Retaining Pin (#6 and #12) are identical. 10 2.1.7 TRIGGER GROUP Figure 16 ‘Trigger Group - Single Action Hammer in Cocked Position Figure 16a ‘Trigger Group - Double Action Hammer in Partially Cocked Position *The trigger group in all Mossberg" shotguns is a factory serviceable unit only. Field repairs on this unit are not authorized. Note: 590DA (Double Action) Trigger Group and Receiver are not interchangeable with 500 or 590 trigger group or receiver. 590DA Trigger Group will only fit 590DA Receiver. n 2.1.8 STOCK ASSEMBLY 2 CY LEGEND Figure 17 Stock Assembly ae Recoil Pad Screws Stock Bolt ‘Stock Bolt Lock Washer Stock Bolt Flat Washer Cruiser Grip Stock Bolt Flat Washer Cruiser Grip Stock Bolt Lock Washer Cruiser Grip Cruiser Grip Stock Bolt Seer Aree p pe oO 2.1.9 ACTION ASSEMBLY Receiver Assembly Action Slide Assembly Figure 18 Action Assembly SPARE 1. Forearm 12. Magazine Follower 13. Magazine Spring 14. Magazine Cap 15. Trigger Housing Pin 16. Magazine Spring Retainer 3.0 HANDLING Note: The operations described in this section are always to be carried out with the trigger fin- ger off the trigger and outside the trigger guard, and the muzzle pointing in a safe direction. Place the safety button in the “On”, fully rearward position. Failure to do so may cause serious injury or death. 3.1 FUNCTIONING OF SHOTGUN The action is cycled manually through a reciprocating motion by pulling the forearm fully rearward and then pushing it fully forward. The pulling action unlocks the bolt assembly, extracts and ejects the fired shell, cocks the hammer on single action types (partially cocks on double action type) and trans- fers a live shell from the magazine to the elevator. The subsequent pushing action lifts the elevator placing the shell in line with the chamber of the barrel where it is inserted by the forward movement of the bolt. The bolt assembly relocks at the end of the cycle. A detailed description of the cycle of oper- ation follows: Cycle of Operation Feeding: Releasing shell from the magazine tube onto the elevator to place the shell in the path of the bolt. : Moving the shell from the elevator into the chamber. Sealing the shell in the chamber and locking the bolt lock into the barre] extension. Ignition of the primer and firing the shell. Unlocking the bolt lock from the barrel extension. “Pulling” the spent shell from the chamber. “Pushing” the spent shell out of the ejection port. Returning the firing mechanism to the cocked position (partially cocked on DA type), ready to fire another shell. 3.1.1 ACTION RELEASE CONTROL The action is held closed by the action lock lever (Figure 19) when the hammer is in the cocked position (Partially cocked on DA type). The action may be opened when the hammer is cocked by manually depressing the action lock lever (Figure 20) and simultaneously pulling the forearm rearward. ‘When inspecting the chamber or to remove a live shell from the chamber, the action lock Jever is actu- ated manuaily by depressing upward into the receiver by hand and holding it into the inward position as the forend is pulled rearward to open the action (Figure 20). ° UP - UNLOCKED. ° * DOWN - LOCKED t ‘ACTION LOCK LEVER DEPRESS ACTION LOCK LEVER per Figure 19 _ Figure 20 ‘Action Lock Lever Action Lock Lever ‘Location Operation 13 3.1.2 UNLOCKING AND LOCKING As the forearm is pulled rearward, a lug on the top of the bolt slide engages a camming surface on the bottom of the bolt lock, unlocking the bolt lock from the barrel extension (Figure 21). ‘The bolt then moves rearward (Figure 22) until the bolt slide stops at the back of the receiver. On the return cycle, as the forearm is pushed forward, the lug on the top of the bolt slide contacts the camming surface on the bottom of the bolt lock. When the bolt is fully forward, the top front end of the bolt lock is cammed up, locking into the barrel extension (Figure 23). Figure 22 Bolt Lock, Unlocked Figure 23 Bolt Lock, Locked in Barrel Extension 31.3 COCKING As the bolt slide moves to the rear, it cams back the hammer assembly to single action* and depresses the disconnector, disengaging it from the sear. When the disconnector is depressed by this movement, the sear is able to reengage the sear notch in the hammer. When the bolt is returned to the fully locked position, the action lock lever is released by the bolt slide and moves up behind the back end of the bolt slide to block any rearward movement, Simultaneously, the disconnector moves up and, if the trigger is released after firing, the disconnector reengages the sear. The trigger must be fully released before the disconnector will reengage the sear. * The hammer in the double action trigger assembly is partially cocked by this movement. Pulling the trigger to the rear completes the cocking cycle and releases the hammer from the sear, firing the shot- gun. 4 3.4 FEEDING AND CHAMBERING ‘As the bolt slide nears the end of its rearward movement, it cams the elevator to its lowered position. The bolt slide also cams the cartridge interrupter into position to block a second shell from being released. Next, the cartridge stop is cammed out of the way by the left side action bar allowing the shell to be pushed onto the elevator by the magazine follower. When the bolt slide moves forward, it cams the ele- vator up bringing the shell into alignment with the chamber. As the shell is pushed forward by the bolt into the chamber, it is captured by the extractors. When the bolt nears the limit of its forward travel, the right side action bar cams the cartridge interrupter down releasing the next shell to rest against the car- tridge stop. The feeding cycle is now complete. 3.1.5 MANUAL SAFETY OPERATION AND DESCRIPTION ‘A manual safety device has been provided which prevents firing of the shotgun when in the “SAFE”, (fully rearward), position. The safety button (Figure 24) is manually moveable between the “SAFE” detent position and the “FIRE” detent position and will remain in the position set until reset manually. A red dot (located at the top rear portion of the receiver in the safety button slot) has been provided as a training aid. The user must insure the safety bution is manually set fully rearward to be in the “ON” or “SAFE” position, except when actually engaged in firing the shotgun. MOVE FORWARD TO FIRE “f— —,. MOVE FULLY REARWARD TO "ON" OR "SAFE" POSITION (es shown) Figure 24 Safety Button Position The fully rearward movement of the safety button places the safety block in a position that will inter- rupt the movement of the trigger by blocking the upward travel of the connector. Moving the safety button fully forward positions the safety block so that it no longer blocks the trigger / connector, allowing the shotgun to be fired. 31.6 FIRING Single Action Operation - Models 500° and 590° When there is a shotshell in the chamber with the bolt forward and fully locked and the safety button is in the “Off”, fully forward position, the shotgun will fire when trigger is depressed. The firing cycle begins by depressing the trigger rearward which moves the disconnector forward to disengage the sear from the hammer causing the hammer's release. The hammer, driven by the stored ‘energy in the mainspring, rotates and strikes the firing pin. ‘The firing pin in turn moves forward to strike the primer of the round in the chamber, firing that round. See Figures 25, 26 & 27. 15 Double Action Operation - Model 590DA™ ‘When there is a shotshell in the chamber with the bolt forward and fully locked and the safety button is in the “Off”, fully forward position, the shotgun will fire when trigger is depressed. The firing cycle begins by pulling the trigger to the rear which rotates the hammer by the sear until it reach- ¢s the “fully cocked” position, at which time the sear is cammed out of the way, releasing the hammer. This action causes the firing pin to be struck. A cam surface on the side of the hammer pushes down the front end of the action lock lever allowing the shotgun to be cycled after firing. See Figures 25a, 26a & 27a. There is no second strike capability. ‘The action must be manually cycled to partially cock the hammer before pulling the trigger will produce another hammer strike. As the action is moved rearward after firing, the bolt slide depresses the disconnector. ‘This “disconnects” the trigger from the sear allowing the hammer to be recocked. Figure 25 Figure 25a ‘Trigger/Sear Relationship at Rest - SA. ‘Trigger/Sear Relationship at Rest - DA Figure 26a ‘Trigger/Sear Relationship, Pulling Trigger - SA Trigger/Sear Relationship, Pulling Trigger - DA Figure 27 Figure 27a ‘Trigger/Sear Relationship, Firing - SA igger/Sear Relationship, Firing - DA 34.7 EXTRACTION AND EJECTION The fired shotshell is extracted from the chamber (Figure 28) and ejected from the receiver by pulling the forearm fully rearward. The shotshell, which is captured between the extractors and the bolt face, strikes the ejector (Figure 29) and is pivoted out through the ejection port near the end of the rearward stroke. CHAMBER ‘TAKE DOWNHOUNT EJECTOR TANG MAGAZINE TUBE “TAKE DOWN SCREW Figure 28 Receiver and Barrel Showing Chamber (Model 500° shown) Figure 29 Ejector and Ejection Port in Receiver 3.2 LOADING SAFETY WARNING: During loading, keep the muzzle pointed in a safe direction, never allow your fingers or any object to enter the trigger guard or contact the trigger, and keep the safety button in the “ON” fully rearward position. With the safety button in the “ON”, fully rearward position and the muzzle pointed in a safe direction, ‘open the action fully by pressing upward on the action lock lever at the left rear of the trigger guard while pulling back on the forearm. Insert one shell facing forward (brass to the rear) through the ejection port on the right side of the receiver (Figure 30) and close the action to chamber the shell. Hold the shotgun with the top of the receiver facing downward, muzzle forward and stock against your torso. Insert second shell nose first into magazine tube, pressing inward against the magazine follower (Figure 31) until the shell is retained by the cartridge stop. Insert additional shells in the same way until all are loaded, Figure 30 Loading the Chamber Figure 31. Loading the Magazine Tube 18 3.3. UNLOADING SAFETY WARNING: During unloading, keep the muzzle pointed in a safe direction, never allow your fingers or any object to enter the trigger guard or contact the trigger, and keep the safety button in the “ON” fully rearward position. Point the shotgun in a safe direction and move the safety button to the “ON”, fully rearward position. Depress the action lock Jever and slowly pull the forearm rearward until the live shotshell is completely withdrawn and visible in the ejection port. Cover the ejection port with a portion of your hand to prevent ejection and complete the rearward movement of the forearm to release the next shotshell onto the elevator. ‘Tur the shotgun so the ejection port faces downward to allow the two released shotshells to drop out through the ejection port and into your hand. Push the forearm completely forward, watching to be certain the bolt is closing on an empty chamber. Depress the left side internal cartridge stop in the receiver to release, one at a time, any remaining shot- shells in the magazine tube (Figure 32). Repeat until all shotshells are removed. Depress the action lock lever and pull the forearm completely rearward. Visually and physically inspect the chamber, elevator and magazine tube to insure that no shotshells remain in the shotgun. Verify by inspecting a second time. Leave the action in an open condition with the safety button in the “ON”, fully rearward position. Figure 32 Unloading the Magazine Tube 3.4 FIRING THE SHOTGUN ‘The Models 500®, 590° and 590DA" are designed as fast operating repeaters. Immediately upon firing, and as quickly as the shot charge is out of the muzzle, the action unlocks to begin the cycle for a manu- ally controlled repeat shot. However fast the action seems to be, the bolt remains locked until the shot charge is on the way to the target and the peak pressure in the barrel has passed. The Cruiser® grip shotgun is unique in that it is not shoulder fired and is only controlled by the hands. Upon firing, recoil force will cause the shotgun to move rearward and upward. To properly employ this model and avoid possible injury, grip the shotgun securely with one hand on the forearm and one hand on the pistol grip. Hold between waist level and armpit level with the hand gripping the Cruiser® grip braced against the torso when firing. This position anchors the shotgun against the torso for stability while providing peripheral aiming on the identified target. The shoulder stock models are fired with conventional shotgun techniques, from the shoulder, hip, or high tuck positions. 9 4.0 GENERAL DISASSEMBLY AND ASSEMBLY - USER LEVEL 4.1 DISASSEMBLY - SEQUENCE OF OPERATIONS BE SURE SHOTGUN IS NOT LOADED (Reference Unload Section page 19). WEAR WRAP AROUND OR SIDE-PANEL EYE PROTECTION DURING DISASSEMBLY. Unload and verify unloaded condition both visually and physically by inspecting the chamber, elevator and magazine tube. Keep muzzle point- ed in a safe direction at all times. * Move the safety button located at the top rear of the receiver to the “ON”, (fully rearward) position. * Depress the action lock lever and open the action by pulling the forearm fully rearward. + Move the forearm slowly forward until the front of the bolt is in the middle of the ejection port (Figure 33). EXECTION PORT TAKE DOWN scAEW wooeL sco Figure 33, Barrel Removal - Bolt Position 41.1 MODEL 500 + Loosen the takedown screw by turning counterclockwise until the screw threads are completely disen- gaged from the end of the magazine tube (Figure 34). nw Figure 34 Barrel Removal-Model 500° ‘Takedown Screw + Remove the barrel by alternately rotating the barrel clockwise and counterclockwise while pulling the barrel from the receiver assembly. 41.2 MODEL 590 is disengaged from the magazine tube + Loosen the magazine cap by turning counterclockwise until it thread (Figure 35) and remove. Removal of the magazine cap allows access to the magazine retainer (if applicable) and magazine spring. The magazine cap and/or retainer are under spring pressure. Wear eye protection and direct the magazine cap or retainer away from your face while removing them to avoid possible injury. {3 Figure 35 Barrel Removal - Model 590° Magazine Cap + Remove the retainer (if applicable), magazine spring, then the magazine follower from the magazine tube. + Remove the barrel by alternately rotating the barrel clockwise and counterclockwise while pulling the barre! from the receiver assembly. 42 ASSEMBLY - SEQUENCE OF OPERATIONS Make sure the shotgun is unloaded throughout the assembly procedure. Keep muzzle pointed in a safe direction at all times. Proceed as follows: + Move the safety button to the “ON”, fully rearward position. * Move the forearm until the front of the bolt aligns with the middle of the ejection port. + Insert the barrel into the receiver by pushing, and rotate the barrel clockwise and counterclockwise to fully seat. * Working away from your face, insert the magazine follower, the magazine spring then the retainer (if applicable) into the magazine tube by compressing the magazine spring (Model 590°). + Replace the (590*) magazine cap or tighten the (500*) takedown screw. + Carry out function checks - See Chapter 5.0 - Weapon Inspection on page 22. 2 5.0 WEAPON INSPECTION - ARMORER / INSTRUCTOR LEVEL 51 GENERAL ‘This section contains repair instructions and direct and general support maintenance procedures. It cov- rs the removal, disassembly, cleaning, inspection, lubrication, repair and installation of major groups and assemblies of the law enforcemeni/military shotgun. The factory certified Armorer should carry out the following inspections: 1. Function inspection 2. Parts inspection 5.2 FUNCTION INSPECTION ‘Move the safety button to the “ON”, fully rearward position (Reference Safety Section 3.1.5). In a des- ignated safe area, unload and make the weapon safe (Reference Unload Section 3.3). BE SURE THE SHOTGUN IS NOT LOADED! Keep the muzzle pointed in a safe direction throughout this function check. Visually and physically verify by checking the chamber, elevator and magazine tube. A function inspection is to be carried out on the assembled weapon: To determine cause of malfunction * Following cleaning and during weapon inspection After repair work or parts inspection. 5.2.2 TRIGGER & HAMMER MECHANISM * Close the action fully. Action lock lever should be fully down. + With safety engaged, pull trigger. Hammer should not fall. Failure requires factory repair. + Put safety in the “Off” (fire) position by pushing the safety fully forward. * Pull trigger. Hammer should fall and action lock lever should be fully up. + Hold trigger to rear and recock* hammer by opening and then closing the action fully. Hammer should not fall. + Release trigger. Hammer should not fall and trigger should return to its forward posit + Pull trigger. Hammer should fall and action lock lever should move fully up. + Release trigger and recock* hammer by opening and closing the action fully. Hammer should not fall. *Hammer of DA type will only be partially cocked. 5.23 MAGAZINE TUBE * Visually check the condition of the magazine tube, cap or takedown screw, magazine spring retainer, magazine spring and magazine follower. Make sure that the magazine is tightly fastened in the receiver. A ‘tube which is slightly loose in the receiver may be unscrewed two turns by hand only, threads degreased, Loctite* R/C 609 applied to threads, tightened by hand only, and allowed to dry before being, retumed to service. + Check for smooth movement and return of the magazine follower inside the magazine tube by pushing inward on the follower with your finger and releasing. 2 5.2.4 CHECKING HEADSPACE Headspace should be checked using the following two (2) gauges: “NO GO” and “GO” + NO GO - Install headspace gauge into chamber and close action slowly. Bolt assembly should not Jock up. Action lock lever should still be up. + GO - Install headspace gauge into chamber and close action slowly. Bolt assembly should lock up. Action lock lever should be down. Shotguns which fail either the “GO” or “NO GO” gauge checks should be reassembled with one or more of the following substitute assemblies or component parts and re-checked for proper headspace: + Barrel Assembly + Bolt Assembly + Bolt Slide 5.2.5 CYCLE OF OPERATION SAFETY WARNING: Dummy shotshells are inert shells containing no powder or live primer. ‘They should have an empty primer pocket, solid head (without primer pocket or primer) or fired (indented) primer. Dummies are not the same as “blanks”. Move the safety button to the “ON”, fully rearward position. Load two (2) DUMMY SHOTSHELLS into magazine tube Depress action lock Jever and open the action fully, one shell should feed onto the elevator. Release action lock lever and close action fully. Dummy shell should feed into chamber. Action lock lever should be fully down. Depress action lock lever and open the action fully. First dummy shell should be extracted and ejected and the second dummy shell should feed onto elevator. Release action lock lever and close action fully. Second dummy shell should feed into the chamber. Depress action Jock lever and open the action fully. Second dummy shell should be extracted and ejected. 5.3 PARTS INSPECTION 53.1 BARREL ASSEMBLY INSPECTION General + Inspect for damage which would affect function, + Inspect all parts for wear or damage by comparison to standard. + Perform headspace check (see section 5.2.4) Barrel and Barrel Extension ‘Inspect surfaces for wear or other non-conformances. * Check barrel extension for burrs or damaged bolt lock slot. * Check bore for cleanliness, corrosion or obstruction. + Ringed bores and bores ringed sufficiently to bulge the outside surface of the barre are cause for rejection. + Inspect chamber for carbon deposits and corrosion. 23 ‘Takedown Screw Assembly (Model 500°) + Inspect to make sure that retaining ring is attached to the underside of the takedown screw. += Inspect to make sure takedown screw assembly will rotate freely in takedown mount. += Inspect to make sure click ball is in place. Front Swivel Assembly * Inspect to make sure washer is under front swivel assembly or that the swivel screw is in place. Front Sight + Inspect to make sure sight is not bent, broken or loose. 5.3.2 ACTION ASSEMBLY INSPECTION General = Inspect for damage which would affect function. ‘Inspect all parts for damage or excessive wear. + Check springs for breaks or deformations. Receiver Assembly * Check to make sure that ejector screw is tight. DO NOT FORCE. ‘+ Inspect to make sure that ejector is not broken. + Check to make sure that ejector moves freely. Depress and let go. Ejector should return to original position. * Check to make sure that safety button screw is tight. * Inspect to make sure that safety button is not cracked or broken. * Check to make sure that safety button moves forward and rearward the entire length of safety button slot in receiver. Positive force should be required to move safety button, and it should click and move positively from one position to the other. * Inspect to make sure safety block is not broken or loose, and that it is installed with downward leg to the rear (see figure 11). Magazine Tube Assembly * Check to make sure that tube is not loose. * Check for exterior dents which would leave depressions on the inside of the tube and cause the magazine follower not to function properly. Magazine Follower and Magazine Spring * Inspect to see that the back end of the magazine follower is protruding into the inside of receiver ‘opening approximately 1/16 of an inch. « Inspect around outer rear edge of magazine follower where it stops in the receiver for cleanliness and freedom from corrosion which could impair functioning. * Check to see that magazine follower is free and that there is tension on it from the magazine spring by first depressing and then releasing it. The follower should forcefully return to its original position. 24 Action Slide Tube Assembly * Check to see that the assembly moves freely in its tracks in the receiver by cycling back and forth. * With action slide assembly forward, check cam surface on left hand action slide bar for damaged or broken cam surface by having bottom of receiver facing up and front end pointing away. Look down at the bottom side of the bar just behind the forearm (bar will be on your right hand side). Surface will show normal wear after use-(Figure 36). Figure 36 Action Slide Assembly Cam Inspection Check bolt slide notches in action bars located at rear end of bars for worn or broken notches. Also check for cracks at base of notches (front and back). With action slide assembly rearward, both action slide bars can be seen clearly from bottom of receiver. Forearm and Action Slide Tube Nut + Check around forearm for cracks. * With action slide assembly fully rearward, check to see that the end of the forearm and its inside surfaces are not rubbing on sides of receiver. + Check to see that forearm is tight on the action slide assembly. If loose, tighten action slide tube nut. Use caution not to cross-thread slide tube nut if removed completely, ‘Stock Assembly, Stock Bolt and Stock Bolt Washers * Check to see that stock assembly is secured tightly to the receiver assembly by trying to rotate the stock with one hand while holding the receiver tightly in the other hand (trigger housing assembly must be removed prior to checking). If it is loose, remove bottom recoil pad screw and loosen the top screw 10 pivot the recoil pad out of the way. Align stock to receiver and tighten stock bolt. Resecure recoil pad. * Models with cruiser grip must have action assembly assembled (including trigger housing assembly) prior to checking as above. * Check to see that recoil pad is secure to stock assembly. If loose, tighten recoil pad screws. 25 533 BOLT ASSEMBLY INSPECTION General + Inspect for damage which would affect function. + Inspect all parts for wear or damage. * Check springs for breaks or deformation. Bolt + Check for damage in bolt lock pin hole area and inside front surface of bolt lock slot at comers, top and bottom sides of bolt. + Inspect bolt for pitted or damaged bolt face and elongated firing pin hole. + Bolt lock should be inspected periodically for wear, paying particular attention to the rear shoulder of the lug where it meets the body of the bolt lock. Bolt lock with lug exhibiting deformation must be replaced. + Bolt Jock pin should be checked to see that it is flush or below the surface of the bolt on both sides when assembled. Extractors + Inspect for excessive wear or bending in the hook area. * Check to see that extractors are not jammed by foreign matter or dirt. * Check to see that extractor springs are unbroken and move freely. + Right hand extractor pin should be checked to see that it is flush or below the top surface of the bolt. + Left hand extractor pin should be checked to see that it is flush or below the top surface of the bolt and it is not protruding below the bottom surface of the extractor into the ejector slot. Firing Pin + Inspect firing pin for wear and burrs. + Check to see that the firing pin spring and firing pin collar are assembled correctly. 26 53.4 ELEVATOR ASSEMBLY INSPECTION + Inspect for damage that would affect function. Functional areas will show normal wear after use. ‘* Inspect for loose studs. 535 BOLT SLIDE INSPECTION + Inspect action bar lugs on each side for damage and wear. + Inspect all other areas of bolt slide that are functional for damage. Functional areas will show normal wear after use, but there should be no cracks or damage which would affect function. 53.6 CARTRIDGE STOP INSPECTION + Inspect for damaged or broken cam surface. Surface will show normal wear after use. + Inspect for damaged or broken cartridge stop surface. 53.7 CARTRIDGE INTERRUPTER ASSEMBLY INSPECTION + Inspect for damaged or broken cartridge stop surface. + Inspect for damaged or broken front tab. ‘Inspect for damaged or broken rear tab. + Inspect for loose stud on cartridge interrupter. 53.8 TRIGGER GROUP INSPECTION General + Inspect for cleanliness + Inspect for damage which would affect function. + Trigger Group is treated as a modular component. Any failure of the trigger/hammer mechanism during the function check requires a new modular component to be installed. Individual parts of the trigger group are not field serviceable. + Inspect trigger housing to see that the lugs on each side of the front end of the trigger housing which fit into the slots on each side of the receiver are not cracked or broken. * Connector top slants down to the rear. 53.9 TRIGGER HOUSING PIN INSPECTION + Inspect for worn or mutilated grooves. Replace if damaged. 53.10 RECEIVER INSPECTION + Ejector undamaged. + Ejector screw tight in receiver. + Safety button undamaged. * Safety button screw is tight. * Safety button clicks and moves “positively” from one extreme to the other. D 6.0 CLEANING AND LUBRICATION 6.1 GENERAL - WEAR EYE PROTECTION DURING ALL PROCEDURES ‘The shotgun must be stored in a dry location. Humidity, rapid temperature changes and environmental conditions are detrimental and encourage corrosion. If the shotgun is to be stored for extended periods, lubricate all internal and external components and leave all metal surfaces with a thin film of rust pre- ventive lubricant. Clean the shotgun after each use and afier exposure to dirt, dust, wet weather, condensation, perspiration, or other moisture or adverse environmental conditions. Your role in the performance of cleaning and lubrication is to: + Be sure the shotgun has been safely unloaded and all ammunition has been removed from the work area before performing any cleaning procedure. + Depending on agency policy, properly clean and lubricate the shotgun each time the weapon is fired or exposed to adverse environmental conditions. + Perform routine maintenance (cleaning, inspecting and lubricating) on a regular schedule. * Understand your agency's policy on the maintenance, repair, or replacement of unserviceable weapons. ‘+ Understand any liability issues related to improper maintenance, unauthorized repair, or unauthorized modification to the weapon system. + Use the appropriate tools, lubricants and solvents in the recommended manner when performing ‘weapon maintenane: + Make sure the barrel is free of obstructions and excessive lubricant after cleaning. 62 CLEANING EQUIPMENT Cleaning Rod ‘The cleaning rod is used to push cleaning attachments, i.e., brushes, patches or jags through the barrel. ‘The cleaning rod should be inserted from the chamber end of the barrel when possible. It should be long enough to pass completely through the barrel and strong enough to resist bending when pressure is applied. Bore Brush Bore brushes can be of several types: nylon, brass or bronze, and stainless steel. The brass or bronze brush is recommended for cleaning the bore. Nylon bristles are rarely strong enough to loosen bore fouling and stainless steel bristles are overly aggressive due to their stiffness. Do not reverse direction while the brush is actually in the barrel, as scoring or scratching may result. Instead, push the brush slowly all the way through and out of the barrel before reversing direction. ‘This will maximize the cleaning potential of the bore brush, as well as maintain its usefulness over a longer peri- od of time. Slotted Patch Holder and Jag ‘These devices are used for pushing the patches through the barrel. The slotied tip allows the patch to be moved through the bore primarily for solvent or lubricant distribution. The jag allows for a more precise fit of the patch in the bore to enhance removal of firing residue. Use the correct diameter jag to ensure a tight fit of the patch in the bore. 28 Patches Patches are either round or square and should be made of soft, absorbent material: Some patches have a woven side and a fibrous side. The woven side may assist in introducing solvent into the barrel and provides a scrubbing surface, while the fibrous side may be used to remove the residue left by the sol- vent’s chemical action. Patches may also be used to dry the bore and lightly lubricate the entire shotgun. Barrel mops are also helpful. Cleaning Solvent ‘There are many commercially available cleaning solvents that do an excellent job of removing powder residue, metal fouling and plastic fouling. Cleaning solvents should be used to loosen and remove pow- der residue and copper, lead and plastic fouling. Use cleaning solvents that are manufactured for weapon use only. If a cleaning solvent is used, be sure all solvent is removed before applying any lubricant as the solvent will reduce the effectiveness of the lubricant. Exercise caution when using strong solvents to avoid exposure to camouflage surfaces. Lubricant/Preservative Use a good, commercially available lubricant/preservative to lubricate moving parts to reduce friction and wear. A thin coating should also be maintained on all metal surfaces except the receiver to prevent rust or corrosion. Solvent Brush ‘A nylon brush with solvent can be used to clean areas of the weapon that are hard to reach. A solvent- moistened brush works well on the interior of the receiver, the bolt assembly, behind the extractors, and any other location where firing residue may accumulate. Dry Brush ‘A dry nylon brush makes the cleaning process easier in areas where solvent is not desired. Cleaning Cloth {A clean, absorbent, lint free cloth is necessary for cleaning the weapon and to protect it from hard sur- faces during the cleanirig process. Cheese cloth is recommended. ‘Treated Cloth There are a number of separate applications for the treated cloth. This makes it extremely important to read the instructions on the packaging concerning both use and storage. The most widely used cloths are impregnated with a finish preservative. Silicon, microscopic solids, or petroleum based substances are used to cover surface areas of shotguns to prevent deterioration of the finish due to oxidation and corrosion. Other types of cloths are designed for lead removal in the bore as well as fouling accumulation elsewhere. ‘These cloths may contain abrasive particles which are harmful to the weapon's finish, and should only be used following the manufacturer's recommendations. 63 CLEANING PROCEDURES - EYE PROTECTION REQUIRED After unloading (Reference Unload Section 3.3) your firearm, field disassemble in accordance with instructions in Section 4.0. After the shotgun has been field disassembled, it is to be cleaned as follows: Barrel Bore Dip the bore cleaning brush in bore cleaning solution and brush the chamber and bore from the chamber end of the barrel. Push the brush completely through the chamber and bore. Continue the reciprocating brushing motion until the chamber and bore are well covered with solution and fouling is loosened. Then remove solvent and fouling using clean, dry patches. When wiping out the barrel chamber and bore, use a new patch inserted in the cleaning rod slotted patch holder for each pass through the barrel. Continue this process until a patch comes out of the barrel clean and dry. Repeat brushing with solvent as needed to remove all fouling, then repeat dry patches through bore. Finish with a patch lightly moistened with lubricant/preventative to establish a rust-preventative coating. Barrel Assembly and Bolt Assembly Use the solvent brush with bore cleaning solution and clean all carbon and powder residue from the shell headseat and extractor cuts in barrel, bolt lock detent in barrel extension and the bolt face. Also carefully clean under the hooks of the extractors. Other Metal Surfaces ‘Using the solvent brush and cleaning solution, clean the balance of the surfaces on all metal parts. Carefully clean around the ejector. With the exception of the receiver, all metal surfaces should be covered with a thin film of rust preventing lubricant. Wipe all metal parts of the shotgun with clean, dry, cleaning cloths or patches. CAUTION: Take care to dry all excess solvent and lubricant from the chamber, bolt face and inside of magazine tube as excess solvent or lubricant in these locations can affect ammunition primers and cause misfires. ‘Wood Parts ‘Wood parts of the stock and forearm may be cleaned hy wiping with a slightly oily rag and then polish- ing with a clean dry rag. When wooden parts have a rubbed oil finish without varnish, a light applica- tion of raw linseed oil should be applied with a rag and rubbed into the wood. Care should be observed to prevent linseed oil from getting on metal parts or into mechanism of gun as it becomes gummy when dry. Dispose of treated rags in accordance with oi] manufacturer's instructions. 64 LUBRICATION ‘The purpose of lubrication is to provide a molecular barrier between metal parts to reduce friction, wear and prevent build-up of firing residue. A lubricant/preservative is used to maintain the integrity of the finish by establishing a molecular barrier between the shotgun’s surface areas and its environment. These products are available in a number of different consistencies that range from grease, to liquid, to dry, all of which have an application. (See CAUTION in section 6.3) 65 REASSEMBLY After shotgun has been lubricated, assemble in accordance with instructions in Section 4.2. 66 REQUIREMENT FOR FUNCTION INSPECTION Perform function inspection in accordance with instructions in Section 5.2. 30 7.0 DISASSEMBLY INSTRUCTIONS - ARMORER LEVEL 741 GENERAL This chapter contains instructions for the armorer on disassembly of the shotgun that are not covered in Chapter 4.0 General Disassembly and Assembly. The information and instructions provided in this chapter are beyond the scope of the training available to the operator. 72 TOOLS REQUIRED ‘The tools needed by the armorer to perform the required disassembly are: 1 ToolBox 13.10" Extension 2. Assembly/Disasserbly Mat 14 Stock Bolt Bit 3.Pin Pusher 15. Magna-Tip Law Enforcement Handle 4, GuPats Cleaning Brush 16. 180-4 Bit (for safety) 5. Clymer 12 ga. “Go” Gauge 17. #1360 Phillips Bit (for recoil pads & butt plate) 6. Clymer 12 ga. “No Go” Gauge 18. #300-5 Bit (for ejector) 7.1" NylowBrass Hammer 19. Mossberg® 500° Forend Wrench 8. 1" Nylon/Brass Punch Set 20. Long Shaft Flat Head Screwdriver (7/4" shaft, 9. 1/8" Starrett Punch 1/2" head) 10. 1/16" Starrett Punch 21. Safety Glasses 11, 5/32" Starrett Punch 22. Center Punch 12. “T” Handle 23. 1/2" Socket 73 DISASSEMBLY Disassemble the components to be examined or repaired only to the extent needed to repair or replace a part. The figures that follow have step by step instructions to accomplish the disassembly. Detailed dis- assembly and maintenance should be conducted by trained armorers at intervals of 12 months or 3000 rounds, whichever comes first. 734 TRIGGER GROUP REMOVAL * Position the receiver on a clean surface with the trigger guard facing up. Using a 1/8” diameter punch, push out the trigger housing retainer pin. + Remove the trigger group by rotating the rear portion up and out. (Figure 37). Figure 37 ‘Trigger Group Removal HOLE FOR TRIGGER HOUSING RETAINER PIN CAUTION: Do not pull the trigger and allow the hammer to fall when the trigger group is removed from the receiver, without -using your thumb to restrain the movement of the hammer. To do so may result in personal injury or damage to the assembly. The trigger group is treated as a modular component. Any failure of the trigger/hammer mechanisms during the User Level Function Check and verified by the armorer requires a new modular component to be installed. Individual parts of the trigger group are not field serviceable. 31 7.3.2 REMOVAL OF INTERNAL RECEIVER COMPONEN’ NOTE: Before performing any further disassembly, study how the internal components are arranged inside the receiver. The position of the bolt, bolt slide and action slide bar assembly must be in the same relationship during reassembly. + Remove barrel. + Remove the cartridge interrupter from the ejection port side of the receiver and cartridge stop from the opposite side of the receiver (Figure 38). (It may be necessary to tap the sides of the receiver lightly with a plastic hammer to release these parts). ance wremnren Figure 38 Cartridge Stop and Interrupter Assembly Figure * Pull the forearm/action slide assembly to the rear so that the bottom of the bolt slide is aligned with the clearance cuts in the sides of the receiver. From the rear, lift the bolt slide up and out of the receiver Figure 39). Figure 39 Bolt Slide Removal from Receiver ‘+ Remove the forearm carefully by pushing it forward and off of the magazine tube. + Remove the bolt assembly by pushing forward on the bolt and withdrawing it from the barrel opening in the receiver (Figure 40). + Remove the elevator by pivoting it upward, then compressing the sides simultaneously to release the buttons from their corresponding holes in the receiver (Figure 40). Figure 40 Bolt and Elevator Assembly 7.3.3 DISASSEMBLY OF BOLT ASSEMBLY NOTE: Use a 1/16” diameter drive pin punch when removing right hand extractor, left hand extractor or firing pin retaining pins. Use a 1/8” diameter drive pin punch when removing bolt lock pin. sassembly of Extractors NOTE: Extractors do not have to be removed in order to disassemble bolt lock and firing pin. « Extractors are spring loaded. Apply pressure on extractor to be removed to avoid Joss of parts. Remove extractor retaining pin from bottom side (Figure 41). Figure 41 Removal of Extractor Pins + Remove extractor and extractor spring (Figure 42). + Repeat this process to remove other extractor retaining pin, extractor and spring. Figure 42 Extractors Removed Disassembly of Bolt Lock and Firing Pin + Remove bolt lock pin from right side (Figure 43). Note: Bolt lock pin is not reusable! Replace with a new pin. Figure 43 Bolt Lock Pin Removal S 33 + Bolt lock pin and bolt lock removed (Figure 44). —& a Bolt Lock Removed ee + Remove firing pin retaining pin from bottom side (Figure 45). Note: Firing pin retaining pin is not reusable! Replace with a new pin. Figure 45 Firing Pin Retaining Pin Removal ‘+ Removal of component parts. (Figure 46). 3 LEGEND Figure 46 1, gam ining vi 1. Firing pin retaining pin ‘i Firing Pin Removed 2. Firing pin . 3. Firing pin spring ox 4. Firing pin washer 5. Bolt 134 DISASSEMBLY OF ACTION SLIDE ASSEMBLY Disassembly of Forearm + Remove action slide assembly/forearm assembly from action. + Slide forearm wrench into magazine tube nut with lugs on end facing forearm. + Engage lugs of wrench into slots in action slide tube nut and unscrew nut counterclockwise (Figure 47). Figure 47 Figure 48 Action Slide Tube Nut Removed 71.3.5 DISASSEMBLY OF EJECTOR + Using a flat blade screwdriver, unscrew the ejector screw counterclockwise (Figure 49). Note: The ejector is secured using LocTite” - Use caution and direct pressure to avoid stripping ejector screw. Note: Tapping or adding heat to dislodge LocTite* may be necessary. Figure 49 Ejector Screw Removal Figure 50 Fjector Removed 7.3.6 DISASSEMBLY OF SAFETY BUTTON + The safety button is attached with a one way screw. To remove, proceed as follows: with the receiver secured in a padded vise, place prick punch point on screw as shown in (Figure 50a). By lightly tapping the punch, the screw may be loosened sufficiently to be removed with an ordinary flat bladed screwdriver (Figure 50b). * Safety bution screw, safety button, safety detent plate and safety block removed with safety detent ball and spring shown (Figure 50c). Note: Maintain a surplus supply of safety button screws. " Figure 50c Figure 50a Figure 50b igi Prick Punch Placement Safety Button q Safety Removal Screw Removal ae ‘\ 7.3.7 DISASSEMBLY OF STOCK e Disassembly of Shoulder Stock + Using a Phillips screwdriver, unscrew (counterclockwise) bottom recoil pad screw and remove. + Loosen top recoil pad screw. ‘+ Swing recoil pad out of the way to expose the stock bolt hole. + Insert wrench into stock bolt hole, engage and unscrew bolt counterclockwise (Figure 51). (Note: Older versions may have a slotted screw head, requiring a long-shanked flat-blade screwdriver for removal.) Figure 51 Stock Bolt Removal Disassembly of Cruiser Grip + Using a long arm 1/4” hex key, insert it into stock bolt and unscrew bolt counterclockwise (Figure 52). Figure 52 Cruiser Grip Removal 36 738 DISASSEMBLY OF MAGAZINE TUBE Note: Magazine tube is screwed into receiver using Loc-Tite. Solvent or careful application of heat may be used to soften the Loc-Tite bond. 1. Insert forward end of magazine tube assembly into a vise no more than 1” (to avoid crushing tube) and tighten vise (Figure 52 a) Figure 52 (a) Magazine Tube Locked in Vise Note: Inside of vise jaws should be lined with leather or other suitable material to prevent scratching of tube. Note:A metal, plastic or hardwood plug of proper diameter can be used inside the end of the Model 590 ‘magazine tube to prevent it being crushed in the vise. Note: A strap wrench may be used instead of the vise to grip and turn the magazine tube. 2. (a) Insert wrench or block into receiver. (b) ‘Unscrew magazine tube assembly by revolv- ing receiver counterclockwise (Figure 52b). Figure 52 (b) ‘Magazine Removed NG 3. Remove magazine tube assem- bly, magazine spring and maga- zine follower. (Figure 52c). s—_]q somn§_—§ —_—_—_> Figure 52 (c) Magazine Tube Removal 8.0 ASSEMBLY INSTRUCTIONS - ARMORER LEVEL 8.1 GENERAL This chapter contains assembly instructions that are not covered in Chapter 4.0 General Disassembly and Assembly. The information and instructions provided in this chapter are normally beyond the scope of the training available to the operator. 82 ASSEMBLY The figures that follow have step-by-step instructions for assembling the components that were disassembled in Chapter 7. 824 BOLT ASSEMBLY Assembly of Firing Pin and Bolt Lock + Insert firing pin into rear of bolt. + With front end of firing pin partially protruding into bolt lock slot, install firing pin washer over front end of firing pin. «Install firing pin spring over front end of firing pin. + Insert front end of firing pin into front firing pin hole in bolt (Figure 53). Figure 53 Firing Pin and Spring Installation + Insert new firing pin retaining pin from top side with grooved end sticking out. + Make sure that the flat on the rear end of firing pin is parallel to the retaining pin. This can be seen from the rear end of bolt. * Drive the end of the pin in flush with the top of the bolt (Figure 54). Figure 54 Firing Pin Retaining Pin Installation 38 ‘+ Make sure firing pin moves freely and fully rearward. * Using rear end of bolt lock, compress front end of firing pin spring rearward and insert bolt lock (from top side) into bolt lock slot over firing pin. ‘= Insert new bolt lock pin from left side into bolt and partially into bolt lock. = Drive the pin in so that it is flush on both sides of the bolt. ‘Test to insure that pin fits properly and is not loose (Figure 55). NOTE: Always replace bolt lock pin with a new pin when bolt disassembly occurs. Figure 55 Bolt Lock Pin Installation Assembly of Extractors NOTE: The right and left hand extractors are different. The right extractor has a sharp angle and the left extractor has a round angie. Also, the left side extractor retaining pin is shorter than the right side extractor retaining pin. Right hand extractor retaining pin and firing pin retaining pin are identical. + Insert extractor spring into extractor spring hole. + Insert extractor into extractor slot with rear end over extractor spring. * Insert new extractor retaining pin, grooved end up, into bolt and partially into extractor while holding extractor in slot (Figure 56). 0 Figure 56 Extractor Placement a + While stil holding extractor, drive pin in the rest of the way, flush to below radius of the bolt. (Figure 57). + Repeat above procedure to install remaining extractor. Figure 57 Bolt Assembly 39 822 ASSEMBLY OF INTERNAL RECEIVER COMPONENTS. Assembly of Ejector + Clean and dry ejector screw threads, apply one drop LocTite* R/C 609 to threads. Place ejector in receiver. Using a flat blade screwdriver, turn the ejector screw clockwise and tighten securely (Figure 58). Figure 58 Ejector and Ejector Screw Assembly of Safety Button * Position safety detent spring in hole in receiver, with safety detent ball on top of spring. * Position safety block in place from inside of receiver, being sure downward extension is to the rear of receiver (see figure 11). Hold safety block in place with fingers. + Position safety detent plate and safety button in place, taking care not to dislodge safety detent ball. ‘Holding parts in place with fingers, insert and tighten safety button screw. Figure 59 Action Bar Assembly to Receiver Assembly of Action Slide and Forearm Assembly * Check to be certain that the safety button is in the “ON”, fully rearward position. Slide the action slide onto the magazine tube while guiding the action slide bars into the corresponding cuts in the inside front of the receiver (Figure 59). * Slide forearm over action slide tube. * Thread tube nut to slide tube (do not cross-thread, start nut carefully, threads are very fine). Assembly of Elevator, Bolt and Bolt Slide + Assemble the elevator by squeezing the arms together sufficiently to position them in the receiver so that the studs on the elevator fit into the corresponding (1/4") diameter holes in the receiver (Figure 60). Figure 60 Bolt and Elevator Assembly * Pivot the elevator so that its forward portion is even with the outside edge of the opening in the receiver. * Insert the rear of the bolt assembly into the barrel opening of the receiver. Depress the ejector (located in the side of the receiver opposite the ejection port) to allow the bolt assembly to slide fully rearward into the receiver. The ejector must fit into the corresponding slot in the bolt (Figure 62).. + Move the elevator down until it rests against the extractors in the bolt. + Position the rear of the bolt assembly even with the rear of the clearance cuts in the sides of the receiver (Figure 61), + Position the forearm assembly so the front edges of the action bar slots are even with the front edge of the clearance cuts in the front of the receiver. : a bolt a should be positioned with the hook end downward and toward the front of the receiver ‘igure 61). + Assemble the bolt slide, hook end first, lowering the front (hook end) of the bolt slide so that it hooks into the corresponding cut on the bottom of the bolt lock and action bar slots (Figure 62). + Hold the bolt slide down and move the forearm assembly forward. The bolt and bolt slide should move freely in their cuts in the receiver. If parts do not slide easily - DO NOT FORCE - disassemble and reassemble, paying attention to the relationship of the bolt, bolt slide and action slide bars. BOLT SLIDE [ACTION SLIDE BAR ACTION SLIDE BAR eour ReceweR Figure61 Figure 62 Bolt Slide Assembly to Receiver Bolt Slide Assembly to Receiver Step 1 Step 2 4 Assembly of Cartridge Stop and Interrupter * Position the cartridge stop and cartridge interrupter in their proper places on the inside walls of the receiver (Figure 63). + The hooks must face inward toward the center of the cavity away from the receiver walls. ‘CARTRIDGE INTERRUPTER Figure 63 oomees Cartridge Stop & Interrupter Assembly to Receiver ‘Trigger Housing Assembly Installation NOTE: Hammer must be in the fully-cocked (single action) or partially cocked (double action) position to allow the trigger housing to be inserted in the receiver. Make sure all pins are flush! ‘+ Hold the cartridge stop and cartridge interrupter in place firmly against the receiver walls with one hand and grasp the trigger housing assembly with the other. + Insert the lugs on each side of the front comer of the trigger housing into the slots on each side of the receiver. Ease the rear of the housing assembly down and into position. DO NOT FORCE! (Excessive force can deform or break the ears on the trigger housing). + Align the trigger housing pin hole in the trigger housing assembly with those in the receiver. Insert trigger housing pin and push in fully until flush with the side of the receiver (Figure 64).. ‘RIaGER HOUSING LUGS ®> 4) necevensior | [Ao WEG P Figure 64 ‘Trigger Group Assembly to Receiver HOLE FOR TRIGGER HOUSING PIN NOTE: If the trigger housing does not easily fit into place, check that all internal pins in the trigger hous- ing are flush with the sides of the housing and that the cartridge interrupter and cartridge stop are posi- tioned properly. a2 82.3 BARREL REASSEMBLY Model 590° - insert magazine follower into the forward end of the magazine tube being sure that the closed end of the follower enters the magazine tube first. Insert the magazine spring next, followed by the magazine spring retainer (if applicable). * Visually inspect the inside of the barrel to make certain it is free of any obstructions, excessive oil or grease. Failure to do so may result in weapon damage and/or serious personal injury when the shotgun is fired. + Move the safety button to the “ON”, fully rearward position. * Depress the action lock lever and pull the forearm rearward until the front of the bolt is in the middle of the ejection port. * Slide the barrel into the receiver and tighten the takedown screw (Mode! 500*) or magazine cap (Model 590°), finger tight only. DO NOT use pliers or a wrench to tighten. A little space between the magazine tube and the takedown screw on the Mode! 500° is normal. On the Model 590°, the magazine cap should fit snug against the takedown lug. NOTE: Check to be certain that the barrel is fully seated into the receiver by looking through the ejection port. The barrel extension must rest firmly against the corresponding cut (shoulder) in the top, inside of the receiver. Figure 65 Receiver and Barrel Showing Barrel Seat 824 ASSEMBLY OF STOCK * Put lock washer on stock bolt, followed by the flat washer. Note: Failure to use both washers may allow stock bolt to protrude too far into receiver, damaging Trigger Group. * Insert stock bolt with two washers into the stock bolt hole in the rear of the stock. + Mate the stock to the receiver. Note: The stock has an annulus on the front surface which fits into a corresponding annular groove in the back of the receiver. * Using stock bolt wrench or Jong flat blade screwdriver, screw stock bolt into receiver and tighten Figure 66). * Reinstall buttplate or recoil pad using a Phillips head screwdriver. Figure 66 Stock Bolt Installation 9.0 FINAL INSPECTION / CERTIFICATION FOR DUTY 91 GENERAL ‘This chapter contains instructions for the final inspection of repaired shotguns and those subject to sched- uled maintenance. As applicable, the shotgun should be checked in accordance with the procedures out- lined herein. BE SURE SHOTGUN IS NOT LOADED! VISUALLY AND PHYSICALLY INSPECT CHAMBER, ELEVATOR AND MAGAZINE! 92 VISUAL INSPECTION Overall appearance shall be approximately that of a new shotgun. 9.2.1 METAL COATINGS Suitable touch-up solutions may be used on alloy parts. 92.2 CORRODED COMPONENTS Corroded components must be replaced. 93 FUNCTIONAL INSPECTION The instructions for accomplishing a functional inspection are contained in Chapter 5.0. In addition, the shotgun shall be tested by firing (5) service rounds. 94 LOGBOOK A log book should be maintained on all shotguns indicating dates of inspection, service and repair, problems noted, specific parts replaced or adjustments made, and name of armorer performing the work. 10.0 DIAGNOSTICS AND TROUBLESHOOTING ‘The troubleshooting instructions which follow are to aid the armorer to diagnose and restore worn, dam- aged or inoperative shotguns to a serviceable condition. The listed probable causes and corrective actions are neither exhaustive nor all-encompassing. If the armorer cannot restore the shotgun to a reliable func- tioning condition, he/she should contact the Customer Service Department and/or return the firearm to Mossberg for inspection and repair. Malfunction Probable Cause Corrective Action Failure to fire Safety is “On”. Move to forward (fire) position. (no primer indent) (fully rearward position) Failure to fully lock. See Corrective Action under “Failure to Fully Lock”. Damaged firing pin. Replace. Improper assembly of Remove firing pin and install firing pin in bolt assembly. correctly, using new retaining pin. Failure to fire Defective ammunition Use proper ammunition (primer indented) Failure to Unlock ‘Action lock lever not up. Depress action lock lever. Replace trigger housing assembly. Bolt assembly or barrel Hold shotgun pointing up, assembly damaged, or depress action lock lever extension burred or dirty. and strike butt sharply on ground ‘or rubber block while pulling back on forearm, WARNING: Make certain to be clear of muzzle. Point muzzle in safe direction. Make sure safety button is in the “on” position. Keep finger ‘outside trigger guard. Strike butt squarely on ground or rubber block to Prevent damage to stock. Replace damaged components. Trigger group inoperative. Replace. Failure to Extract Powder residue, rust or dirt Clean chamber. in chamber, Inegular chamber surface. Replace bairel. Powder residue and dirt Disassemble and clean. build-up in extractor recesses or under extractor hooks. Damaged or missing Replace. extractors, extractor springs, or pins. 45 Malfunction Failure to Eject Failure to Remain Cocked Probable Cause Corrective Action Loose ejector screw. Clean, apply LocTite®, tighten. Broken ejector. Replace, Damaged extractors, Replace. extractor springs, or pins. Right and left extractors Remove and reassemble reversed. properly. Trigger group inoperative. Replace. Failure to Feed (onto elevator) Loose magazine tube. Degrease threads, apply LocTite* and tighten by hand (see 5.2.3). Dirty magazine tube. Disassemble Cap, Retainer, ‘Spring, Follower and clean. Damaged magazine tbe. Replace. Damaged cartridge stop. Replace. Demaged cartridge: Replace: interrupter Weak magazine spring. Replace. Shell drops from Cartridge stop. Replace. magazine through loading port. Double Feed Cartridge interrupter Replace. assembly. Failure to Fully Lock Damaged or defective Replace. ammunition. Debris, damage or corrosion Clean, ‘on bolt lock, barrel extension locking lug or bolt face. Jammed extractors. Remove, clean and lubricate. Dirty chamber. Clean. Doon Action lock lever not #p Check bolt slide position and (trigger group). bolt lock in barrel extension. Inoperable or Damaged Safety Replace parts as needed and function check. 4 SECTION 11.0 - APPENDIX APPENDIX A - Shotgun Cleaning Kit {Storage Case 3. Cleaning Rod 4, Gun LubricanuPreservative 5. Solvent (bore cleaner) 6. Bronze Bore Brush 7. Slotted Cleaning Tip 8 Cleaning Patches 9. GunvParts Cleaning Nylon Brush APPENDIX B - Armorer's Kit 1. Too! Box 2, Assembly /Disassembly Mat 3. Pin Pusher 4. Gun/Parts Cleaning Brush 5. Clymer 12 ga. “Go” Gauge 6. Clymer 12 ga. “No Go" Gauge 7. 1 NylowBrass Hammer 8.1" NylowBrass Punch Set 9. 1/8" Starett Punch 10. 1/16" Starrett Punch 13, $232" Surrett Punch 12.1" Handle APPENDIX C — Special Tools 1. LocTite* R/C 609 2. Magazine Tube Cap Pliers 3. Smooth American Cut 8" File File Handle (for above file) ‘5. Magazine Tube Torque Tool 13. 10" Extension 14, Stock Bolt Bit 15. Magna-Tip Law Enforcement Handle 16, 180-4 Bit (for safety) 17-41360 Phillips Bit for recoil pads & butt plate) 18. #300-5 Bit (or ejector) 19. Mossbers® 500° Forend Wrench 20. Long Shaft Flat Head Screwdriver 21. Safety Glasses, 22. Center Punch 23. 172" Socket APPENDIX D ~ Exploded Views and Part Descriptions MIA CACOTdXa VIL oe r u t B . “A ; oe - 2 ve reer) AY A ; P

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