Merkel Shotgun Instructions Manual

							bore if (assuming the trigger has been pulled with a live shotshell in the
chamber) the shotshell contains no powder, or the powder fails to ignite,
and only the primer charge ignites, resulting in insufficient force to pro-
pel the wad or shot column out of the bore.  Whenever an obstruction
occurs, keep the muzzle of the shotgun pointing in a safe direction and
proceed as follows:
¥  Any shotshells should be removed.
¥  Insert a proper size cleaning rod (without a tip or brush) into the bore
from the muzzle and remove the obstruction. If the obstruction does not
readily dislodge, it may be necessary to lightly tap the handle end of the
cleaning rod. Do not attempt to remove an obstruction using a blank
shotshell, or a shotshell from which the shot or projectile has been
removed, or by any other means other than the use of a cleaning rod.
Be certain all loose powder has been removed from the bore and action
before inserting the rod. If you are unable to remove the obstruction,
take the shotgun to the nearest repair facility, or call GSI Inc., 108
Morrow Avenue, P.O. Box 129, Trussville, Alabama 35173, Tel. (205)
655-8299.
¥  After removing the obstruction, reinspect the bore to be certain it is
free of powder particles or other debris. Clean the mechanism of
unburned powder grains.
REMEMBER!  ALWAYS CHECK THE BORE FOR AN OBSTRUC-
TION IF YOU EXPERIENCE DIFFICULTY IN CHAMBERING A
SHOTSHELL, EXPERIENCE A FAILURE TO EXTRACT, HAVE A
MISFIRE, OR THE SHOTGUN DOES NOT MAKE A NORMAL
LOUD REPORT ON FIRING.  A MISFIRE OR UNUSUAL
REPORT IS ALWAYS A SIGNAL TO CEASE FIRING.  FOLLOW-
ING A MISFIRE OR AN UNUSUAL REPORT, KEEP THE MUZ-
ZLE POINTED IN A SAFE DIRECTION AND WAIT TWO MIN-
UTES BEFORE UNLOADING THE CHAMBER AND EXAMIN-
ING THE BORE OF THE SHOTGUN.
WARNING!  IF A LOADED SHOTSHELL IS LODGED IN THE
CHAMBER, DO NOT ATTEMPT TO REMOVE A LODGED
SHOTSHELL BY USING A CLEANING ROD.  TAKE THE
SHOTGUN TO THE NEAREST REPAIR FACILITY, OR CALL
GSI, Inc., 108 Morrow Avenue, P.O. Box 129, Trussville,
Alabama 35173, Tel. (205) 655-8299.
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							11
Forearm Bracket
Forearm Latch 
Forearm  Barrel
Muzzle
Forearm Lug
TriggerReceiver Barrel Lugs
Hinge Pin
Buttstock Hinge Pin RecessChamber
Safety Top Lever
Figure 1-Parts Identification 
						

							MERKEL
Over & Under Shotguns
SPECIAL NOTE:
Unlike most firearms, your Merkel shotgun is individually handcrafted by
skilled gun makers who have inherited and acquired their skills from genera-
tions of the master gun makers in Suhl, Germany. Upon assembly you will
notice that the working parts of your shotgun will have distinctive tight fit-
ting characteristics and may therefore, be somewhat difficult to open, close,
and lock the action.
These characteristics are typical of quality hand-fitted shotguns that are built
to the highest standards of precision machining. After initial firing of 100-
200 rounds the shotgun action will begin to work more smoothly and will be
easier to operate.
SERIAL NUMBER 
The serial number of your Merkel Shotgun is engraved on the receiver and
the barrel. It is a good practice to record the serial number in a separate
ledger for future reference.
GENERAL SPECIFICATIONS
Merkel Over & Under shotguns are two barreled firearms with the barrels
aligned one over the other with the sighting rib positioned along the center
of the top barrel.  Traditional models are typically equipped with two triggers
each of which correspond to its respective barrel. A single selective trigger
model is also available.
OPERATION OF SHOTGUN SAFETY MECHANISM
The shotgun safety mechanism is located on the tang of the receiver assem-
bly just in front of the buttstock on the top side (See figure 2).  The shotgun
is in the Safe position when the safety is moved fully rearward and the let-
ter S appears on the receiver tang directly in front of the safety. In this
position sear engagement is blocked to prevent discharge under non-firing
conditions.
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							Figure 2 Over & Under Safety Mechanism
WARNING! SAFETIES ARE MECHANICAL DEVICES THAT MAY FAIL
OR MALFUNCTION LIKE ANY OTHER MECHANICAL DEVICE!
ALWAYS HANDLE THE SHOTGUN CAREFULLY AND DO NOT PER-
MIT THE SHOTGUN TO POINT IN AN UNSAFE DIRECTION!
ALWAYS TREAT THE SHOTGUN AS IF IT WERE LOADED AND
READY TO FIRE! ALWAYS OBSERVE SAFETY RULES WHEN HAN-
DLING THE SHOTGUN! THE SAFETY SHOULD ALWAYS BE IN THE
ÒSAFEÓ  POSITION  EXCEPT WHEN THE SHOOTER IS ACTUALLY
FIRING THE GUN. THE SAFETY SHOULD BE MOVED TO THE
ÒSAFEÓ  POSITION  WHENEVER THE SHOOTER CEASES FIRING,
EVEN TEMPORARILY. KEEP THE MUZZLE OF THE SHOTGUN
POINTED IN A SAFE DIRECTION AT ALL TIMES!
ATTENTION-MANUAL SAFETY MECHANISM!
THE SAFETY PROVIDED ON MERKEL OVER & UNDER
SHOTGUNS IS MANUALLY OPERATED AND DOES NOT
OPERATE AUTOMATICALLY. THE SHOOTER MUST
MANUALLY MOVE THE SAFETY TO BOTH ITS SAFE
AND FIRE POSITION. FAILURE TO MANUALLY MOVE
THE SAFETY TO ITS DESIRED POSITION COULD CAUSE
AN ACCIDENTAL DISCHARGE!
Safety
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							When the safety is indexed forward to its most forward position the shotgun
is in its firing mode. In this condition the trigger(s) can be pulled to fire the
shotgun. The letter S inscribed on the tang of the receiver will be covered
and obscured from view in this condition.
When you are not using your shotgun, be sure your gun is pointed in a safe
direction, avoid contact with the trigger and make sure the safety is in its
ÒSafeÓ position to prevent accidental discharge. Maintain the shotgun safety
in the Safe position at all times, unless you are actually firing the gun.
DOUBLE TRIGGER SHOTGUNS
On shotgun models equipped with two triggers each trigger operates its
own barrel. The front trigger will fire the bottom barrel and the rear trig-
ger will fire the top barrel. Do not pull both triggers at the same time in
order to avoid excessive recoil or kick from simultaneous discharge of
both barrels.
SINGLE SELECTIVE TRIGGER SHOTGUNS
Shotguns with single triggers are equipped with a barrel selector located
on the upper portion of the trigger assembly (See figure 3). The barrel
selector can be indexed to the right or left with the firing finger. The
position of the barrel selector controls the firing order of the two barrels.
When the selector is positioned to the right the bottom barrel fires first
and the top barrel will be subsequently discharged when the trigger is
pulled a second time. The top barrel is fired first when the selector is
positioned on the left side of the trigger. Ensure that the safety is in the
ÒSafeÓ or  ÒSÓ position, and be careful to avoid contact with the trigger
mechanism when the barrel selector is being moved.
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							Figure  3 - Barrel Selector on Single Trigger Shotguns
TOP LEVER
The top lever operates the locking bolt, which securely aligns and clasps
the barrel assembly shut to the receiver for firing. The locking bolt and
barrel lugs are designed for gradual wear of locking surfaces and may
therefore exhibit tight fitting characteristics during initial use. The close
tolerances of these locking surfaces ensure that the breech of the shotgun
remains tight throughout use.
When closing the breech of the action let the top lever move freely to
its locked (in line with the safety) position (see figure 5). Do not restrain
its travel with your thumb.
It is recommended that the top lever be indexed to the left in its locked
position with slight finger or thumb pressure to make sure that the bolt is
fully closed. If the bolt does not fully close it is possible dirt or debris
have accumulated to a level preventing full closure of the breech.   In
this condition open the action and unload the shotgun.  Carefully
inspect the action and remove any dirt or debris. Keep the breech surface
clean and lightly lubricated.
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Barrel
Selector 
						

							Figure  4 - Disconnectable Ejectors
EJECTORS
Most Merkel Over and Under Shotguns are equipped with discon-
nectable automatic ejectors.  The ejector springs on these models can be
easily deactivated to convert the shotgun from its normal automatic
ejector operation to that of extractors by turning two small slot headed
screws that are located inside the forearm assembly (See Figure 4 ).
When the action is opened in the extractor mode of operation spent
shotshell casings are elevated above the chamber for removal by hand
rather than being automatically ejected from the chambers.
To change the ejector operation mode to that of extractor operation,
open the action and unload any ammunition that might be in the cham-
ber.  Remove the forearm from the barrel assembly.  The ejectors springs
are disengaged by turning the two small slot headed screws located inside
the forearm assembly ninety degrees clockwise with a small slot headed
screwdriver.  In this position, the slotted screw heads are perpendicular
to the axis of the barrel.
To change the shotgun back to ejector operation simply rotate the screws
ninety degrees counterclockwise.  In this position the slotted screw heads
are parallel with the axis of the barrel.  When set for automatic ejector
operation, Be careful to position the breech away from your face when
unloading the shotgun to avoid being hit by ejected spent shotshell
cases.
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Ejector
Selector Screws Ejectors On
Ejectors Off 
						

							LOADING AND FIRING
Before loading the shotgun, visually inspect your safety and make sure it
is in the ÒSafeÓ position. Never load the shotgun with the safety in the
firing position. Avoid contact with the trigger mechanism while loading
ammunition and at all times prior to firing.
To insert shotshells in the chamber, move the top lever to the right with
the thumb of your firing hand and open the breech. Inspect the cham-
bers and barrel bores to be sure they are free of any obstructions.  Insert a
shotshell in each chamber and close the action. Be sure the shotshell
primer and rim is facing rearward when inserting shells in the chamber. 
When you close the breech of the action, let the top lever move freely to
its locked position. Do not restrain its travel with your thumb. It is rec-
ommended that the top lever be indexed to the left with slight pressure
to make sure that the bolt is fully closed. (See figure 5).
Figure 5 -Closing the Breech
SHOTGUN ASSEMBLY
Before assembly, be certain there is no ammunition in either chamber and
position the safety in the ÒSÓ or ÒSafeÓ position.
Remove all protective lubricants from your shotgun before initial assembly.
Use a cleaning rod, patches and a light gun oil or solvent to clean the interi-
or of the shotgun bore. Use a cleaning cloth and light gun oil to remove 
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Locked (Fully Closed) Position 
						

							Figure 6 - Removal of Forearm
protective lubricants from metal parts on the receiver and barrel assemblies.
Remove the forearm from the barrels by pulling the forearm latch out and
away from the underside of the forearm (See figure 6). Remove all protective
lubricants from the exposed metal surfaces with light gun oil and a cleaning
cloth. After cleaning, place a couple of drops of gun oil on the metal bearing
surfaces of the hingepin, barrel lugs and on the forearm bracket (see figure 1).
The barrels are attached to the action by grasping the stock grip with the fir-
ing hand and supporting the buttstock in between the firing elbow and body
(See figure 7). Grasp the barrels with the non-firing hand and connect the
barrel lug with the receiver hinge pin. Use the thumb of the firing hand to
move the top lever sideways to its most right position.
Figure 7 -Barrel Assembly
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							Maintain pressure on the barrels to keep the hinge pin aligned with the bar-
rel lug hinge pin recess, and rotate barrels upward to close the action. Release
the top lever at this time.
Pivot the forearm assembly onto the barrels. Align the forearm in its proper
position on the barrels and push the forearm lever upward into its housing.
This locks the forearm back into its original position on the barrels.
ATTENTION!While assembling your shotgun, do not use excessive
force when closing the action! If the action and barrels are not aligned
properly, excessive force applied during assembly can deform or mar the
fitted surfaces of the shotgun. If you perceive any interference while
installing the barrels to the receiver repeat the assembly procedures from
beginning, and be extra careful to align the barrel lug hinge pin recess
and the receiver hinge pin properly. If you continue to experience diffi-
culty in the assembly of your shotgun, call GSI or seek assistance from a
qualified gunsmith.
GAUGE, CHAMBER LENGTH AND
CHOKE DESIGNATION
It is most important that the correct ammunition is used with your shot-
gun. Use of incorrect ammunition with your shotgun could cause injury
or death to the shooter and damage to the shotgun. Never use shot-
shells that do not match the corresponding gauge of the shotgun. For
example, do not use 20 gauge ammunition in a 12 gauge gun. In addi-
tion, do not use shotshells with chamber lengths that exceed the
chamber length of the shotgun barrel.
DANGER - AMMUNITION WARNING!
SERIOUS INJURY OR DEATH OR PROPERTY DAMAGE
MAY RESULT FROM ANY CONDITION WHICH CON-
TRIBUTES TO THE GENERATION OF EXCESSIVE
PRESSURE, OR THE UNCONTROLLED RELEASE OF
GAS, WITHIN A SHOTGUN. THE FOREGOING
ADVERSE CONDITIONS CAN BE CAUSED BY BORE
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