Robinson Armament M96 Expeditionary, M 96Recon Instruction Manual

							OPERATOR’S MANUAL 
 
WARNING! READ THIS MANUAL 
CARFULLY BEFORE USING THESE 
FIREARMS  
 
 M96 Expeditionary® Rifle  
 
   
 
 
 
 
 
 M96 Recon™ Carbine
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
ROBINSON ARMAMENT CO.PO BOX 16776 
SALT LAKE CITY, UT 84116 
Website:  www.robarm.com  
 
 
2
 
WARNING! 
 
 
 THE M96 HAS SOME UNIQUE FEATURES THAT 
REQUIRE SPECIAL INSTRUCTIONS AND WARNINGS 
FOR SAFE USE.    FAILURE TO STRICTLY FOLLOW THE 
INSTRUCTIONS AND WARNINGS CONTAINED IN THIS 
OPERATOR’S MANUAL COULD RESULT IN DEATH OR 
SERIOUS BODILY INJURY TO THE OPERATOR AND 
OTHERS, AND DAMAGE TO PROPERTY.    
 
READ AND STUDY THIS MANUAL CAREFULLY AND 
RECEIVE SAFETY TRAINING FROM A COMPETANT 
FIREARMS INSTRUCTOR BEFORE HANDLING OR USING 
THIS FIREARM. 
 
NEITHER ROBINSON ARMAMENT CO. NOR ZDF 
IMPORT/EXPORT, INC. SHALL BE LIABLE FOR ANY 
INJURY TO PERSONS OR ANY DAMAGE TO PROPERTY 
RESULTING FROM THE USE OF THIS FIREARM. 
 
THIS OPERATOR’S MANUAL SHOULD ACCOMPANY THE 
FIREARM AT ALL TIMES AND SHOULD BE 
TRANSFERRED WITH POSSESSION OF THE FIREARM TO 
ANY SUBSEQUENT OWNER OR OPERATOR.   
 
ALWAYS REMEMBER TO KEEP FIREARMS AND 
AMMUNITION LOCKED UP, OUT OF SIGHT, AND OUT OF 
THE REACH OF CHILDREN AND OTHER 
UNAUTHORIZED PERSONS.  SAFETY IS YOUR 
RESPONSIBILITY! 
 
 
 2002 Robinson Armament Co. 
All Rights Reserved 
  
						

							 
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TABLE OF CONTENTS 
 
SECTON I          FIREARM SAFETY RULES  …………..4 
 
SECTION II       TERMINOLOGY  ………………………6  
    
SECTION III      SPECIFICATIONS   ……………………9  
 
SECTION IV      METHOD OF OPERATION  …………10  
 
SECTION V       BEFORE LOADING  ………………….12 
 
SECTION VI      LOADING  …………………………….13 
 
SECTION VII     AIMING & SIGHT ADJUSTMENT  …16 
 
SECTION VIII    FIRING  ……………………………….18 
 
SECTION IX      BREAK IN & GAS SYSTEM  
      ADJUSTMENT   ………………….20 
 
SECTION X       UNLOADING  ……………………...….22 
 
SECTION XI      DISASSEMBLY  ………………………23 
 
SECTION XII     ASSEMBLY  ………………………...…31 
 
SECTION XIII    MALFUNCTIONS & 
                               TROUBLE SHOOTING…………..38 
 
SECTION XIV    MAINTENANCE  ………………...…...42 
 
SECTION XV     CHILD SAFETY LOCK  …………..….44 
 
SECTION XVI    ACCESSORIES &  
      MODIFICATIONS  ………………..45  
 
4
 WARNING!   THESE SAFETY RULES ARE OF A 
GENERAL NATURE ONLY.   THEY ARE NOT 
INTENDED TO BE EXHAUSTIVE NOR ARE THEY 
INTENDED TO BE A SUBSTITUTE FOR PROPER 
FIREARMS TRAINING FROM A COMPETANT 
FIREARMS INSTRUCTOR.  Always keep the firearm pointed in a safe direction.  Firearms 
must be treated as if always loaded and always firing a steady 
stream of bullets.  Do not point the muzzle of the firearm at any 
thing you do not intend to kill or destroy.  Never rely on the safety 
mechanism.   The firearm is safe only as long as you use it safely. 
 
Never load a round into the chamber until you are ready to fire.    
Only load a round into the chamber when you have assumed a 
stable shooting position and the muzzle is pointed in a safe 
direction. 
 
Never walk with a loaded firearm, put a loaded firearm in a 
vehicle, store a loaded firearm, or leave a loaded firearm 
unattended. Firearms have been known to accidentally fire when 
dropped, struck, snagged, etc.  Unattended firearms can be stolen or 
misused. 
 
Never place your finger on the trigger or inside the trigger 
guard until you are ready to fire.  Before placing your finger on 
the trigger or inside the trigger guard, make sure that you have first 
assumed a stable shooting position and have your intended target 
clearly within your sights.  
 
Always assume a stable shooting position and clearly identify 
your target and backstop before you pull the trigger.  Rifle 
cartridges are very powerful, have a lethal range of many miles, and 
can often penetrate hard objects such as walls and metal.  Before 
you pull the trigger, it is vital that you clearly identify your target 
and have a backstop behind the target capable of stopping rifle 
projectiles.  Never fire at hard objects or water, which may cause  
						

							 
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projectiles to ricochet and kill or seriously injure persons and 
damage property. 
 
Always wear adequate eye and hearing protection while 
shooting.  Firearms, upon discharge, are extremely loud, and 
violently eject spent cases, hot gasses and particles.  Operators and 
bystanders must wear adequate eye and hearing protection at all 
times while shooting to prevent permanent vision and hearing loss. 
 
Never drop a firearm or allow the muzzle to strike hard objects.  
Sharp blows to a firearm my cause it to fire accidentally or damage 
it making it unsafe to fire.  Always unload the firearm and check 
the bore of the barrel to make sure there are no obstructions 
after dropping the firearm.  Never shoot a firearm which has an 
obstructed bore or which has been damaged.   If unsure as to the 
condition of a firearm, have it examined by a competent 
gunsmith before shooting. 
 
Always unload the firearm when finished shooting. While 
unloading, always keep the firearm pointed in a safe direction, 
remove the magazine, empty the chamber and visually inspect it 
to make sure no round is present. 
 
Never use a firearm if you have consumed alcohol, or if you are 
taking drugs or medication which could alter or impair your 
vision, physical responses, or judgement. 
 
Always store your firearms, unloaded, locked up, and out of the 
sight and out of the reach of children and other unauthorized 
persons.   It is your responsibility to make sure that children and 
other unauthorized persons do not have access to your firearms and 
that the firearms are safely stored out of sight and in a secure place. 
 
 
 
 
 
 
 
 
6 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 SECTION II - TERMINOLOGY 
 
IT IS MANDATORY THAT YOU THOROUGHLY FAMILIARIZE YOURSELF
WITH THE TERMS IN THIS SECTION DESCRIBING THE FEATURES AND
COMPONENTS OF THE M96 AS THESE TERMS WILL BE USED THROUGHOUT
THIS MANUAL.          
						

							 
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8  
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 M96 Field Stripped Major Subassemblies 
1) Operating Rod; 2) Gas Tube; 3) Rear Sight; 4) Receiver; 5) Bolt Carrier; 6) Barrel; 7) Hand Guard; 8) 
Magazine Well; 9) Lower Receiver; and 10) Buttstoc
k  
						

							 
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SECTION III – SPECIFICATIONS  M96 Expeditionary® Rifle  Caliber:………………………………..223 Rem. (5.56 NATO) 
Barrel Length:………………………...20.25” incl. Muzzle Brake 
Sight Radius…………………………...21.9” 
Rate of Twist:…………………………1 in 9” 
Overall Length:……………………….39.75” 
Weight (with empty Magazine):…...…8.4 Lbs. 
Feeding Devices:……………..………AR15/M16 Magazines 
Operating System:……………………Gas Operated Piston 
Bolt Type:…………………………….Multi-Lugged Proprietary 
Charging Device:……………………..Left Side, Non-Reciprocating 
Front Sight:…………………………...Post, Adjustable for W & E 
Rear Sight:……………………………Peep, Adjustable for W 
Receiver Construction:……………….Stainless Steel 
Metal Finish:………………………….Hard Matte Black 
Furniture:……………………………...Fiber Reinforced Plastic  M96 Recon™ Carbine  Caliber:………………………………..223 Rem. (5.56 NATO) 
Barrel Length:………………………...16.20” incl. Muzzle Brake 
Sight Radius…………………………...19.1” 
Rate of Twist:…………………………1 in 9” 
Overall Length:……………………….35.7” 
Weight (with empty Magazine):….…...7.82 Lbs. 
Feeding Devices:……………..………AR15/M16 Magazines 
Operating System:……………………Gas Operated Piston 
Bolt Type:…………………………….Multi-Lugged Proprietary 
Charging Device:……………………..Left Side, Non-Reciprocating 
Front Sight:…………………………...Post, Adjustable for W & E 
Rear Sight:……………………………Peep, Adjustable for W 
Receiver Construction:……………….Stainless Steel 
Metal Finish:………………………….Hard Matte Black 
Furniture:……………………………...Fiber Reinforced Plastic
 
 
 
 
 
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SECTION IV – METHOD OF OPERATION
 
 
 
The M96 is a gas operated, semiautomatic, sporting rifle.  The 
action of the M96 Expeditionary
 Rifle is similar to other gas 
operated semi-automatic rifles.  The method of operation is briefly 
described below. 
 
To begin the description of the operating cycle, it is assumed that the 
following operations have been performed:   A loaded magazine has 
been inserted into the firearm. And a cartridge has been manually 
cycled (loaded) into the chamber.  The hammer is held back by the 
trigger. 
 
As the trigger is pulled, the hammer is released from engagement 
with the trigger.  The hammer, under the force of its spring, rotates 
forward and upward into contact with the firing pin which is 
contained in the bolt which is itself contained in the bolt carrier. 
 
As the hammer strikes the end of the firing pin, the tip of the firing 
pin is forced to strike the primer of the cartridge causing it to ignite.  
The ignited primer causes the powder within the cartridge case to 
burn.  The burning powder creates gasses that expand under very 
high pressures to force the bullet out of the cartridge case and down 
the bore of the barrel. 
 
As the bullet passes the gas port in the barrel, some of the gasses are 
forced through the gas port into the gas block.  Some of the excess 
gasses are allowed to bleed from the gas bleed port.  The gas block 
diverts most of the gasses into the gas tube allowing them to 
impinge upon the piston of the operating rod, forcing it and the bolt 
carrier assembly to the rear of the firearm against the force of the 
recoil spring.  As the bolt carrier is forced to the rear, a camed slot in 
its side engages the caming lug of the bolt causing it to rotate.  The 
rotation of the bolt causes the locking lugs of the bolt to rotate out of 
engagement with locking lugs of the barrel.  The bolt is now 
unlocked and may travel to the rear of the receiver with the bolt 
carrier.  
						

							 
11
As the bolt carrier and bolt travel further to the rear of the firearm, 
the extractor which is engaging the rim of the cartridge pulls the 
empty cartridge from the chamber.  As the Bolt carrying the empty 
cartridge passes the ejector, the spent case is forced out of the grip 
of the extractor and is ejected from the right side of the firearm 
through the ejection port.  During the bolt carrier’s rearward 
movement the hammer is rotated against the force of its spring into 
engagement with the trigger. 
 
As the bolt carrier with its bolt reaches the rear limit of its travel, the 
compressed recoil spring forces the bolt carrier and bolt forward.  
As the bolt passes the rear of the magazine, a new cartridge is 
stripped from the magazine and forced into the chamber.  
Simultaneously, the extractor is forced over the rim of the new 
cartridge and the lugs of the bolt are rotated into engagement with 
the locking lugs of the barrel extension.  The bolt carrier continues 
forward until it reaches its forward limit. 
 
The disconnect of the trigger catches the hammer so that it cannot 
rotate forward.  As the trigger is released, the disconnect disengages 
the hammer allowing it to be caught by the trigger sear.  One 
complete cycle has now been completed and the rifle is ready to be 
fired again by pulling the trigger. 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
12
SECTION V – BEFORE LOADING  WARNING! FIRING THE FIREARM WITH ANY 
OBSTRUCTION IN THE BARREL MAY RESULT 
IN DEATH OR SERIOUS BODILY INJURY TO THE 
OPERATOR AND OTHERS AS WELL AS  
DAMAGE TO THE RIFLE AND OTHER 
PROPERTY.   
 
WARNING!  DO NOT LOOK DOWN THE BORE OF 
THE BARREL OF THE FIREARM UNLESS IT HAS 
BEEN UNLOADED (SEE SECTION X FOR 
UNLOADING INSTRUCTIONS) AND THE BOLT 
CARRIER OR BARREL HAVE BEEN REMOVED 
(SEE SECTIONS XI FOR BOLT CARRIER AND 
BARREL REMOVAL INSTRUCTIONS.). 
 
WARNING! FIRING AN IMPROPERLY 
ASSEBMLED FIREARM MAY RESULT IN DEATH 
OR SERIOUS BODILY INJURY  TO THE 
OPERATOR AND OTHERS AS WELL AS DAMAGE 
TO THE RIFLE AND OTHER PROPERTY.  When your M96 left the factory, it was properly assembled, cleaned, 
and tested.  However, during shipment or in distribution, the barrel 
may have become obstructed or the rifle may have been 
disassembled and improperly assembled.  
 
Before loading or firing the M96, inspect the bore of the barrel for 
any obstructions such as dirt, cleaning patches, lodged bullets, 
grease, moisture, etc.  Also make sure the barrel and other 
components have been properly attached to the rifle.  See SECTION  
XII for assembly instructions.  If you have any questions consult a 
competent gunsmith familiar with the M96 or call our service 
department:  Robinson Armament, Co., Salt Lake City, Utah, Phone:  
801-355-0401.  
						

							 
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Fig. 2 
SECTION VI – LOADING  WARNING! USE ONLY NEW, CLEAN, 
UNDAMAGED, COMMERCIAL GRADE 
AMMUNITION MEETING SAAMI 
SPECIFICATIONS OF THE PROPER CALIBER 
WITH THE RIFLE. DO NOT USE RELOADED OR 
REMANUFACTURED AMMUNITION.  STEEL 
CASED AMMUNITION SHOULD NOT BE USED.  
FAILURE TO USE THE PROPER AMMUNTION 
COULD CAUSE DEATH OR SERIOUS BODILY 
INJURY TO THE OPERATOR AND OTHERS AS 
WELL AS DAMAGE TO THE RIFLE AND OTHER 
PROPERTY.  The caliber of your M96 is indicated on the bottom of the muzzle 
brake of the barrel.  See Fig. 1. 
 
 
  
 
 
 
Loading the Magazine 
 The M96 is not issued with a 
magazine.  The M96 rifle was 
designed to be used with standard 
AR15/M16 magazines that were 
manufactured to military 
specifications.   Load the 
magazine by taking it in your 
hand, while using the thumb of 
your other hand to push one live 
Fig. 1 
 
14
Fig. 4 
 
Fig. 3
 
 
cartridge at a time into the magazine as shown in Fig. 2.  
 
Continue this process until you cannot easily load any more 
cartridges into the magazine.  Do not overfill the magazine. If the 
last cartridge is difficult to push into the magazine, omit or remove it 
from the magazine.   
 
 Inserting the Magazine 
 
WARNING!  KEEP THE BARREL OF THE 
FIREARM POINTED IN A SAFE DIRECTION 
WHILE INSERTING A MAGAZINE INTO THE 
RIFLE.   THE BOLT MAY CLOSE UPON 
INSERTION OF A MAGAZINE AND THE INERTIA 
FROM THE FIRING PIN MAY CAUSE A ROUND 
TO FIRE.  1.  Move the safety lever 
to the safe position as 
indicated by the letter 
“S”.  See Fig. 3.  
2.  Holding the rifle by the 
pistol grip, insert a 
magazine into the 
magazine well as 
shown in Fig. 4.  Push 
the magazine straight 
into the magazine well 
until the magazine 
catch engages the 
magazine. 3. 
Lightly tug on the 
magazine to make sure 
the catch has firmly 
engaged the magazine.
 
  
						

							 
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Fig. 5 
Loading a Round into the Chamber 
 
WARNING!  ASSUME A STABLE SHOOTING 
POSITION AND KEEP THE BARREL OF THE 
FIREARM POINTED IN A SAFE DIRECTION 
WHILE LOADING A CARTRIDGE INTO THE 
CHAMBER AS FORWARD INERTIA OF THE 
FIRING PIN MAY CAUSE THE FIREARM TO 
FIRE.  
1.  Move the safety lever to the 
fire position indicated by the 
letter “F” (Fig. 5). 
2.  Having  inserted  a  loaded           
magazine into the magazine 
well, pull the charging handle 
to the rear as far as it will go.   
3. Release the charging handle 
quickly and completely so that 
it has the full force of the recoil 
spring to carry the bolt carrier forward.  The rifle now has a live 
cartridge in the chamber and is ready to fire. 
4.  Now engage the safety by moving the safety lever to the safe 
position as indicated by the letter “S”.  NOTE:  The charging handle cannot be pulled all the way to the rear 
if the rifle has been “dry fired” (i.e., the trigger has been pulled with 
no round in the chamber) and then the selector lever has been 
rotated to the safe position (“S”).  Keeping the rifle pointed in as 
safe direction, rotate the safety lever to the fire position (“F”).  Now 
the charging handle maybe pulled completely to the rear and the 
safety lever returned to the Safe position (“S”).  
 
 
 
 
 
 
 
16
 
Fig. 6 Fig. 7 Fig. 8 
SECTION VII – AIMING & SIGHT ADJUSTMENT 
 
Aiming the M96  Align the front sight post and its 
protective ears with the aperture of the 
rear sight as shown in Fig.6.   The flat 
edge at the top of the front sight post 
should be in the middle of the rear sight 
aperture and the target.  Sight Adjustment  Front Sight
 
 
The barrel of the M96 contains a front 
sight which is adjustable for both windage 
and elevation.  The front sight can be 
adjusted for elevation by depressing the 
front sight detent with the tip of a 
cartridge or similar object while turning it 
to clockwise (lowering it) or counter clock 
wise (raising it).  See Fig.7.  
 
The front sight can be adjusted for 
windage by turning the Phillips head 
screws at the base of the front sight 
(Fig.8).  To move the front sight either 
right or left, loosen the Phillips head screw 
on the side of the direction you want the 
sight to move and then tighten the Phillips 
head screw on the opposite side.  This moves the sight in the 
direction you want to move it. 
 
 
 
 
  
						

							 
17
 
Fig. 9 – 100 Yrd. Aperture Fig. 10 
Whether adjusting for windage or elevation, the movement of the 
bullet’s point of impact will be opposite the direction you move the 
front sight.  When the front sight is in the desired position, tighten 
the screws firmly but gently. 
   
NOTE:  Overtighenting the screws can damage the front sight and 
the gas block. 
  Rear Sight
 
 
There are two rear sight 
apertures on the M96.  When 
the aperture with the vertical 
mark is lying against the sight 
base, the 500 yard sight 
aperture is visible (Fig.9).  
When the aperture with the 
vertical mark is perpendicular 
with the sight base, the 100 yard 
aperture is visible.  
 
The rear sight aperture can be 
adjusted for windage with the 
windage adjustment knob.  See 
Fig.10.  Each click of the 
windage adjustment knob is 
equal to approximately ½”  of 
movement at 100 yards. 
 
To zero the rifle sights, use the 
rear aperture for 100 yards and 
set the vertical line of the rear 
sight on the middle mark of the 
rear sight base.  See Fig.9.  Next shoot a close grouping of three or 
more shots.  Adjust only the front sight for windage and elevation 
until zeroed.  The rear sight adjustment knob is for adjustments in 
the field. 
 
 
18
SECTION  VIII - FIRING 
 
WARNING!  ALWAYS ASSUME A STABLE 
SHOOTING POSITION, CLEARLY IDENTIFY 
YOUR TARGET, AND HAVE AN ADEQUATE 
BACKSTOP BEFORE FIRING THE RIFLE. 
 
WARNING!  IF YOU EXPERIENCE A JAM OF ANY 
KIND, A MISSFIRE (I.E., THE TRIGGER IS 
PULLED AND NOTHING HAPPENS), OR THE 
CARTRIDGE FIRES BUT ITS REPORT IS 
UNUSUALLY QUIET, KEEP THE  RIFLE POINTED 
IN A SAFE DIRECTION AND IMMEDIATELY 
FOLLOW THE INSTRUCTIONS IN SECTION XIII  
OF THIS MANUAL. 
 
WARNING! KEEP ALL BODY PARTS AWAY 
FROM THE EJECTION PORT.   KEEP YOUR 
FINGERS AND HANDS OUT OF THE EJECTION 
PORT.  FAILURE TO FOLLOW THIS WARNING 
COULD RESULT IN SERIOUS BODILY INJURY.  NOTE:  If you are firing your rifle for the first time, you should read 
SECTION IX entitled Break In and Adjustment of Gas System. 
 
Holding the rifle by the pistol grip with your finger placed 
completely outside the trigger guard, disengage the safety with your 
thumb by moving the safety lever to the fire position as indicated by 
the letter “F”. See Fig. 5 on Page 15. 
 
Having your sights properly aligned on the intended target, place 
your finger on the trigger.  Keeping your sights properly aligned on 
the target at all times, gently and slowly squeeze the trigger until the 
rifle fires.   
  
						

							 
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If your sights move out of alignment with the target during the 
trigger pull, release the trigger immediately.  You may begin pulling 
the trigger again when your sights are properly aligned on the target.  WARNING!  AFTER YOU HAVE FIRED A SHOT, 
THE RIFLE IS READY TO SHOOT AGAIN.
   
 
The above procedure may be repeated until the rifle is empty.   
Upon firing the last cartridge in a magazine, the bolt should stay 
open.  Remove the empty magazine (See Section X).  To close the 
bolt, pull the charging handle all the way to the rear and let go of it.   
 
Insert another loaded magazine into the rifle, keeping the muzzle of 
the rifle pointed in a safe direction at all times.  With the muzzle still 
pointed in a safe direction, pull the charging handle all the way to 
the rear and let go of it.  This will chamber another round and allow 
you to resume firing. 
 WARNING!  IF THE BARREL BECOMES TOO 
HOT, THE HEAT MAY CAUSE A CARTRIDGE IN 
THE CHAMBER TO FIRE WITHOUT THE 
TRIGGER BEING PULLED
. 
 
If the rifle is hot, stop firing, remove the magazine, empty the 
chamber, and let it cool.  A good indication that the barrel is too hot 
is when the handguard becomes hot.  Use good judgement.  
  
 
 
 
 
 
 
 
 
 
 
 
20
 
Fig. 11 – Fully Closed 
SECTION IX – BREAK IN & GAS SYSTEM 
ADJUSTMENT 
 
WARNING! THE GAS REGULATOR WILL 
BECOME EXTREMELY HOT ONCE THE RIFLE 
HAS BEEN FIRED.   DO NOT TOUCH THE 
BARREL, THE GAS TUBE, OR THE FRONT SIGHT 
WITH ANY PART OF YOUR BODY OR YOUR 
CLOTHING.  FAILURE TO FOLLOW THIS 
INSTRUCTION COULD RESULT IN SERIOUS 
BURNS AND OTHER INJURIES. 
 
WARNING!  MAKE SURE THE RIFLE IS POINTED 
IN A SAFE DIRECTION WHILE ADJUSTING THE 
GAS REGULATOR.  DO NOT GET IN FRONT OF 
THE MUZZLE.   Adjustment of Gas Regulator  
The M96 is equipped with a gas regulator so the operator can use the 
minimum amount of gas necessary to reliably cycle the action.  
Using more gas than is necessary to cycle the action will result in 
harsher recoil and more wear on the firearm than is necessary.   
Typically, more gas may be necessary where the temperatures are 
cold, the ammunition is weak, or the firearm is dirty or brand new.  
Less gas may be necessary when temperatures are hot, the 
ammunition is strong, the rifle clean, or the rifle has been previously 
fired.  The gas regulator works by regulating 
the amount of gas used to cycle the 
action of the firearm. The M96 uses a 
“gas bleed” system regulator. The gas 
regulator has six different positions 
which include five gas bleed ports 
(holes) of varying size and one position