M242 Bushmaster Gun Theory

Since the introduction of the M242, 25-mm automatic can non in 1980, detailed training materials on its principles of operation, cycle of function, and gear flow are not readily available to non commissioned officers (NCOs) in the force. Army Training Manual (TM) 9-1005-200-23&P/Marine Corps TM 08672A-23&P is meant to be used as a technical manual for unit and direct support maintenance for the M242, containing detailed information about the various components and functions of the M242. However, since June 11, 2001, there have been no updates to Army TM 9-1005-200-23&P/Marine Corps TM 08672A-23&P, and no official publication had been created as a ref erence or training resource for Bradley commanders and Bradley gunners. Overview Training Circular (TC) 3-20.31-242, Mastery: Gun Theory, M242 which is currently available through the Army Publishing Directorate (APD), was cre ated as a primary reference designed to provide Bradley commanders and Bradley gunners mastery-level under standing in a comprehensive, yet easy to understand format.1,2 This TC is specifically designed to provide the Bradley commander and Bradley gunners a detailed text reference of “how” this complex autocannon works. It de scribes the interaction, movement, and function of each gear, lever, switch, and component of the gun in a stepby-step manner. It will provide Bradley commanders and Bradley gunners a mastery-level understanding of the M242 and highlights the importance of understanding the equipment that Bradley crewmembers operate during training and combat operations. This TC allows Bradley Master Gunners (MG) and Bradley commanders to pro vide mastery-level instruction to their crews before, during, and after their scheduled gunnery density. It is meant to be easy to read for those who are unfamiliar with the M242 and displays graphics to enhance the readers’ understanding of the text that accompany it. Investing Into the Future of the Bradley Master Gunner TC 3-20.31-242 was designed by Bradley MGs for Bradley MGs, enabling unit-level, subject-matter expert (SME) Image 1. M242 Bushmaster component weight description chart. (U. S. Army graphic) Gun Theory

Winter 2025 led instruction to a mastery-level un derstanding. This manual is a primary reference for units conducting sabot academy lessons to improve unit lethality. TC 3-20.31-242 is written in a progressional format, beginning with introducing the reader to the history and lineage of the M242, 25-mm auto matic cannon, highlighting the devel opment process that occurred before the creation of this automatic cannon. Chapter 2 transitions into depicting and describing the different gears, switches, levers, and components of the M242 and how they interact with each other during normal gun functions. This is followed by Chapter 3, describing the overarching theory of operation of the M242 by describing how the muzzle brake, bolt and carrier as sembly, mechanical safety interlock system (MSIS), dual-feed system, and power train operates, and describes how double feeds are prevented. Chapter 4 and Chapter 5 then describe the cycles of function and how the electrical system functions, and what occurs when each sensor is displayed through the bolt position indicator (BPI). To enhance Bradley crewmem bers ability to maintain the M242, Chapters 6-8 focus on pre-combat procedures, troubleshooting procedures (specifically highlighting how to identify and remediate symptoms that prevent firing operations), and how to properly clean and lubricate every component of the M242. Appendix A then provides services information, with graphical training aid (GTA) 17-06- 242 – M242 operational readiness ref erence, being made available and de signed for unit standard operation procedure integration.3 Bradley command ers and Bradley gunners can print these GTAs with ½ page portrait for matting so that they may be integrated into the Bradley crew’s pre-to-fire checklists and services checklists. GTA 17-06-242 is available through the Central Army Registry (CAR).4 Appendix B provides diagrams and instructions for proper storing of the M242, while also including diagrams for construction of gun stands. Finally, Appendix C pro vides Bradley commanders and Bradley gunners the most important terms and definitions to solidify a mastery-level understanding of the M242, in an easy-to-read format. 3D Modeling This GTA features higher quality images using 3-dimensional models and easily identifiable callouts of the differ ent components of the M242. These callouts help readers identify where the component is located within the feeder or receiver assemblies, and where they are located amongst other smaller components. A brief explanation of each component is provided within the graphic, while a more de tailed description is provided in the main text. Gear Flow Chart The gear flow chart has been recreat ed, with the intent of replacing the old hand drawn style callouts with accurate picture representations of the different gears included in the receiver and feeder assemblies. Additionally, the gear flow chart has been broken down into two separate graphics, that depict the gears that are contained within the feeder assembly and what gears are contained within the receiver assembly, respectively. The gear flow chart is one of the most crucial concepts to understand when operat ing the M242, as it can assist Bradley commanders and Bradley gunners in understanding why and how a mal function has occurred. Timing of the gears of the M242 is a crucial step of pre-combat procedures, and TC 3-20.31-242 describes why it is such an important event that must not be over looked when preparing for firing operations. Storage/Gun Stand for the M242 TC 3-20.31-242 also contains dimensions for M242 related equipment, such as dimensions of storage contain ers and gun stands. The storage crate dimensions provided can be used for securely packaging M242 components by units that are preparing to deploy their Bradley formations anywhere in the world. These crates reduce the abuse that the M242’s receive when they are simply bubble wrapped and strapped to the troop seat of a Bradley Fighting Vehicle (BFV). The gun stand is also provided and will enable more in-depth instruction at the platoon lev el, as well as providing a means to con duct more thorough weekly maintenance on the M242, keeping the weapon system off the back ramp of the Figure 2. 3D rendering illustrating the large and small bevel gears. (U. S. Army graphic)

Winter 2025 BFV. Gun stands are an especially crucial item that can enhance the training value of any class involving the M242, by allowing the instructor to bring the M242 out of the Bradley turret and al lowing for a more hands-on program of instruction from SMEs. These graphics provide the measure ments and materials required, while the text provides the steps for creating these items, as well as what markings are required for transport and storage. Sergeant First Class Marc E. Price cur rently serves as a Training Developer/ Writer in the Weapons and Gunnery Branch, DOTD, at Fort Benning, GA. His previous positions include Brigade Master Gunner for HHT, 3ABCT, 1CD at Fort Hood, TX; Battalion Master Gunner for HHC, 1-12 CAV, 3ABCT, 1CD at Fort Hood; Platoon Sergeant for 2nd Platoon, B TRP, 6-9 CAV, 3ABCT, 1CD at Fort Hood; Section Sergeant for B SEC, 2nd Platoon, B TRP, 6-9 CAV, 3ABCT, 1CD at Fort Hood; and Team Leader for B SEC, SCT PLT, HHC, 1-66 AR, 4ID at Fort Carson, CO. His military education includes the Maneuver Leaders’ Maintenance Course, Cavalry Leader’s Course, and Doctrine Developers Course at Fort Benning, as well as the Maneuver Senior Leader Course at Camp Shelby, MS, and the Bradley Master Gunner School at Fort Benning. SFC Price holds an associate’s of arts in interdisciplinary studies from American Military University. His awards and rec ognitions include various commenda tions reflecting his service and exper tise. Notes 1 TC 3-20.31-242, Mastery: Gun Theory, M242, https://armypubs.army.mil/Pro ductMaps/PubForm/Details.aspx? PUB_ ID=1031337 2 Army Publishing Directorate (2025, July). APD – Army Publishing Directorate. Retrieved from ArmyPubs: https://army pubs.army.mil/ProductMaps/PubForm/ Details.aspx? PUB_ID=1031337 3 GTA 17-06-242 – M242 Operational Readiness Reference, from https://rdl. train.army.mil/catalog/#/search?search_ terms=17-06-242 4 Central Army Registry (2025, July). CAR – Central Army Registry. Retrived from https://rdl.train.army.mil/catalog/#/ search?search_terms=17-06-242