Dillon Precision XL 650 Instruction Manual

							illon
recision
Products, Inc.Manufacturers of 
The Worlds Finest
Loading Equipment
XL 650
Instruction Manual
Version 6.1 
						

							Dillon Precision Products, Inc.
8009 E. Dillon’s Way
Scottsdale, AZ  85260
(480) 948-8009
FAX (480) 998-2786
Web Site: www.dillonprecision.com
E-mail: [email protected]
Technical Support & Customer Service
(800) 223-4570
On the cover…
The XL 650 is pictured with optional accessories:
Strong Mount (550/650) #22051
Strong Mount (650 only) #22052
Aluminum Roller Handle #17950
Low Powder Sensor #16306
Bullet Tray #22214
Powdercheck System #21044
Electric Casefeeder                                                (four sizes available)
Other accessories available for the XL 650 include:
Video Instruction Manual #15064
Machine Cover #10443
Maintenance Kit & Spare Parts Kit #97017
The Blue Press, Dillon’s monthly catalog, has a complete listing 
of accessories available for all machines.
Part #13524      Spot   Manuals     XL 650 Folder     XL 650 Man. 6.1   9/01   WJC 
						

							Page #
Mandatory Safety Measures 5
Getting Started 6
1. Unboxing your machine 6
2. Mounting your XL 650 7
3. Initial Set-Up 7
A.  Installation of Handle 7
B.  Installation of the Spent Primer Cup and Cartridge Bin 8
C.  Installation of the Casefeed Post 8
D.  Installation of the Casefeed Tube Bracket 8
E.  Installation of the Optional Casefeeder 9
4. Toolhead Overview 11
Lubricating Brass 11
Pistol Section – Toolhead Set Up 12
A. Station One – Installation of the Sizing/Decapping Die 12
B. Station One – The Decapping assembly 12
C. Station Two – Installation of the Powder Measure Assembly 12
D. Station Two – About Powder Bars 13
E. Station Two – Adjustment of the Powder Die/Powder Funnel 14
F. Station Two – Installation of the Failsafe Rod Assembly 15
G. Station Three – Installation of the Powder Check System 16
H. Station Four – General Information on Bullet Seating 17
I. Station Four – Seating Stems 18
J. Station Four – Installation and Adjustment of the Seating Die 18
K. Station Five – Installation and Adjustment of the Crimp Die 18
Rifle Section – Toolhead Set Up 20
A. Station One – About the Case Gage 20
B. How to Use the Case Gage 20
C. Station One – Installation of the Sizing/Decapping Die 21
D. Station One – The Decapping assembly 22
E. Station Two – Installation of the Powder Measure Assembly 22
F. Station Two – About Powder Bars 23
G. Station Two – Adjustment of the Powder Die/Powder Funnel 23
H. Station Two – Installation of the Failsafe Rod Assembly 25
I.  Station Three – Installation of the Powder Check System 25
J.  Station Four – How to Determine the Proper Seating Depth 26
K. Station Four – Seating Stems 27
L. Station Four – Installation and Adjustment of the Seating Die 27
M. Station Five – Installation and Adjustment of the Crimp Die 28
Final Assembly 29
1. The Primer Magazine 29
2. Installation of the Primer Early Warning System 29
3. Installation of the Locator Buttons 30
Loading Components Section
1. Primer System Overview (how it works) 30
2. Powder Bar Adjustment 30
3. Powder Check System Adjustment 31
A.  Installation and Adjustment of the Powder Check Rods 31
B.  Powder Check System demonstration 32
4. Filling the Primer System 32
Station Orientation and Loading Funtions 34
Caliber Conversion Section 35-42
Trouble Shooting 43-45
Caliber Conversion Chart 46-48
Schematics 49-58
Table of Contents 
						

							Reloading small arms ammuni-
tion involves the use of highly
explosive primers and powder.
Handling these materials is inher-
ently dangerous. You should rec-
ognize this danger and take certain
minimum precautions to lessen
your exposure to injury.
Never operate the machine
without ear and eye protection on.
Call our customer service depart-
ment at (800) 223-4570 for informa-
tion on the wide variety of shoot-
ing/safety glasses and hearing
protection that Dillon has to offer.
• PAY ATTENTION: Load only
when you can give your com-
plete attention to the loading
process. Don’t watch television
or try to carry on a conversation
and load at the same time. Watch
the automatic systems operate
and make sure they are function-
ing properly. If you are interrupt-
ed or must leave and come back
to your loading, always inspect
the cases at every station to
insure that the proper operations
have been accomplished.
• SMOKING: Do not smoke
while reloading or allow anyone
else to smoke in your reloading
area. Do not allow open flames
in reloading area.
•  SAFETY DEVICES: Do not
remove any safety devices from
your machine or modify your
machine in any way.
• LEAD WARNING: Be sure to
have proper ventilation while han-
dling lead components or when
shooting lead bullets. Lead is
known to cause birth defects, other
reproductive harm and cancer.
Wash your hands thoroughly after
handling anything made of lead.
• LOADS AND LENGTHS:
Avoid maximum loads and pres-
sures at all times. Use only rec-
ommended loads from manuals
and information supplied by reli-
able component manufacturersand suppliers. Since Dillon
Precision has no control over the
components which may be used
on their equipment, no responsi-
bility is implied or assumed for
results obtained through the use
of any such components. 
Seat bullets as close to maxi-
mum cartridge length as possible.
Under some conditions, seating
bullets excessively deep can raise
pressures to unsafe levels. Refer to
a reliable loading manual for over-
all length (OAL).
• QUALITY CHECKS: Every 50-
100 rounds, perform periodic qual-
ity control checks on the ammuni-
tion being produced. Check the
amount of powder being dropped
and primer supply.
•  RELOADING AREA: Keep your
components safely stored. Clear
your work area of loose powder,
primers and other flammables
before loading.
• COMPONENTS: Never have
more than one type of powder in
your reloading area at a time. The
risk of a mix-up is too great. Keep
powder containers closed.
Be sure to inspect brass prior to
reloading for flaws, cracks, splits
or defects. Throw these cases away. 
Keep components and ammuni-
tion out of reach of children.
• BLACK POWDER: Do not use
black powder or black powder
substitutes in any Dillon powder
measure. Loading black powder
cartridges requires specialized
loading equipment and tech-
niques. Failure to do so can result
in severe injury or death.
•  PRIMERS: Never force primers.
If they get stuck in the operation of
the machine, disassemble it and
gently remove the obstruction. 
Never attempt to clear primers
that are stuck in either the primer
pickup tube or the primer maga-
zine tube. Never, under any cir-
cumstances, insert any type of rodto attempt to force stuck primers
out of these tubes. Trying to force
primers out of the tube will cause
the primers to explode causing
serious injury or even death. 
If primers get stuck in a primer
magazine or pickup tube flood the
tube with a penetrating oil (WD-
40), throw the tube in the garbage
and call us for a free replacement.
Never attempt to deprime live
primers – eventually one will go
off. When it does it will detonate
the others in the spent primer cup.
Depriming live primers is the sin-
gle most dangerous thing you can
do in reloading and can cause
grave injury or death.
• LOADED AMMUNITION:
Properly label all of your loaded
ammunition (Date, Type of
Bullet, Primer, Powder, Powder
Charge, etc.).
•  BE PATIENT: Our loading
equipment is conservatively rated
and you should have no trouble
achieving the published rates with
a smooth, steady hand. If some-
thing doesn’t seem right, stop,
look and listen. If the problem or
the solution isn’t obvious, call us.
The reloading bench is no place
to get into a hurry.
We have done everything we
know how to make your machine
as safe as possible. We cannot,
however, guarantee your complete
safety. To minimize your risk, use
common sense when reloading
and follow these basic rules.
•  REMEMBER: If your machine
does not perform to your expecta-
tions, or if you are having technical
difficulties, give us a call.
Technical Support (800) 223-4570
A
LL ELECTRICAL/ELECTRONIC COM-
PONENTS INDILLON EQUIPMENT ARE
COVERED BY A ONE
-YEAR WARRANTY.
5
MANDATORY SAFETY MEASURES 
						

							6
GETTING STARTED
1. Unboxing Your 
Machine:
After opening the box, check the con-
tents against the list below. If any items are
missing or damaged, call us right away so
we can send out a replacement at no
charge.
You should have the following:
1.Machine with toolhead and toolhead 
retaining pins installed
2.Operating handle assembly with washer 
and lock nut
3.Casefeed mounting post
4.Casefeed tube
5.Casefeed support bracket
6.Primer Early Warning System bag 
containing:
a.Primer Early Warning System (with 
AAA battery included)
b.Primer follower rod (16” black plastic 
rod)
7.Primer system parts bag containing:
a.Powder Measure Failsafe assem-
bly (10” black metal rod w/ hardware)
b.One small and one large primer pickup 
tube – 12” aluminum tube each withplastic tip - green tip (large), yellow tip 
(small)
c.One large and one small plastic tip, 
(spares)
d.Primer feed disk (2” diameter metal
disk w/16 small holes)
e.Primer magazine (15” aluminum tube
w/ brass tip)
f.Primer punch assembly. (metal 
w/spring, approximately 2 x 1/2”)
g.Two steel hitchpins
8.Conversion kit box (empty)
9.Conversion kit includes caliber specific:
a.Powder funnel
b.Casefeed adapter
c.Three locator buttons
d.Shellplate (installed)
e.Station 1 locator (installed)
f.Casefeed arm bushing (installed)
g.Body bushing (installed)
10. Powder system with powder die
11. Accessory box containing:
a.Cartridge bin (blue plastic,
approximately 3 x 4 x7”)
b.Ejected cartridge chute (black 
metal, wrapped in bubble pack)
c.Two 1/4” x 20 x 3”: hex bolts and two 
1/4” x 20 nutsd.Two Aluminum tube clamps
e.Spent primer cup (blue plastic)
f.Extra powder bar
g.Three die lockrings (7/8 x 14” thread)
h.Seven Allen wrenches (1/4”, 3/16”, 
5/32”, 9/64”, 1/8”, 3/32”, 5/64”)
12.Casefeed assembly (optional)
13.Casefeed accessory bag containing:
a.Casefeed funnel adapter (white)
b.Spacer washer
c.Casefeed mounting post set screw
14.Mounting hardware kit (optional)
15.Three die set (optional)
16.Powder check system (optional)
11
1
16
4
5
3
8
6
7
2
9
13
1415
1210 
						

							7
2. Mounting your XL 650:
A.Locate a sturdy bench at least 
24” wide and 14” deep, with 44” of 
overhead clearance. We suggest a 
minimum of 1” plywood or equivalent, 
secured to the back wall. The work-
bench should be tall enough to place 
your eye level about 18” above the 
bench.
Note:It is important that the leading edge
of the bench has an overhang of at
least 3/4”. If the overhang is less 
than 3/4”, the crank will interfere 
with the front of the bench when the 
operating handle is lowered. Unless
you have Strong Mounts, then none 
of this is necessary. 
B. Tools Needed: 
You will need the following to mount and
set up your machine:
1.Electric drill
2.17/64” drill bit preferred, 1/4” – 9/32” OK
3.Mounting Hardware Kit (#14355) or
four 1/4” through bolts with nuts and 
washers
Note:The bolts should be at least 1 1/2”
longer than the thickness of the 
mounting surface.
4.Two 7/16” wrenches if using kit
FIG 1
C. Drill the mounting holes FIG 1:
1.Using the machine as a template, mark 
the four holes.
2.Using a 1/4” bit, drill the holes.
FIG 2
D.Bolting the machine to the
bench FIG 2:
Note:If you do not have a Mounting Hard-
ware Kit, ensure that you use 1/4” 
or equivalent through bolts (with 
large area washers if mounting to 
wood). Do not use lag bolts or wood 
screws!
FIG 3
1.Mount the left side of the machine with
the small washers on top and the large 
washers on the bottom FIG 3. Run 
the two left side nuts down finger tight.  
2.Place the chute/bin bracket FIG 2on 
the right side of the machine. As 
before, place the small washer on top 
and the large washers on the bottom 
and thread the nuts.
Note: The chute/bin mount goes under 
the two right hand mounting bolts so 
it must be installed as you are 
mounting the machine FIG 2. 
Check the fit of the chute/bin 
mount. The chute/bin mount 
should rest snugly against the 
frame. Also, make sure that the 
walls of the chute are parallel andhave not been bent during ship-
ping or installation.
3.Using two 7/16” wrenches, tighten all 
four bolts down.
3. Initial Set Up
If you ordered your XL 650 for a specific
caliber, it comes factory adjusted for that
caliber (minus dies) with the appropriate
“caliber specific” parts included.  In fact, a
Dillon technician runs casings and primers
through the machine to check its function.
Note:As you assemble your machine, 
we recommend that you cross 
check caliber specific parts, includ-
ed with your machine, with those 
specified in the caliber conversion 
chart (pages 42-44). The 
point being – if we sent you the 
wrong part, you’ll want to know it 
before getting started. Reference 
page 35 for instructions on how to 
use the caliber conversion chart.
FIG 4
A. Installation of the handle FIG 4:
1.Hold the washer (see arrow FIG 4) 
over the hole on the right side of the 
crank and insert the handle.
2.Place a 5/32” Allen wrench or screw 
driver through the hole in the handle to 
help your grip.
3.Tighten the nut using a 7/8” wrench.  
						

							FIG 5
Operate the handle slowly to ensure that
the machine operates smoothly. Make sure
that the handle and the crank completely
clear the bench. Contact with the bench may
hinder its range of movement.  Observe the
movement of the shellplate platform and veri-
fy that there is no interference or contact of
the case insert slide and the chute/bin mount
FIG 5.
FIG 6
B. Installation of the Spent 
Primer Cup FIG 7 and 
Cartridge Bin FIG 6:
1.Raise the platform (i.e., lower the
handle all the way).
FIG 7
2.Slide the spent primer cup onto the
rails as shown. Make sure when
installing the cup that it is on both
rails.
FIG 8
3. Place the cartridge bin on the
chute/bin bracket. Push the handle aft
FIG 8while sliding the bin toward
the handle as shown. With the handle
pushed to its full aft position, there
should be a space between the han-
dle and bin.
FIG 9
C. Installation of the Casefeed 
Post
1.Remove the bolts, nuts and clamp
from the spacer kit and assemble
them as shown inFIG 9.
FIG 10
FIG 11
2.Install the casefeed post as shown in
FIG 10. Make sure the bend in the
post is facing away from you FIG 11.
3.Using two 7/16” wrenches, tighten
the bolts.
D.Installation of the Casefeed 
Tube Bracket FIG 11.
Install as shown in FIG11.
Note:If you ordered your machine with 
the optional casefeed assembly, 
you won’t need to use the casefeed 
tube bracket. This is because the 
upper end of the casefeed tube is 
supported by the casefeed bowl.
8 
						

							9
E. Installation of the Optional 
Casefeeder FIG 12:
FIG 12
1.Remove the casefeed parts bag
from the casefeed bowl and remove
the casefeed assembly from the box
FIG 12.
FIG 13
a. Spacer Washer  FIG 13:(see casefeed-
er schematic page 57)
Some calibers call for a spacer washer to
be used under the casefeed plate.
Installation of this washer raises the plate up
a bit to make the feeder function properly
with longer pistol cases (such as .357
Magnum, .44 Magnum and .30 M1 – this
listing of calibers requiring the spacer is
repeated in the caliber conversion chart on
pages 46-48 of this manual).
Note:The spacer washer does not come  
factory installed.
FIG 14
To Install the Spacer Washer:
a.1. FIG 14 Remove the casefeed plate.
a.2. With the casefeed plate removed, dis-
assemble the clutch drive. To do so
unscrew the two clutch screws.
a.3. Install the spacer washer as illustrated
in the casefeed schematic (page 57).
IMPORTANT:The spacer washer goes
between the lower clutch and the case-
feed plate.
a.4. Reassemble the clutch drive and rein-
stall the casefeed plate. (Note how the
clutch drive engages the drive pin).
FIG 15
b. Clutch Adjustment FIG 15:
Note:The clutch comes factory adjusted 
(if you don’t have to install the 
spacer washer you shouldn’t have 
to adjust the clutch drive).
The two socket-head machine screws (pt#
13732) should be just tight enough for the
clutch to drive the casefeed plate under a
normal load of brass. To check this, place
the casefeed assembly in front of you on the
bench. With the switch off, plug the case-
feeder in. Turn the switch to the down (low)
position and observe the movement of the
plate. You should be able to cause the
clutch to slip, using moderate finger pres-sure, without stalling the motor. Alternately
tighten and loosen the two machine screws
evenly, observing the effect on the holding
power of the clutch.  The correct setting
will stall the plate before stalling the motor,
yet not slip when the casefeed bowl is
about half full of brass.
Note:The casefeed bowl is not designed 
to be completely filled with brass. If 
it is fully loaded it will not function 
reliably. The rated capacity of the 
casefeeder is about 1/2 of the 
bowl’s physical capacity.
FIG 16
c. Casefeed Funnel Adapter FIG 16:
Some calibers call for the white plastic
funnel adapter to be used, located in the
casefeed accessory bag FIG 16. It is used
for feeding 9mm, .38 Super, .32 H&R, and
.380 ACP. (This listing of calibers is repeat-
ed in the caliber conversion chart on pages
46-48). Without this funnel adapter these
calibers will occasionally hang up in the
clear plastic funnel FIG 17at the top of the
casefeed tube.
FIG 17
Note:The casefeed funnel adapter does 
not come factory installed. 
						

							10
To Install the casefeed funnel adapter
FIG 18:
FIG 18
Remove the screws that attach the clear
casefeed funnel. Slide the front cover down
a bit, and slip the white plastic funnel
adapter into the funnel FIG 18. Reassemble.
Note:Do not loosen the two screws that 
are holding the microswitch (pt# 
13779).
Note:Occasional jams will occur. To 
keep them to a minimum, be sure 
to use the spacer washerFIG 13
or white casefeed funnel adapter 
FIG 16when called for. Use the 
low setting if it will keep up with 
your loading pace, and do not over-
load the casefeed bowl. The rated 
capacity of the casefeeder is about 
1/2 of the bowl’s physical capacity.
Before placing the casefeed bowl on the
casefeed post, take a moment to look over
and understand the casefeed assembly and
how it works. If you like, you can run the
casefeeder before placing it on top of the
casefeed post. This will allow you to get a
better idea of how it works. To do so, plug
in the casefeeder and fill it with about 50
cases.  Hold the casefeeder FIG 19so the
funnel is vertical. Place the cartridge bin
under the funnel and turn it on. Experi-ment
using both the high and low settings.
FIG 19
FIG 20
2.Remove the set screw from the acces-
sory bag and thread it into the case-
feed assembly FIG 20.
FIG 21
3. Place the casefeed bowl onto the
casefeed post FIG 21.
FIG 22
4.Place the casefeed adapter on the case-
feed body FIG 22. Note how the key
fits into the notch on the casefeed
body.
Note:Casefeed adapters are caliber spe-
cific. Crosscheck your casefeed 
adapter with the one listed in the 
caliber conversion chart (for the cal-
iber you’re loading) to ensure that 
you have the correct one installed in
your machine.
FIG 23
5.Align the casefeed bowl so the spring
clamp is directly over the casefeed
adapter. Place the casefeed tube into
the casefeed adapter then snap the
tube into the clamp FIG 23. 
						

							11
Note:One end of the casefeed tube is 
beveled and one end is squared off.
Insert the squared end of the tube 
(down) into the top of the casefeed 
adapter. 
FIG 24
6.Using A 5/32” Allen wrench, snug
the machine screw against the case-
feed mounting postFIG 24to pre-
vent the casefeed bowl from rotat-
ing.
4.Toolhead Overview
You’re now ready to install the toolhead
and adjust the dies. But first, we’ll give a
brief overview of the location and function
of each station, we’ll then follow up with a
detailed illustration.
FIG 25
Station 1
- Sizing/Decapping
The stations on the toolhead are num-
bered 1-5.  Station 1 is for the sizing/decap-
ping die FIG 25. This die can be easily
identified by the decapping pin sticking out
the bottom as well as by its label. This die
removes or “decaps” the old primer and
resizes the case.
Warning:  Never decap live primers! (See 
mandatory safety procedures.) 
Station 2- Powder Measure 
FIG 26
Station 2 is for the powder die, which
comes attached to the powder measure
FIG 26. Here several operations are con-
ducted. The case is primed, straightwalled
pistol cases are belled, and powder is
dropped. The purpose of the bell at the
mouth of the case is simply to help align
the bullet and to keep the case from shav-
ing lead during the seating process.  Note:
Only straight-walled cases receive a bell,
bottle-necked cases (rifle cartridges) are
not belled.
FIG 27
Station 3
- Powder Check
Station 3 is used for the optional powder
check system FIG 27. This system is located
in a separate package and can be identified
by the blue warning buzzer attached to a
die. This system is designed to detect gross
deviations in the powder charge, i.e. a dou-
ble charge of powder or no powder at all.
Station 4- Bullet Seating
Station 4 is for the seating die FIG 25.
This is where the bullet is pushed into the
case.
Station 5- Crimp
Station 5 is for the crimp die FIG 25. This
die not only removes the bell created at
Station 2, but rolls the mouth of the case
inward to insure proper feeding and to
secure the bullet.
LUBRICATING BRASS
To lubricate brass, use “Dillon Case
Lubricant” (item# 13733).
Pistol
– If you’re using a carbide sizing
die, you will not need to lubricate your
cases (before sizing) when loading straight-
walled cases. If you’re not using a carbide
sizing die, you must lube the brass before
sizing. We do, however, recommend lubri-
cating all brass.
Rifle
– Lubricateallbottle-necked cases,
even if you’re using a carbide sizing die.
To lubricate your cases, start by ensur-
ing that they are clean. Place your clean
brass in a shallow box so the cases are lay-
ing on their side. Pump a couple of sprays
of Dillon Case Lubricant over the cases.
Shake the box so the cases will tumble and
roll. Repeat this process again making sure
that the lubricant is well distributed over the
cases.
Note:When loading rifle cartridges, if your 
sizing die doesn’t have a carbide 
case mouth expander, you may 
want to allow a little bit of lube to get 
inside the case mouth.
Note:When loading bottle-necked            
cartridges, if you get an excessive 
amount of lube on the shoulder of 
the case, it will leave oil dents. 
Regardless of whether you’re lubri
cating pistol or rifle cases – do not 
drench the cases in lubricant. A light 
film of lubricant is sufficient.
Toolhead Head Setup:
Pistol – go to page 12
Rifle – go to page 20