Dillon Precision XL 650 Instruction Manual

							D.Station 1 – The decapping 
assembly FIG 78:
Dillon decapping assemblies are made
with replaceable decap pins. One extra pin
is included with each sizing die. To replace
a bent or broken pin, simply:
FIG 83
1.Unscrew the decapping assembly
from the top of the die FIG 83.
FIG 84
2.Unscrew the decapping pin (see
arrow FIG 84), and replace it with a
new one.
3.Screw the decapping assembly back
into the sizing die.
Note:The decapping assembly can be 
removed from the sizing die without 
affecting the adjustment of the siz-
ing die or sizing operation.
Note:The decapping assembly must be 
removed when loading primed 
cases. 
FIG 85
FIG 86
FIG 87 
E. Station 2 – Installation 
of powder measure assem-
bly FIG 85:
1. Using a 5/32” Allen wrench, loosen
the two collar clamp screws and
remove the powder dieFIG 86 & 87.
FIG 88
2.Thread the powder die into Station 2.
Screw it down about halfway FIG 88.
FIG 89
3.Remove the powder funnel from the
bag containing the brass locator but-
tons FIG 89.
22 
						

							FIG 90
In FIG 90are two examples of the many
powder funnels available for the XL 650.
On the left is a typical pistol caliber fun-
nel. On the right, a rifle or bottle-necked
type. The bottom of the rifle style funnel
fits snugly over the neck of the case allow-
ing powder to drop in without spilling (the
rifle style powder funnel does not bell the
mouth of the case). The bottom of the pis-
tol funnel, on the other hand, fits inside
and actually expands the case mouth as it
guides the powder into the case (the
expansion of the case mouth is where the
mouth of the case gets its bell). Powder
funnels are caliber specific so be sure you
have the correct funnel by referring to the
caliber conversion chart.
FIG 91
4.Insert the funnel into the die FIG 91.
Regardless of whether you’re using a
rifle or pistol powder funnel, make
sure that you insert the funnel into the
die with the grooved end up. It
should move up and down freely.
FIG 92
5.Remove the lid and the protective
cardboard tube from the powder mea-
sure and place it onto the powder die
FIG 92. Turn down the two clamp
screws until they are snug. Then
loosen them slightly. The measure
should move freely atop the die.
F. Station 2 – About powder 
bars:
Dillon Precision manufactures four types
of powder bars for the XL 650:
1.Extra Small – use for dropping less
than 3 grains of powder.
2.Small – use for dropping 3 to 10
grains of powder.
3.Large – use for dropping 10 to
approx. 45-50 grains of powder.
4.Magnum – use for dropping more
than approx. 45-50 grains of powder.
The extra small powder bar is used when
loading .32 Auto, .32 S&W and .32 SWL.
Both the extra small powder bar and the
magnum powder bar are non-standard
items and are ordered separately. The large
and small powder bar, on the other hand,
are standard equipment and are included
with every XL 650. If you ordered your
machine set up for a specific caliber, the
proper size powder bar should already be
installed. If you need to change out the
powder bar – refer to“Powder Bar
Adjustment”in the Caliber Conversion
Section on page 30.
G. Station 2 – Adjustment 
of Powder Die/Powder 
Funnel
Important:Adjusting the powder die for a 
bottle-necked case is notthe same 
as adjusting the powder die for 
straight-walled cases. This is 
because bottle-necked cartridges 
are notgiven a bell – straight-
walled cases are given a bell. For 
straight-walled cartridges refer to 
the pistol section. 
FIG 93
For the powder bar to properly dispense a
measured powder charge, the powder bar
must travel its full distance. To travel its full
distance, the white cube must contact the
powder measure body (see arrow FIG 93).
When adjusting the powder die for a
bottle-necked cartridge, the objective is to
adjust the powder die so that the powder
bar just travels the full distance and no
further (see arrow FIG 93). If you try to
apply the procedures used for belling a
straight walled case, as when loading pis-
tol cartridges, you will crush the bottle-
necked case and possibly damage the
powder measure.
Note:If the powder die is not adjusted 
down far enough to cause the pow-
der bar to travel its full distance the 
powder charge will be erratic.
Note:Whenever sizing a bottle-necked 
case you must lubricate the case 
first, otherwise you will stick the 
case inside the sizing die. For 
more information refer to the section 
“Lubricating Your Brass” (page 11).
23 
						

							FIG 94
To adjust the powder die/powder
funnel:
1.Drop a lubricated case into the case-
feed funnel and cycle the handle. The
case should now be in the shellplate
at Station 1.
2.Raise the platform. Notice the resis-
tance at the end of the downstroke.
This is the resistance of the case in
the sizing die. Lower the platform.
The case will index to Station 2.
3.Raise the platform. Check to see
how far the powder bar has traveled
FIG 94.
FIG 95
4.If the white cube has not traveled its
full distance, lower the platform just
enough to pull the case off of the
powder funnel (this will prevent the
shellplate from indexing while you
adjust the powder die). While holding
the powder measure, turn the die
down 1/8 of a turn FIG 95. Again
raise the platform and observe the
travel of the powder bar.
5.Repeat step four until the powder bar
travels its full distance FIG 94.
Note:If you screw the powder die down 
too far, the powder bar will travel its 
full distance before the handle is all 
the way down. If this happens – DO 
NOT FORCE THE HANDLE 
DOWN. Instead lower the platform 
and back the powder die out by turning it counter-clockwise. If you 
force the handle, you will crush the 
case and possibly damage the pow-
der measure.
FIG 96
6.Once the powder bar is traveling its
full distance – with the case in Station
2 – raise the platform. Run the lock-
ring down hand tight FIG 96.
FIG 97FIG 98
7.Insure the bellcrank and the failsafe
bracket are aligned, FIG 97. Using a
5/32” Allen wrench snug the collar
clamp screws, FIG 98.
FIG 99
8.While holding the powder measure,
snug the lockring using a 1 1/8”
wrench FIG 99. Now lower the plat-
form.
24 
						

							FIG 100
H. Station 2 – Installation of 
the failsafe rod assembly 
FIG 100:
The purpose of the powder measure fail-
safe rod is to return the powder bar to its re-
charge position.
FIG 101
1.Using your forefinger, move the lock-
link down to align the hole with the
slot on the Powder Measure bellcrank
FIG 101.
FIG 102
2. Insert the rod (#13629) through the
holes FIG 102.
3. Loosen the blue plastic wing nut
(#13799) FIG 102.
FIG 103
4.Slide the failsafe rod into the failsafe
return bracket. Push the shoulder
washer up into place (see arrow FIG
103) and tighten the blue plastic wing
nut until the spring just touches the
underside of the bracket.
Note:The powder measure is filled and 
the powder bar is adjusted after 
installing and adjusting the rest of 
the dies.
FIG 104
I. Station 3 – Installation of 
the Powder Check System
FIG 104:
Note:The powder check system does not 
guarantee the accuracy of the pow-
der charge. It is designed to warn 
you if the powder charge is grossly 
out of tolerance, i.e., no powder or a 
double charge.
Warning:  A double-charged round (a 
loaded round with twice as much 
powder as it should have) can dam-
age your gun as well as cause bodi-
ly injury.
Warning:A round loaded without powder 
can also damage your gun as well 
as cause bodily injury. If a round 
without powder is fired in your gun, 
the detonation of the primer will 
push the bullet part way down the 
barrel. If the lodged bullet is not 
removed before another round is 
fired, the gun will be damaged.
FIG 105
1.Loosen the die clamp screwFIG 105
and remove the die.
FIG 106
2.Raise the platform and screw the
powder check die into Station 3 and
raise the platform. There should be a
1/8 to 1/4 inch space between the
shellplate and the bottom of the die
FIG 106.
25 
						

							3.Run the lockring down. Using a 1-
1/8” wrench snug the lockring.  
FIG 107
FIG 108
4.Remove the 10-24 screw and nut
from the black push rod FIG 107and
place the powder check system on
the powder check die FIG 108.
Center the black push rod (see arrow
FIG 108) in the hole that is to the left
of the die. 
FIG 109
5.Reinstall and snug the die clamp
screwFIG 109.
FIG 110
FIG 111
6. FIG 110Screw the 10-24 screw and
nut fully into the rod. Raise the plat-
form. Unscrew the 10-24 screw
until it contacts the edge of the plat-
form FIG 110. Lower the platform
part way and unscrew the screw
(counter-clockwise) until raising theplatform causes the buzzer housing
to rock into the side of the die collar
FIG 111.
FIG 112
7.Secure the jam nut by holding the
black push rod while tightening it
using a 3/8” wrench FIG 112.
Note:Once you’ve adjusted the powder 
bar for the desired powder charge – 
installation and adjustment of the 
powder check system can be com-
pleted.
J. Station 4 – How to deter-
mine the proper seating 
depth:
Before installing and adjusting the seating
die you’ll need to know how to determine
the proper seating depth. How far the bullet
is seated into the case will determine the
overall length (OAL). Several factors go into
determining the proper OAL – such as, the
maximum recommended OAL, listed in the
reloading manual, and the type of bullet
being loaded. The type of bullet can deter-
mine the OAL by one of two ways.  If the
bullet has what is called a cannelure, FIG
113, this will determine the proper OAL. 
FIG 113
26 
						

							FIG 114
If the bullet you’re using doesn’t have a
cannelure, then you’ll need to refer to
your reloading manual for the suggested
OAL. The purpose of the cannelure is to
secure the bullet by giving the mouth of
the case something to dig into when being
crimped.  When the bullet is properly
seated, the mouth of the cartridge case
should be in the middle of the cannelure,
see arrow  FIG 114.
Refer to your reloading manual. Under
the section specified for the caliber you’re
loading, you’ll find a schematic of the car-
tridge. For example, .30-06 lists a maximum
OAL of 3.340” (Lyman Reloading
Handbook). If you’re seating the bullet to
the cannelure, the OAL should be well
within the maximum OAL listed, however,
use a set of dial calipers to check it. (Dial
calipers are available from Dillon
Precision). If the bullet you’re using doesn’t
have a cannelure, refer to its specific type in
the reloading manual. For example – if
you’re loading a .30-06 180 gr. JHPBT, and
it doesn’t have a cannelure, use the suggest-
ed OAL of 3.280 (Lyman Reloading
Handbook).
FIG 115
K. Station 4 – Seating Stem 
for rifle FIG 115:
Unlike pistol seating dies, rifle seating dies
come with only one type of seating stem.
Dillon seating dies, which are being
used in this manual, are easily disassem-
bled. Should you need to disassemble the
rifle seating die – simply unscrew the seat-
ing stem from the top of the seating die
FIG 115. 
L. Station 4 – Installation and 
Adjustment of the 
Seating Die
1.Place a lubricated sized case into
Station 4 and raise the platform.
FIG 116
2.Thread the seating die into Station 4.
Continue to screw it down until it
contacts the case FIG 116. Once the
die is in contact with the case back
the die off (counter-clockwise) 1/4 of
a turn. Using a 1 1/8” wrench snug
the lockring on the seating die.
FIG 117
FIG 118
3.Lower the platform.
4. FIG 117Back the seating stem all the
way out of the seating die. Now
screw the seating stem back into the
seating die two full turns FIG 118.
5.Place a bullet on the case mouth and
raise the platform – then lower the
platform just enough to inspect the
bullet without indexing the shellplate.
a.If the bullet is not pushed down far
enough – go to step 6.
b.If the bullet is pushed down too far:
b.1.Pull the bullet from the case
using a Dillon bullet puller.
b.2.Back the seating stem out by









 

































































































 
























 























27 
						

							turning it counter clockwise and try
again.
6.Screw the seating stem down 1/2 turn
at a time FIG 118.
FIG 119
7.Repeat as necessary until the correct
overall length is achieved. Use a dial
caliper or equivalent to measure the
overall length of the cartridge FIG
119. Check the overall length of the
round against the information in your
reloading manual.
FIG 120
8.Once you have obtained the proper
OAL, replace the cartridge into
Station 4, raise the platform and
snug the lockring on the seating stem
FIG 120.
FIG 121
M. Station 5 – Installation and 
adjustment of the Crimp 
Die FIG 121:
1.Screw the crimp die into Station 5.
Screw it down until it is flush with the
bottom of the toolhead. This is a good
starting point for the crimp adjust-
ment.
2.Place a lubricated cartridge with a
properly seated bullet into Station 5.
3.Raise the platform and continue to
screw the die down until it stops.
4.Lower the platform and give the die a
half turn down; again, raise the plat-
form.
5.Lower the platform halfway and
inspect the cartridge. If the desired
amount of crimp has not been
achieved, give the die a 1/4 turn
down and try again. Continue making
small adjustments to your crimp die
until the desired amount of crimp has
been achieved.
6.Once the adjustment is complete,
place the case back into Station 5 and
raise the platform. Using a 1 1/8”
wrench to turn the lockring and a
7/8” wrench to hold the die body,
snug the lockring.
Go to Loading Components
Section - Page 30
28
Sizing/Decapping Die
Seating DieCrimp Die 
						

							Final Assembly
FIG 122
FIG 123
1. The Primer Magazine
The XL 650 comes equipped with an
automatic primer system.The XL 650’s auto-
matic primer system is protected by a steel
shield which is permanently secured to the
primer feed body and must never be
removed. The primer magazine is located
inside of a steel shield FIG 122. Primer
magazines come in two different sizes –
large and small FIG 123. Your machine
comes with both. One comes installed in
the machine, the other is located in the
primer accessory package. If you ordered
your machine set up in a particular caliber,
the magazine installed should be the proper
one for the caliber you selected. However,
you should check to make sure. By compar-
ing the two magazines FIG 123you will be
able to determine which is large and which
is small.
FIG 124
To change the primer magazine:
1. Remove the primer shield capFIG
124.
2. Remove the primer magazine by
pulling it straight up FIG 122.
3. Insert the new primer magazine FIG
125and replace the primer shield
cap.
FIG 125FIG 126
2. Installation of the Primer
Early Warning System:
FIG 126The purpose of the Primer Early
Warning system is to warn you when the
primer magazine is low on primers. When
you hear the buzzer, it’s time to reload the
primer magazine tube.
FIG 127
1. Insert the battery into its receptacle
FIG 127and push the black switch
lever to insure the device is working
properly.
2. Install the Primer Early Warning sys-
tem on top of the primer magazine
shield FIG 126. Lightly tighten the
clamp screw with a 3/32” Allen
wrench.
29 
						

							FIG 128
3. Installation of the Locator 
Buttons FIG 128:
Install the three brass locator pins in the
shell platform at stations 3, 4 and 5. These
pins retain the cases during loading while
providing an easy way to remove a case
from the shellplate at any stage without dis-
turbing the other rounds. Note: The locator
buttons are caliber specific and can be
properly identified by referencing the cal-
iber conversion chart on pages 42-44.
LOADING COMPONENTS
SECTION
1. The Rotary Primer System  
(how it works):
Warning: Wear safety glasses whenever 
working with live primers. Safety 
glasses are available from Dillon 
Precision Products.
Observe how the rotary primer system
works, how to charge it and how to seat a
primer. To do so:
1. Put on your safety glasses.
FIG 129
2. Place five or six primers into the
primer magazine shiny side down
FIG 129.
3. Cycle the machine until a primer
appears in Station 2.
FIG 130
FIG 131
When you cycle the machine, the rotary
primer disc rotates one notch, advancing
another primer into position. When the
handle is pushed to its full aft stop FIG 131,
the primer seating punch pushes the primer
up through the rotary primer disc FIG 130,
fully inserting it onto the primer pocket of
the case. If there is no case in Station 2 to
receive the primer, the primer will return to
the rotary disc and continue around until
being dropped down a chute FIG 132
where it can be retrieved.
FIG 132
4. Drop an unprimed case into the case-
feed funnel and cycle the machine
twice. As the case is rotated into
Station 2, complete the downstroke of
the platform by firmly pushing the
handle to its full aft stop FIG 131–
this will ensure that the primer is fully
seated.
5. Set aside the primed case, it will be
used later for adjusting the powder
measure.
FIG 133
2. Powder Bar Adjustment
FIG 133:
FIG 134
Note:Although a scale is not included with
the machine, you’ll need one to 
30 
						

							31
properly adjust the powder bar. 
Dillon Precision Products offers two 
types of scales FIG 134. On the 
right, and electronic scale, and on 
the left, a balance beam scale.
FIG 135
You are now ready to fill the powder
measure FIG 135, but first you’ll need to
refer to your reloading handbook.  Under
the section specified for the caliber you’re
loading you’ll see a number of suitable
powders. Also given are “suggested starting
loads” and “maximum loads” (Lyman
Reloading Handbook).
Note:We do not recommend using  IMR 
stick powders (looks like pencil
lead) when loading a caliber size 
less than 25 caliber. We do not 
recommend using maximum loads 
of powder.
Warning:  Wear safety glasses whenever 
working with live primers. Safety 
glasses are available from Dillon 
Precision Products.
Note:Insure that you have the proper 
powder bar installed. To do so refer 
to “About Powder Bars” on page 13.
For instructions on how to change 
the powder bar, refer to Step 19 in 
the Caliber Conversion Section, 
page 41.
1. Put on your safety glasses.
FIG 136
2. Fill the powder measure and replace
the cap on both the powder measure
and the powder containerFIG 136.
3. Place a primed case into Station 2.
Note:Using a case with a primer in it will 
keep the powder from leaking out 
through the primer flash hole.
FIG 137
4. Cycle the machine to charge the
case. Using your powder scale, weigh
the powder chargeFIG 137. (From
this initial measurement, you will be
able to determine whether you’ll
need to increase or decrease the
powder charge.)
FIG 138
5. Using a 7/16” wrench, give the pow-
der bar bolt a quarter of a turn clock-
wise or counter-clockwise as neces-
sary to adjust the powder charge FIG
138. Clockwise will increase the
powder charge and vice versa.
Warning:As always, be sure to replace
the lid on the powder measure.
6. IMPORTANT!  Before measuring the
next load, charge the case then empty
the powder back into the powder
measure. This will allow the powder
in the newly adjusted powder bar to
settle and give an accurate reading.
7. Replace the cartridge into Station 2
and charge the case. Continue this
process until the charge is reading
correctly. Once you have achieved
the desired powder charge weigh two
more charges to insure the powder
bar is throwing a consistent charge.
3. Powder Check System 
Adjustment:
Once the powder bar is throwing the
desired charge, the powder check rod can
be installed and adjusted.
Warning:  A double-charged round (a 
loaded round with twice as much 
powder as it should have) can dam-
age your gun as well as cause bodi-
ly injury.
Warning:A round loaded without powder 
can also damage your gun as well 
as cause bodily injury. If a round 
without powder is fired in your gun, 
the detonation of the primer will 
push the bullet part way down the 
barrel. If the lodged bullet is not 
removed before another round is 
fired, the gun will be damaged.