Dillon Precision XL 650 Instruction Manual

							FIG 139
A. Installation and adjustment of 
the powder check rods 
FIG 139:
1. Remove the powder check rods from
the bag FIG 139. The three rods fit
different calibers. On the left .44-.45
caliber, center .30-.41 caliber and on
the right .22-.29 caliber.
FIG 140
2. Choose the correct rod for the caliber
you’re loading. For example – if
you’re loading .38 Spl. you would
use the .30-.41 caliber rod. If the rod
you’re using doesn’t have the
grooved sleeve on it, remove the
grooved sleeve from the one you’re
not using and thread it onto the cor-
rect rod FIG 140.
FIG 141
3. Insert the rod into the powder check
die FIG 141.
4. Put on your safety glasses.
5. Place a case with the proper powder
charge into Station 3 and raise the
platform. Leave the platform in the
raised position.
FIG 142
6. Thread the grooved sleeve down so
that the contact pin fits inside the
groove as seen in FIG 142.
FIG 143
7. Snug the lock nut with a 3/8” wrench
FIG 143.
FIG 144
B. Powder Check System
Demonstration:
1. Place a primed but empty case (case
with no powder) into Station 3 and
raise the platform. The contact pin is
above the groove FIG 144(the alarm
sounds) indicating that the case has a
low or no charge.  
2. Lower the platform. Remove the
empty case from Station 4 and place
it in Station 2.
3. With the empty case in Station 2 give
it a double charge.
To do so:
a.Raise the platform all the way to
charge the case.
b.Lower the platform halfway (enough
for the powder bar to return to its start-
ing point without indexing the case to
Station 3 and releasing the locklink).
c.Again, raise the platform to give the
case a second charge of powder.
d. Index the case to Station 3 by lower-
ing the platform all the way. (The case
is now double charged and ready to be
checked by the Powder Check System.)
FIG 145
4. Raise the platformFIG 145. The con-
tact pin is below the groove (the
alarm sounds) indicating that the
powder charge is double or more.
32 
						

							Note:If the buzzer to the powder check 
system goes off, stop loading and 
check the powders weight with the 
scale. The primer warning buzzer 
and the powder check system have 
different pitch buzzers to distinguish 
the two. The primer system is a 
deep buzz and the powder check is 
a high pitched tone.
4. Filling the Primer System:
Warning:Wear safety glasses whenever 
working with live primers. Safety 
glasses are available from Dillon 
Precision Products.
FIG 146
Now it’s time to fill the primer maga-
zine. To begin, you’ll need the proper size
primer pickup tube. Primer pickup tubes
come in either large or small. In FIG 146
are the two primer pickup tubes included
with your XL 650. 
FIG 147
FIG 148
On the left is the large pickup tube (with
a green tip), on the right is the small pickup
tube (with a yellow tip). Make sure theretaining clip FIG 147 is always in place
before using either tube. You’ll need the
proper size primers and we suggest using this
optional Dillon Primer Flip Tray FIG 148. It
will make this task quite a bit easier.
1. Put on your safety glasses.
2. Separate the two halves of the primer
flip tray.
3. Place the primers onto the grooved
surface of the primer flip tray.  
FIG 149
4. Slowly shake the flip tray until all
the primers rest shiny side down
FIG 149.
FIG 150
5. Place the smooth lid on top, and
flip the entire tray. Remove the
grooved lid. 
Now all the primers should be shiny side
up on the smooth side of the primer flip
tray.FIG 150.
FIG 151
6.FIG 151Collect the primers using the
plastic tip end of the primer pickup
tube. Make sure all primers are shiny
side up, and fill the tube. 
FIG 152
7. When the primer pickup tube is full,
pivot the black switch lever away
from the primer magazine shield.
Rotate the tube upside down over the
primer magazine shield and remove
the retaining clipFIG 152. After fill-
ing the primer magazine return the
switch lever to its normal position.
FIG 153
8. Slide the follower rod through the
hole in the switch lever until it touch-
es the primers FIG 153. When the
machine is nearly out of primers the
rod will activate the buzzer.
33 
						

							Add some empty cases to your casefeeder
and turn the unit “on”. The motor will run
until the clear casefeed tube fills and then it
will automatically shut off.
The reloading process on an XL 650
begins with one complete stroke or cycle of
the handle, which causes the first case to be
cycled through the casefeed system and fed
into the shellplate.
Station One
The first case is at station one of the
machine and a new primer is ready at sta-
tion 2. Move the handle down, the sizing
die reforms and also deprimes the first case.
Return the handle to its rest position. Using
a smooth, fluid motion, move the handle up
to its full aft stop to seat the new primer into
the case and release the handle. At the
same time, another case has been fed into
the shellplate.
Station Two
Again, cycle the handle completely. The
first case now gets a charge of powder, the
second case is resized and deprimed, then
they both advance to the next stations.
Using a smooth, fluid motion, move the
handle up to its full aft stop to seat the
new primer into the case. Return the han-
dle to its rest position. Now three cases
are in the shellplate. 
Station Three
Cycle the handle. The first case enters the
powder checker, the second case is charged
with powder and the third case is resized
and deprimed. Again, return the handle to
its rest position and all the cases advance to
their next stations and the fourth case is
inserted into the shellplate. 
Station Four
It is now time to begin placing a bullet on
the case at station four. Cycle the handle
down and then back up to its rest position.
The first case now has a bullet seated into it
and has advanced to station five. At this
point the shellplate is full.
Seat a primer into a case at the full aft
stroke of the handle and a case is inserted
into the shellplate automatically.
Station Five
Using your left hand, place a bullet on the
case at station four. Cycle the handle and
the first case is crimped at station five and
then ejected out at the right rear of the
machine into the collection bin. Repeat the
process by placing a bullet into the case at
station four and seating the primer into the
case at station two.
At this point a completed round is ejected
from the machine with every complete
stroke of the handle.When operating the handle, pay close
attention to the cases, noting the changes
that take place as they go through the
machine. 
Pace yourself when operating the
machine. Do not crash the handle down
against its stop and do not snatch the han-
dle upward. It should take two or more
seconds to move the handle from its rest
position, down and then back up to its
rest position.
Station/Toolhead Orientation
34
Now its Time to Start Loading
Station Orientation and Loading Functions
Sta. 4
Seat DieSta. 5
Crimp Die
Sta. 1
Sizing Die
Sta. 2
Powder
Measure Toolhead
Pin (2) Sta. 3
Powder Check
System (optional) 
						

							1. How to use the Caliber
Conversion Chart:
To explain the Caliber Conversion
Chart we are going to compare the pistol
caliber of .38 Spl. to the rifle caliber of
.30-06 FIG 154.
By comparing the two columns, you can
see which parts need to be changed. In this
comparison, .38 Spl. vs. .30-06, you can
see that none of the part numbers match up,
therefore, all of the those parts would need
to be changed. This, however, is not always
the case. If you compare .30-06 to
.308/7.62 Nato, you’ll find that they are
exactly the same. Another example would
be .38 Spl. vs. .357 Magnum. As you can
see, they too are identical. Some caliber
comparisons will show that only a couple
of parts are different – in this case, instead
of ordering an entirely new caliber conver-
sion kit, you have the option of ordering
only those parts needed to complete your
caliber conversion. 
2. Conducting the Caliber 
Conversion 
(The following steps are in the sequential
order in which the caliber conversion is to
be conducted):
Note:Included in the following is a com-
plete list of all the items that need to 
be considered when conducting a 
caliber conversion. This is not a list 
of all the items that will need to 
changed or readjusted – this is a 
complete list of all the items that 
may need to be changed or re-
adjusted. The items that need to be 
changed or readjusted will depend 
on the caliber your XL 650 is cur-
rently set up to load and the caliber 
you’re changing to.
Step 1
)Remove the cases from the 
machine:
1. Turn off the casefeed system
2. Remove the remaining cases from the
casefeed tube and the casefeed bowl.  
Step 2
)Remove the powder from the 
powder measure:
Depending on the caliber change, youmay have to change powders and/or the
powder bar. If so, you’ll need to empty the
powder from the powder measure.
FIG 155
1. Disconnect the failsafe rod FIG 155.
FIG 156
2. Loosen the two powder measure
clamp screws FIG 156.
3. Remove the powder measure and
empty the powder back into the pow-
der can.
4. Manually cycle the powder bar to
ensure the powder measure is empty.
5. If you need to change powder bars
refer to Step 19
.
FIG 157
Step 3)Remove the toolhead FIG 157:
1. Disconnect the failsafe rod FIG 155.
2. Remove the toolhead pins and slide
the toolhead out.
Step 4
) Remove the shellplate:
Remove the shellplate only if you need
to either, change the shellplate for a differ-
ent caliber shellplate, or if you need to
remove the primer system (such as when
emptying the primers from the primer sys-
tem).
FIG 158
1. Using a 1/8” Allen wrench loosen the
shellplate set screwFIG 158. The
shellplate set screw is located on the
left side of the mainshaft just below
the shellplate platform. Do not
remove the screw, just loosen it about
a half turn.
35
Caliber Conversion Section
FIG 154 – Caliber Conversion Chart Sample
Caliber Complete Shellplate Locator Funnel Station 1 Casefeed Arm Body Casefeed Primer Powder
Conversion Number Button Locator Adapter Bushing Bushing Disc System Check Rod
38 Spl 21098 (2) 13430 (2) 14062 (D) 13599 13563 (Orange) 13386 (Red) 13403 (Sm38) 13384 (LP) 21072 Sm Med
.30-06 21094 (1) 13204 (1) 13930 (B) 13587 (1) 13595 (Black) 13541 (White) 13661 (Med) 13604 (LR) 21075 Lg Med 
						

							FIG 159
2. Using a 1/4” Allen wrench remove
the shellplate bolt FIG 159.
FIG 160
3. Swing the ejector wire out of the way
and remove the shellplate. Be sure
that index ball and index pawl
remain in placeFIG 160.  
FIG 161
4. Remove the locator buttons FIG 161.
FIG 162
Step 5)Remove the primers:
Remove the primers only if you need to
change to a different size or type of primer.
1. Remove the shellplate (ref. Step 4
).
2. Loosen and remove the two primer
system bolts FIG 162.
FIG 163
3. Carefully lift the primer assembly
away from the machine FIG 163.
FIG 164
4.FIG 164Empty the remaining
primers by placing a finger over the
primer shield cap, inverting the
magazine and carefully pouring the
primers onto the primer flip tray. Put
the primers back into their original
box.
5. If any primers remain in the primer
area (on the machine) carefully
remove them.
6. If you need to change the rotary
primer disc go to Step 6. If you only
to need empty the primer magazine,
reinstall the primer system at this
time.
Note:About Steps 6, 7and 8. If you’re 
changing from a large rifle/pistol 
primer to a small rifle/pistol primer 
or vice versa, the rotary primer disc, 
primer magazine, and primer punch 
will have to be changed. This is 
because each of these three items 
are designed specifically for either 
large rifle/pistol primers or small 
rifle/pistol primers. 
Step 6
)Change the rotary primer disc 
(see note above):
Note:The two different size rotary primer 
discs are labeled L (large) and S 
(small).
1. Remove the shellplate (ref. Step 4
).
2. Remove the primer system and empty
the primer magazine (ref. Step 5
).
36 
						

							FIG 165
3. Rotate the primer system upside
down. Using an 1/8” Allen wrench
unscrew the primer support shim
screw and remove the primer support
shim FIG 165.
FIG 166
4. Remove the rotary primer discFIG
166. Make sure the detent ball
remains in place.
5. Place the other rotary primer disc
onto the disc pin.
6. Slip the primer support shim back
into place and snug the screw.
7. Reinstall the primer system.
FIG 167
Step 7)Change the primer magazine 
(see note just above Step 6
):
1. Remove the Primer Early Warning
System FIG 167.
FIG 168
2. Remove the primer shield cap FIG
168.
FIG 169
3. Remove the primer magazine by
pulling it straight up FIG 169.
4. Insert the new primer magazine.
5. Replace the primer shield cap and
Primer Early Warning System.
FIG 170
Step 8)Change the primer punch (see 
note just above Step 6
):
The primer punch is attached to the
underside of the platform on the right side
FIG 170. 
FIG 171
1. Raise the platform.
2. Using a 9/16” wrench loosen and
remove the primer punch FIG 171.
3. Remove the other size primer punch
from the primer accessory package.
Screw it in and snug it down.
4. Lower the platform.
Step 9
)Install the new shellplate:
This is located in your caliber conver-
sion kit.
1. Remove the shellplate (ref. Step 4
).
2. Place the new shellplate onto the
shellplate platform. The number side
of the shellplate should be face up.
Rotate the shellplate until it seats
itself on the index ball. 
37 
						

							FIG 172
3. Swing the ejector wire back to its
original position over the shell-
plate and insert the shellplate bolt
FIG 172. 
4. Using a 1/4” Allen wrench run the
shellplate bolt down until it stops
then loosen it slightly. Loosen it just
enough to allow the shellplate to
index freely.
FIG 173
5. Snug the shellplate set screw FIG
173.
FIG 174
Step 10)Install new locator pins FIG 174:
The new locator pins are located in your
caliber conversion kit.
1. Install as depicted
FIG 175
Step 11)Install the new Station 1 loca-
tor FIG 175:
The Station 1 locator is located in your
caliber conversion kit. 
FIG 176
Step 12)Change the Body BushingFIG 
176:
The new body bushing is located in the
caliber conversion kit.
FIG 177
1. The body bushing is located on the
right side just above Station 1 FIG
177. Remove the body bushing by
slipping an Allen wrench through the
cross hole and twisting it counter-
clockwise.
2. Install the new body bushing.
FIG 178
Step 13)Replace the casefeed arm     
bushing and casefeed
adapter FIG 178:
The new casefeed adapter and casefeed
arm bushing are located in your caliber
conversion kit.
38 
						

							FIG 179
1. Remove the casefeed tube FIG 179.
FIG 180
2. Remove the casefeed adapter FIG
180.
FIG 181
3. To replace the casefeed arm bushing
first raise the platform. Remove the
casefeed arm bushing (currently
installed in your machine) and
replace it with the new one FIG 181.
4. After installing the new casefeed arm
bushing, install the new casefeed
adapter.
FIG 182
5. Reinstall the casefeed tube by placing
the casefeed tube into the casefeed
adapter and snapping it into the metal
clamp FIG 182.
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 183
Step 14)Case insert slide cam – turn 
around FIG 183:
The case insert slide is reversible. The
long side of the cam (see arrow “A” FIG
184) is for pistol and the short side of the
cam (see arrow “B” FIG 184) is for rifle. As
a reference, any case as long or longer than
.223 Rem. will require that the short (rifle)
side of the cam be used. Reverse the case
insert slide cam only if your caliber conver-
sion requires it.
FIG 184
FIG 185
1. Using a 5/32” Allen wrench, remove
the cam screw FIG 185and reverse
the case insert slide.
FIG 186
2.FIG 186Insure that the back side of
the cam is flush with the cam slide.
3. Replace the cam screw and snug it.
39
B
A 
						

							FIG 187
Step 15)Change out the casefeed disc 
FIG 187:
Change the casefeed disc only if your cal-
iber conversion requires it. 
1. Grip the casefeed plate clutch drive
FIG 187and pull upward. The case-
feed disc will slip off the motor drive
shaft.
2. To install the new casefeed plate –
place the casefeed plate clutch drive
on the motor driveshaft. Slowly rotate
the disc until the groove on the drive
shaft aligns with the notch in the
plate. The casefeed plate will then
slip down onto the motor shaft and
into place.
Note:About Steps 16 and 17. Both the 
camming pin and Station 2 locator 
tab do not require removal or 
replacement. Instead, depending 
on the caliber change, they may 
need to be readjusted. Whether or 
not these two items need to be 
adjusted depends on the diameter 
of the base of the case and noth
ing else. If, for example, you are 
converting  from 9mm to .45 ACP, 
because the diameter of the two 
cases are different, both the cam
ming pin and Station 2 locator 
will need to be read justed. If, on 
the other hand, you are converting 
from, say, .45 ACP to .30-06 or 
.308, you will not have to readjust 
these two items – the diameters at 
the base of these cases are the 
same.FIG 188
Step 16)Adjusting the camming pin FIG 
188(see previous note):
1. Place a case in both Station 1 and
Station 2. The case in Station 2 must
have a primer – the primer can be
spent or new.
FIG 189
2. Using a 9/16” wrench, loosen the lock
nut FIG 189on the camming pin.
FIG 190FIG 191
FIG 192
3.Using a 1/8” Allen wrench, turn the
camming pin clockwise FIG 190four
or five turns – or enough so that when
you push the handle to the full aft
stop FIG 191, the case insert slide
(see arrow FIG 192) does not push
the case fully into Station 1 FIG 192–
this will give you a place to start the
adjustment. 
4. With the handle pushed against its
full aft stop, start backing the cam-
ming pin out by turning it counter
clockwise FIG 190. Continue to back
the camming out until the case stops
its forward movement into the
shellplate. Once the case becomes
fully inserted into Station 1, stop turn-
ing the camming pin.
40 
						

							FIG 193
Note:The objective here is that – at the 
point the case becomes fully insert-
ed into shellplate (with the handle 
against its full aft stop) – the cam-
ming pin is still in contact with the 
case insert slide cam – or at least 
within a 1/16” of the case insert 
slide cam (see arrow FIG 193).
5. Once properly adjusted, tighten the
lock nut. 
Step 17
)Adjusting the Station 2 
Locator Tab (see note just 
above Step 16
):
The adjustment of the Station 2 locator
tab is best accomplished with the toolhead
removed.
1. Place a case in Station 2.
FIG 194
2. Using a 5/64” Allen wrench, insert it
into the side of the primer feed body
FIG 194. Turn the screw to adjust the
locator tab. A turn clockwise will
move the tab back away from the
shellplate and a turn counter clock-
wise will adjust it closer to the
shellplate. 
FIG 195
3. Adjust the locator tab so that the tab
just clears the case FIG 195. The
objective here is, with the case fully
inserted into the shellplate, the loca-
tor tab should not come into contact
with the case. However, the tab
should be close enough so as to not
allow the case to lose its position in
the shellplate. The distance between
the locator tab and the case should
be about .010” or about the thickness
of a business card.
Step 18
)Refer to the Rifle Section or 
Pistol Section to set up the tool
head.
Step 19
)Station 2 – Changing out the 
powder bar:
Refer to “About Powder Bars” under the
Rifle or Pistol Section or refer to the Caliber
Conversion Chart (pages 46-48) to deter-
mine whether or not you’ll need to change
the powder bar.
To change the powder bar:
1. Remove the powder from the powder
measure (ref. Step 2
). 
2. Hold the powder measure over a
powder container and cycle the
powder bar with your thumb to
empty all remaining powder.
FIG 196
3. Using a 5/32” Allen wrench, loosen
the bellcrank screw just enough to
remove the white cube from the side
of the powder bar FIG 196.
FIG 197
4. Remove the white plastic retaining
plug. (FIG 197)
FIG 198
5.a)If the large powder bar is current-
ly installed – remove the large pow-
der bar.
b)If the small powder bar is currently
installed – remove both the small
powder bar and small powder bar
spacer FIG 198. Note: The purpose of
the spacer is simply to make up for
the room allowed for the large pow-
der bar.
41