Dillon Precision XL 650 Instruction Manual

							12
PISTOL SECTION –
Toolhead Set Up
To set up the toolhead you’ll need to have
empty brass, bullets, primers and powder
on hand. (For your convenience Dillon
Precision offers a wide variety of new
primed and unprimed brass, bullets, primers
and powder.) For easy access, place your
brass in an open container. Dillon Precision
also offers a variety of blue bin boxes which
come in handy for this purpose.
A. Station 1 – To install the 
size/decap die FIG 25:
Warning:Never attempt to de-prime live
primers, an explosion may result in
serious injury or even death.
1. Raise the platform, by lowering the
handle all the way down.
2. Screw the sizing die into Station 1.
Continue to screw the die down until
it just touches the shellplate. Tighten
the die lockring finger tight  Now
lower the platform by raising the han-
dle to its upright position. 
3.Place a case in the casefeed funnel.
Here, the case drops to the casefeed
arm bushing.
4.Raise the platform. The inserter cam
pushes the feed arm bushing over the
body, dropping the case onto the
Station 1 locator.
5.Lower the platform. The case is insert-
ed into Station 1. 
FIG 28
Note:After raising the handle, insure that 
you push the handle against its full  aft
stop FIG 28. This will insure 
that the case is fully inserted into 
Station 1. Note:Also, when priming, pushing the 
handle against its full aft stop,FIG 
28, will insure that the primer is 
fully seated.
6.Again, raise the platform. The case is
now sized. If the case has a spent
primer, it will be deprimed. Leave
the platform in the raised position
with the case fully inserted in the
die. This will ensure that the die
remains in alignment when tighten-
ing the lockring.
FIG 29
7. Using a 1-1/8” wrench to turn the
lockring and a 7/8” wrench to hold
the die body, tighten the lockring
FIG 29.
FIG 30
B. Station 1 – The decap-
ping assembly FIG 30:
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:
1.Unscrew the decapping assembly
from the top of the dieFIG 30.
FIG 31
2.Unscrew the knurled retaining nut,
see “A”FIG 31, remove the old pin
and replace it with a new one, see
“B” FIG 31.  
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. (Tip: Check prices of 
components. You can often pur-
chase primed cases for the price 
of the primers and new empty 
cases. Obviously, this is a good 
deal since  you pay the same price 
and save time.)
FIG 32
C. Station 2 – Installation of
powder measure assembly
FIG 32:
A
B 
						

							13
FIG 33
FIG 34 
1.Use a 5/32” Allen wrench to loosen
the two collar clamp screws and
remove the powder die FIG 33 & 34.
FIG 35
2. Screw the powder die into Station 2.
Stop when the die is flush with the
bottom of the toolhead FIG 35.
FIG 36
3.Remove the powder funnel FIG 36
from the bag containing the locator
buttons.
FIG 37
FIG 38
About Powder Funnels: 
In FIG 37are 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-neckedtype. The bottom of the rifle-style funnel
fits snugly over the neck of the case,
allowing powder to drop in without
spilling (the rifle-style powder funnel does
not bell the mouth of the case). The bot-
tom of the pistol funnel, on the other hand,
fits inside and actually expands and bells
as it guides the powder into the case.
Powder funnels are caliber specific, so be
sure you have the correct funnel by refer-
ring to the caliber conversion chart.
4.Insert the funnel into the dieFIG 38.
Make sure that you insert the funnel
into the die with the grooved end up.
The funnel should move up and
down freely.
FIG 39
5.Remove the lid and the protective
cardboard tube from the powder
measure and place it onto the pow-
der die FIG 39. Turn down the two
clamp screws until they are snug.
Then loosen them slightly. The mea-
sure should move freely atop the die.
D.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 20 
grains of powder.
3.Large – use for dropping 20 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, 
						

							14
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 the pow-
der bar – refer to “Powder Bar Adjust-
ment”in the Caliber Conversion Section
on page 30.
E.  Station 2 – Adjustment 
of Powder Die & Powder 
Funnel:
Note:Adjusting the powder die for a 
straight wall case is not the same 
as adjusting a powder die for a 
bottle-necked case. This is 
because straight wall cases are 
given a bell and bottle-necked 
cases are not given a bell. 
Adjusting the powder die for a   
bottle-necked case is covered in 
the rifle section.
FIG 40
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 40). 
FIG 41
Also the belling process does not begin until
after the powder bar has traveled its full dis-
tance. The angled portion on the bottom ofthe powder funnel (see arrow FIG 41) is
what bells the cartridge. Once the white
cube has contacted the powder measure
body the case is forced upward against the
tapered portion of the powder funnel pro-
ducing a bell. The more the powder die is
adjusted down (clockwise) the more the
case will be belled.
Note:If the powder die is not adjusted 
down far enough to cause the 
powder bar to travel its full dis-
tance the powder charge will be 
erratic and the case will not 
receive enough bell.
To adjust the powder die/powder
funnel:
1.Drop a case into the casefeed 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 40.
FIG 42
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 42. 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 40.
FIG 43
Once the powder bar travels fully across
you should continue to adjust the powder
die for the desired amount of bell (turn the
powder die 1/8 of a turn at a time). The
desired amount bell is just enough to allow
the bullet to sit on the case mouth without
falling off and to keep the case from shaving
lead during the seating process (see “A”
FIG 43).
Note:If you screw the die down too far, 
the case will look like example“C” 
FIG 43. You must then discard 
this case, back the powder die off, 
by turning it counter-clockwise, and 
continue with a new sized case.
You’ll soon learn to judge the correct
amount of bell by simply looking at it.  In
the meantime, you might want to use your
dial calipers to check it. Twenty thou-
sandths of an inch greater (at the mouth of
the case) than its original diameter, should
about do it.
A
Correct amount of
bell.
B
Not enough bell.
C
Too much bell. 
						

							15
FIG 44
6. Once you’ve achieved the desired
amount of bell – with the case in
Station 2, raise the platform. Run the
lockring down hand tight FIG 44.
FIG 45
FIG 46
7. Insure the bellcrank and the failsafe
bracket FIG 45are aligned. Using a
5/32” Allen wrench, snug the collar
clamp screws FIG 46.
FIG 47
8.While holding the powder mea-
sure, snug the lockring using a 1
1/8 wrench FIG 47. Now lower the
platform.
FIG 48
F.Station 2 – Installation of
the failsafe rod assembly 
FIG 48:
The purpose of the powder measure fail-
safe rod is to return the powder bar to its re-
charge position.
FIG 49
1.Using your forefinger, move the lock-
link (#17838) down to align the hole
with the slot on the Powder Measure
bellcrank (#97034) FIG 49.
FIG 50
2. Insert the rod (#13629) through the
holes FIG 50.
3. Loosen the blue plastic wing nut
(#13799).
FIG 51
4. Slide the failsafe rod into the failsafe
return bracket. Push the shoulder
washer up into place (see arrow FIG
51) and tighten the blue plastic wing
nut until the spring just touches the
underside of the bracket.
Note:Do not fill the powder measure or 
adjust the powder bar until the rest 
of the dies are installed and adjusted. 
						

							16
FIG 52
G. Station 3 – Installation of  
the Powder Check System 
FIG 52:
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 
and bodily injury may occur.
FIG 53
1.Loosen the die clamp screw FIG 53
and remove the die.
FIG 54
2.Raise the platform and screw the pow-
der check die into Station 3. There
should be a 1/8 to 1/4 inch space
between the shellplate and the bottom
of the die FIG 54.
FIG 55
3.Run the lockring down. Using a
1 1/8” wrench snug the lockring  
FIG 55.
FIG 56FIG 57
4.Remove the 10-24 screw and nut
from the black push rodFIG 56and
place the powder check system on
the powder check die FIG 57.
Center the black push rod (see arrow
FIG 57) in the hole that is to the left
of the die.
FIG 58
5.Reinstall and snug the die clamp screw
FIG 58.
FIG 59 
						

							17
FIG 60
6. FIG 59Screw 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 platform
FIG 59. Lower the platform part way
and unscrew the screw (counter-
clockwise) until raising the platform
causes the buzzer housing to gently
rock into the side of the die collar
FIG 60.
FIG 61
7.Secure the jam nut by holding the
black push rod while tightening it
using a 3/8” wrench FIG 61.
Note: Once you’ve adjusted the powder 
bar for the desired powder charge, 
adjustment of the powder check 
system can be completed.
H. Station 4 – General 
Information on Bullet 
Seating
FIG 62
FIG 63
FIG 64
The purpose of the seating die FIG 62 is
to insert the bullet into the case and to push
it down into the case the proper amount.
How far the bullet is pushed into the case
will determine the overall length (OAL).
Several factors go into determining the
proper OAL – such as, the maximum rec-
ommended OAL, listed in the reloading
manual, and the type of bullet being
loaded. The type of bullet can determine
the OAL in one of two ways.  If the bullet
has what is called a cannelure, or crimping
groove (items A&B inFIG 63), this will
determine the proper OAL. If the bulletyou’re using doesn’t have a cannelure or a
crimping groove (item C in FIG 63), then
you’ll need to refer to your reloading manu-
al for the suggested OAL.  The purpose of
the cannelure and crimping groove is to
secure the bullet by giving the mouth of the
case a place to go (without deforming the
bullet) when being crimped. When the bul-
let is properly seated, the mouth of the car-
tridge case should be near the top of the
cannelure/crimping groove FIG 64.
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, .38 Special lists a max-
imum OAL of 1.55” (Lyman Reloading
Handbook). If you’re seating the bullet to
the cannelure/crimping groove, 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/crimping groove,
refer to the specific type of bullet you’re
using in the reloading manual.  For example
– if you’re loading a 158gr 38sp JHP and it
doesn’t have a cannelure/ crimping groove,
use the suggested OAL of 1.480 (Lyman
Reloading Handbook).


 












 


















 



















 












 


















 

















A
Sizing/Decapping Die
Seating Die Crimp Die
BC 
						

							18
FIG 65
I. Station 4 – Seating Stems 
for pistol FIG 65
All pistol seating dies come with inter-
changeable seating stems. The seating stem
you should use will depend on the shape of
the bullet you’re loading. Three different
types of seating stems may be available –
wadcutter, semi-wadcutter and round nose.
Check to make sure that the seating stem
installed in your seating die matches the
bullet you are loading.
Dillon seating dies, which are being used
in this manual, are easily disassembled.
Simply remove the hitch pin from the top
and slide the seating stem out  FIG 65.
Replace the seating stem and reassemble
the die.
FIG 66
J. Station 4 – Installation and 
Adjustment of the 
Seating Die:
1.Take the seating die from the die box
and screw it into Station 4. Screw
the die down until the bottom of the
die is flush with the bottom of the
toolhead FIG 66. Note: At this point
the die will not be screwed down far
enough to begin seating the bullet,
but it will give you a place to start. 
2.Place a case (with a belled case
mouth) into Station 4.
3.Place a bullet on the belled case
mouth and raise the platform. Then,
lower the platform just enough to
inspect the bullet without indexing the
shellplate.  If the bullet is not seated
deep enough, screw the seating die
down 1/2 turn at a time. As a guide,
one full turn moves the die down
about 70 thousandths of an inch,
about the thickness of a nickel.
Again, cycle the machine and inspect
the seating depth. Repeat these steps
as necessary until the correct overall
length is achieved. Use a dial caliper
or equivalent to measure the overall
length of the cartridge. Check the
overall length of the round against the
information in your reloading manual.
FIG 67
4.Once you have obtained the proper
OAL, replace the cartridge into
Station 4 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
FIG 67.
Note:If you should happen to seat the 
bullet too deep, you can use a 
Dillon bullet puller to reclaim your 
components.
FIG 68
K. Station 5 – Installation and 
adjustment of the Crimp 
Die FIG 68:
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 cartridge with a properly seat-
ed bullet into Station 5.
FIG 69
3.Raise the platform and continue to
screw the die down until it touches
the cartridge FIG 69.
4.Lower the platform and give the die
an 1/8 turn down, again raise the
platform.
5.Lower the platform halfway and
inspect the cartridge. If the bell is still
present, or the desired amount of
crimp has not been achieved, give
the die a 1/8 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.
Sizing/Decapping Die
Seating Die Crimp Die 
						

							FIG 70
Note: FIG 70When adjusting the crimp
die it is important to know what to
look for. Check that the crimp: Looks
OK, allows your firearm to function
consistently and the bullet feels tight
in the case.
The drawing of case #3 FIG 70is a
depiction of a case that has been over
crimped by adjusting the crimp die down
(clockwise) too far. Note the defined line
below the mouth of the case and the bulge
below the line. This is not a proper crimp.
This line is the direct result of the cartridge
being over crimped. A line like this will
only appear if the crimp die is adjusted
down too far.Warning: Over crimping
.45ACP, .38 Super, 9mm, etc., can actually
cause the bullet to be loose in the case. 
Go to Loading Components
Section – Page 30



















 





























 












 


















 




 




 







 












 











19
123 
						

							RIFLE SECTION – 
Toolhead Set Up
To set up the toolhead you’ll need to
have your empty brass on hand.  For your
convenience Dillon Precision offers a wide
variety of new primed and unprimed brass.
For easy access, place your brass in an
open container. Dillon Precision also offers
a variety of blue bin boxes which come in
handy for things like this.
FIG 71
A. Station 1 – About the Case 
Gage FIG 71:
To install and adjust a sizing/decapping
die you must have a case gage and know
how to use it. The sizing die shapes the
case. If the case doesn’t have the proper
shape it won’t fit properly in the chamber of
the rifle. The purpose of the case gage is to
determine whether or not the case has the
proper shape, which in turn will tell you if
your sizing die is properly adjusted. 
Note:Case gages are caliber specific.
B. Station 1 – How to use the 
Case Gage:
The way the case gage works is this:
Once you’ve made a preliminary adjust-
ment to your sizing die drop the sized case
all the way into the case gage FIG 72. Look
at the base of the case. 
FIG 72
FIG 73
FIG 74FIG 75
If the base of the case is below the high step
(see “B” FIG 73) and above the low step
(see “A” FIG 73) then the sizing die is prop-
erly adjusted. If the base of the case is
above the high step FIG 74then you will
need to adjust the sizing die down by turn-
ing it clockwise. 
FIG 76
FIG 77
If the base at the case is below low step
FIG 75then the sizing die is adjusted
down too far and needs to be backed out
by turning it counter-clockwise (Note: this
case should be thrown away). Once the
sizing die is properly adjusted, drop the
properly sized case back into the case
gage and look at the mouth of the case FIG
76. If the case mouth is below the high
step (see “C” FIG 76) and above the low
step (see “D” FIG 76) then the case is the
proper length and will not need to be
trimmed. If the case mouth is above the
high stepFIG 77then the case mouth
needs to be trimmed in order to reduce the
overall length of the case. If you find that
your cases need to be trimmed, Dillon
Precision offers two types of case trimmers.




 













 













 








 








 








 


































Figs 72 & 73
20
A
Low StepB
High Step
C
Low StepD
High Step
ABAB
C
D
AB
C
D 
						

							FIG 78
FIG 79
C. Station 1 – Installation 
and adjustment of the siz-
ing/decapping die FIG 78:
Warning: Never attempt to de-prime a live
primer, an explosion may result 
causing serious injury or even 
death.
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).
1.Raise the platform, by lowering the
handle all the way.
2.Install the sizing die by screwing it
into Station 1 FIG 79. Continue to
screw the die down until the mouth
of the die is about the thickness of a
dime away from the shellplate. Lower
the platform by raising the handle to
its upright position. 
FIG 80
3.Drop a lubricated case into the case-
feed funnel FIG 80. Here the case
drops to the casefeed arm bushing. 
4.Raise the platform. The inserter cam
pushes the feed arm bushing over the
body, dropping the case onto the
Station 1 locator. 
5.Lower the platform. The case is
inserted into Station 1.
FIG 81
Note:After raising the handle, insure that 
you push the handle against its full 
aft stop FIG 81. This will insure 
that the case is fully inserted into 
Station 1. 
Note:When priming, pushing the handle 
against its full aft stop will insure 
that the primer is fully seated. 6.Again raise the platform. The case is
now sized. If the case has a spent
primer, it will be deprimed. Notice
the resistance 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.
7.Remove the case from Station 2 and
place it in the case gage. From this
point – follow the instructions provid-
ed under “Rifle Section B. Station 1 –
How to use the Case Gage.”
8.Once the sizing die is properly
adjusted, replace the case into Station
1 and raise the platform. Leave the
platform in the raised position with
the case fully inserted in the die. This
will ensure that the die remains in
position when tightening the lockring.
FIG 82
9.Run the lockring down until it con-
tacts the toolhead. Using a 1 1/8”
wrench to turn the lockring and a
3/4” wrench to hold the die body,
snug the lockring FIG 82.
21
Sizing/Decapping Die
Seating DieCrimp Die