b) Small powder bar - FIG 202 The retaining plug has a short end and a long end. If the small powder bar is installed:

1) Align the hole in the powder bar spacer with the hole in the top of powder measure body.

2) Insert the long end of the retaining plug into both the top of the powder measure body and the powder bar spacer. Note: The long end of the retaining plug is designed to anchor the spacer that accompanies the small powder bar.

Step 20) Load the components.

Trouble Shooting

Dies Too Short

A. Need Dillon die lockrings (14067).

1. Three extra come with the machine.

2. Threadaphobia (fear of too few threads) can strike anyone-anytime. It is a common but curable disease. You only need one thread showing above the toolhead to hold the die lockring.

Cartridge won't feed into chamber

1. Overall length too long. See loading manual for dimensions.

2. Improper headspace. See loading manual for dimensions. Use head-space case gage.

3. Too much bell left on case. (Not enough crimp.)

4. Case buckled.

a. Too much crimp.

5. Using brass that you picked-up at the range that has been fired in an oversize chamber.

6. Gun operation problems. Hard or Incomplete Indexing

A. Shellplate not indexing smoothly.

1. Shellplate bolt adjusted too tight. Readjust 1/8 turn maximum.

2. Shellplate bolt tightens when shellplate turns.

a. Brass tipped set screw loose or missing.

3. Wrong size locator buttons.

4. Index pawl bent, worn or in backwards.

5. Dirt under shellplate.

a. Keep shellplate clean.

b. When replacing shellplate, bolt (13418) must be lubed with a little all purpose grease.

6. Bent or broken shellplate.

7. Index ball (13891) and/or spring (14118) stuck, missing or broken. Can also cause shellplate to turn backwards after indexing.

8. Not taking full stroke on the handle.

9. Ring indexer (13677) worn or indexer block (16671) needs adjusted. Return spring damaged or missing.

10. Improper type of locator button for caliber.

B. Handle movement difficult

1. Powder or other debris causing jamming of moving parts.

2. Link arm pins (13700) galled.

3. Main shaft (13485) dirty or dry.

a. Clean and lubricate with 30 wt oil.

4. Camming pin on black casefeed slide not lubed.

5. Primer cam worn causing primer indexing arm to drag and stick.

6. Incorrect lubricant used. Do not use solvent blended lubes.


A. Casefeeder is on but will not rotate.

1. Brass caught under casefeed plate.

2. Casefeed is too full.

3. Bad micro-switch.

B. Cases are falling down tube upside down jamming in the top tube, etc.

1. Using the wrong casefeed plate for that caliber.

2. Casefeed baffle (13688) not in place (see conversion chart for which cal. require use of the casefeed baffle)

3. Casefeed is too full.

4. The machine is not secured to a sturdy enough bench.

C. Casefeed tube (13099 or 13101)

appears too short.

1. Casefeed is not pushed down all the way on the casefeed mounting post (17123).

D. Cases hanging up at micro-switch or micro-switch inoperative.

1. Check the angle of the switch lever and adjust as necessary.

a. Too sharp an angle will cause cases to hang up.

b. Too shallow an angle will cause incomplete shutoff.

E. Cases jamming at the casefeed arm (13716).

1. Wrong size or loose body bushing for caliber being loaded.

2. Operating machine too fast.

3. Short stroking the machine.

4. Dented or squashed cases.

Case Insertion

A. Case not getting to shellplate.

1. Wrong size Station 1 locator.

2. Wrong size casefeed adapter.

3. Shellplate bolt is too loose.

4. Dirt in shellplate pockets or damaged shellplate.

5. Handle being moved too rapidly on upstroke.

6. Dirt or media in casefeed track.

B. Case doesn't drop onto platform.

1. Using the wrong arm or body bushing.

C. Cases not fitting in shellplate or staying centered.

1. Locator buttons missing or wrong size for that caliber.

2. Primer Station locator tab (13242) needs to be readjusted.

3. Wrong shellplate caliber being loaded.

4. Wrong cases for caliber being loaded.

5. Debris in pockets of shellplate.

6. Rim of case damaged or shot in open bolt gun. i.e. 9mm sub gun.

7. Cases out of spec.

8. Worn out brass from over use or hot loads.

9. Shellplate damaged from decap pin.

Station 1 - Resizing and Decapping

A. Crushing cases.

1. Incomplete case insertion.

2. Not enough radius on die. Use Dillon dies where available.

3. Unstable bench causes case to move and hit edge of die.

B. Bending or breaking decapping pins.

1. Smaller caliber brass stuck inside of case or on decapping stem.

2. Berdan primed cases.

3. Media and polish has formed a hard mix in bottom of case.

4. Handle being moved too rapidly on the down stroke.

5. Rocks or other foreign objects in cases.

C. Cases are not being pushed all the way into the shellplate by the case insert slide (97082).

1. Not pushing forward enough (or at all) on the handle.

2. Camming pin (13371) needs to be adjusted.

3. Debris or media in shellplate or under Station 1 locator.

4. Bent rail on Station 1 locator.

D. Case insert slide (97082) jams on station 1 locator.

1. Be sure there is lubrication on the case insert slide.

2. Debris under Station 1 locator.

E. Sizing die marking cases.

1. Wrong sizing die for that caliber.

2. Dirty brass.

3. Scratched die.

4. Case shot in large chamber and base is excessively expanded.

5. Brass/nickel adhering to carbide insert.

a. Lube cases properly to prevent this.

b. Clean insert with 600 grit to remove build up.

c. Use Sweets 7.62 Solvent to clean insert.

6. New brass (Sharp edges at case mouth.)

7. Die lockring not tightened with a case in the die.

F. Oil dent in shoulder of case or neck appears wrinkled.

1. Using too much case lubricant.

G. Case sticking in sizing die.

1. Insufficient case lube.

2. Alcohol not yet evaporated from spray-on case lube.

a. Allow five minutes for alcohol to evaporate before sizing cases.

H. Decap pin not decapping.

1. Sizing die not screwed down far enough.

2. Decapping assembly not screwed down all the way.

3. Decapping pin bent, broken or missing.

4. Point of decap pin is squared off not rounded (pin gets stuck in anvil and pulls primer back into primer pocket).

5. Berdan primed brass.

a. Berdan primed brass has two flash holes and should not be reloaded.

I. Case not properly sized.

1. Size die not properly adjusted.

2. Handle not cycled all the way down to stops.

3. Case was shot in an unsupported chamber and base is excessively expanded.

b. Consult a gunsmith about chamber.

J. Spent primers dropping on floor.

1. Spent primer cup bracket (16209) broken or missing.

2. Spent primer cup (16211) broken or missing.

K. Spent primers bouncing out of empty spent primer cup.

1. Place a piece of thin foam to the bottom of the spent primer cup. Station 2 - Priming

A. Primers not feeding properly.

1. Magazine tube is empty.

2. Stuck primer in tube.

a. Tube must be thrown away.

3. Damaged brass tip or tube.

a. Tube must be thrown away.

B. Crushed primers.

1. Dirt or debris in shellplate pockets.

2. Ringed primer. When a spent primer has been pierced by the decapping pin leaving a ring of metal from the primer in the pocket.

3. Chipped or worn primer punch.

4. Hot loaded ammo that has been fired several times and the base of the case has been flattened. Such cases being reloaded need primer pockets swaged - i.e., radiused edges on the primer pocket.

5. Be sure the loading bench is not shaking or rocking. To keep the bench from moving bolt it to the wall. If the bench is not solid the primers will tip and jam.

6. Be sure the primer Station locator tab is adjusted correctly. It should be adjusted so it is approximately 10 thousandths from the case rim (the thickness of a business card).

7. Wrong size/type primer for that caliber.

8. Pushing forward on the handle too hard.

9. Cycle the machine using a smooth continuous motion. Do not make erratic movements.

C. High Primers.

1. Shellplate too loose. Be sure the shellplate is tightened down correctly. This is done by turning the shellplate bolt down until it is tight, then backing it off 1/8 of a turn. Don't forget to loosen the shellplate bolt set screw, on the left side of the mainshaft, before adjusting the shellplate bolt. Tighten the set screw when finished.

2. Erratic handle motion.

3. Push handle forward fully to seat the primer.

4. Handle crank broken or cracked. a. Push forward on the handle and look for hairline cracks.

D. Primer early warning system inoperative.

1. Battery dead, missing or backwards.

2. Follower rod (13707) not in or warped.

3. Buzzer defective.

4. Primers stuck in magazine tube.

E. Rotary primer disc not indexing/jammed.

1. Check indexing lever and replace if bent.

2. Inspect primer cam (13670).

a. Missing.

b. Worn camming surface.

3. Powder debris on platform.

4. Stuck primer catching on shim

(14117) and platform body.

F. Primers going in upside down.

1. Primer punch is not properly aligned with the indexing shellplate. a. Using old index cam (if purchased machine prior to March 95).

Station 2 - Powder Charging and Case Mouth Belling

A. Crushing cases.

1. Locator tab is misadjusted. Adjust tab until there is a small amount of light showing between the case and the locator tab. Approximately 10 thousandths of an inch.

B. Spilling powder.

1. Slamming or going too fast with the operating handle. Common with .380 and 9mm cases which are filled to the top of the case. Slow down and pace yourself.

2. Stick or pencil lead type powders bridging on the case mouth in the powder funnel.

3. Check powder bar adjustment.

4. Machine not secured properly or bench not stable.

5. Small powder bar spacer plug (13921) missing.

6. No primer in case.

C. Erratic belling (too much or too little).

1. Variation in case length. Note: separate cases by brand.

2. Handle not moving all the way down on each cycle.

4. Wrong funnel for that caliber.

5. Improper powder die adjustment.

6. Powder measure loose on powder die (screws not tightened down).

D. Erratic powder charges.

1. Powder bar not moving the full length of its travel. Turn the powder die down until it does.

2. Failsafe rod missing.

3. Powder not settled in hopper.

a. After a powder bar has been readjusted - cycle five cases through the machine dropping powder in each one. Check the powder weight of the fifth case.

4. Not cycling the handle through its full travel.

5. Machine not secured properly or bench not stable.

6. Wrong size bar for requirements. a. Switch to the large bar over 7


7. Powder funnel or drop tube dirty or clogged.

8. Crack in powder measure body.

a. Usually present where bellcrank bolt (13904) enters powder measure body (21274).

9. Small powder bar spacer plug (13921) missing.

10. Erratic handle movement.

11. Using pencil lead/stick type powder.

E. Powder bar sticking

1. Powder bar dirty.

a. Clean with acetone or finger nail polish remover. Keep very clean. Do not lubricate.

b. Do not use sandpaper, file or anything abrasive.

2. Powder bar, powder bar spacer or powder measure body galled. Appearance of a long streak of metal on the bar or spacer.

a. Wipe off with soft cloth soaked in acetone, lighter fluid or rubbing alcohol.

3. Failsafe assembly not installed or broken.

4. Using fine-grained spherical powder. a. Win 296, H110 and Accurate Arms powder have been known to get between the powder bar, spacer and/or the powder measure body and bind movement.

5. Powder bar insert/powder bar adjustment bolt adjusted full open against the stop.

a. This can bind the powder bar insert causing the powder bar to drag.

F. Case sticking to powder funnel.

1. New, extremely clean or liquid cleaned brass.

a. Do not clean cases more than 1 1/2 hours.

b. Worn powder funnel. Streaks on funnel tip. Repolish to high luster.

Station 3 - Powder Check

A. Powder check die inoperative.

1. Check battery.

2. Check adjustments.

Station 4 - Bullet Seating

A. Erratic seating depth of the bullet.

1. Variations of less than 20 thousandths of an inch are due to variations in cases and bullets. This is not a problem.

2. Build up of lead shavings and/or lube in the seater or crimp dies.

3. Bullets having erratic dimension (length and/or the ogive).

4. Use of improper seating plug for the type of bullet being used.

5. Variations in case types and/or lots (sort your brass).

6. Refer to loading manual for dimensions.

B. Shaving brass when bullet is seated or crescent shaped brass falling on shellplate.

2. Too much flare.

C. Shaving lead/lube when bullet is seated.

1. Case not belled enough with funnel.

2. Case was cleaned too long. Case mouth must be deburred.

3. Wrong bullet diameter for caliber.

D. Bullet loose in brass.

1. Bullet is under sized.

a. Measure diameter of bullets.

2. Incorrect powder funnel, i.e., if the funnel is too big it will make the mouth of the case oversized.

E. Bullet tilted after seating.

1. Case not belled enough.

2. Wrong seating stem or die for bullet style or caliber.

3. Missing or wrong locator buttons, i.e., case not centered below the die.

4. Uneven casemouth opening.

5. Using a nominally incorrect bullet. i.e., .38/357 bullet in .38 Super.

6. Die and stem not square to shellplate. a. Snug lockring with case and bullet in die.

F. Seating die deforming top of bullet.

1. Seating stem not matching that style of bullet.

3. Lead and/or wax build-up in die.

4. Case not belled enough.

Station 5 - Crimp

A. Erratic crimping.

1. Variation in case length. Probably due to mixed brands of brass.

2. Dirty or worn out crimp die. Use Dillon dies where available.

B. Loose bullet.

1. Too much taper crimp. This condition can also affect accuracy.

2. Wrong expander.

3. Thin cases. (Use Dillon dies and this won't be a problem.)

4. Wrong crimp die.

C. Too much or too little crimp on completed round.

1. Crimp die adjusted too low or too high. See manual for maximum crimp dimensions. If not available, crimp to 20 thousandths below case diameter.

2. Using wrong crimp die for that case.

3. Not using full stroke of handle.

4. Over flared case.

5. Variations in case length.

Ejecting Finished Cartridges

A. Rounds not ejecting after Station 5.

1. Ejector wire (13298) bent, broken or missing.

2. Wrong locator buttons.

3. Shellplate damaged from decap pin.

B. Finished cartridges do not make it into the catch bin.

1. Operating handle too fast.

2. Chute/bin mount is bent.

3. Bin is missing or improperly located.


Lubrication: Operating circumstances will dictate the frequency of required lubrication. It is highly recommended that the XL 650 be cleaned and lubed after every 3000 rounds of operation. Use oil or wheel bearing grease. Never use penetrating lubricants, aerosol sprays, or solvent type lubes, such as WD-40 or Break Free. Lubrication Points:

Shellplate bolt - Grease.

Main Shaft Lubrication -

Use only 30 wt. motor oil. Once again, do not use penetrating lubricants, aerosol sprays, or solvent type lubricants.

650 Caliber Conversion Chart - Pistol To order a complete conversion use the 5 digit number to the right of the caliber listing. To order individual parts use the 5 digit number below the description. Casefeed discs are not included in caliber conversion kits.

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