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Welcome to Dillon Precision Products'
Technical Help For the AT500.

The following troubleshooting solutions apply to an unmodified AT 500 only. If you have updated your machine with RL 550B parts, you may need to refer to the RL 550B Help Guide  or to
RL 550B Instruction Manual the if the solution is not found in this guide.

space10x5.gif (817 bytes)Sizing Questions
space10x5.gif (817 bytes)Powder and Powder Measure Questions
space10x5.gif (817 bytes)Primer Questions
space10x5.gif (817 bytes)Bullet Seating Questions
space10x5.gif (817 bytes)Shellplate Questions
space10x5.gif (817 bytes)Miscellaneous Topics

Sizing Questions

Primer Questions

Shellplate Questions

Powder and Powder Measure Questions

Bullet Seating Questions

Miscellaneous Topics

Getting marked cases at the sizing station

  1. Using the wrong sizing die for that caliber
    1. make sure to use the correct sizing die for the caliber being loaded
  2. Cases may be oversized from firing in a gun with an oversized chamber
    1. the case may have outlived its useful life
    2. start with new cases and fire only in a known chamber
    3. it could have also been too hot of a load or an over-pressured load
  3. Dirty cases
    1. clean the cases before loading
  4. Brass or nickel is adhering to the carbide insert
    1. lube cases properly to prevent this
    2. clean the insert with 600 grit to remove build-up
    3. use Sweets 762® solvent to clean the die
  5. Using new cases which have sharp edges at the case mouth
    1. deburr the case mouth with a deburring tool
  6. Die not tightened while the case is in place
    1. after setting the sizing die per instructions in the AT 500 manual, put the case back into the shellplate, pull the operating handle down all of the way and then tighten the die lock ring. This helps to keep the die straight in the toolhead
  7. If you are still having difficulty, please E-mail Dillon's Technical Support staff or call 1-800-762-3845 or 602-948-8009
Return to Sizing Questions | Top of Page

Cases are not properly sized

  1. Not pulling the operating handle (part #511 or #20636) down all of the way
    1. pull the handle down all of the way and then push it up all of the way
  2. Case may be oversized from firing in a gun with an oversized chamber
    1. the case may have outlived its useful life
    2. start with new cases and fire only in a known chamber
    3. it could have also been too hot of a load or an over-pressured load
  3. Sizing die is not adjusted properly
    1. pull the operating handle down all of the way and screw the sizing die down all of the way to the shellplate. Raise the handle and insert an unsized case into the shellplate. Pull the handle down all of the way and tighten the die lock nut
  4. If you are still having difficulty, please E-mail Dillon's Technical Support staff or call 1-800-762-3845 or 602-948-8009
Return to Sizing Questions | Top of Page

Cases are sticking in the sizing die

  1. Insufficient case lube was used
    1. cartridges for which Dillon recommends case lube are: .44-40, .44 Mag, .41 Mag, .45LC and all rifle calibers
    2. spread the lube evenly on the cases
  2. Alcohol has not yet evaporated from Dillon Case Lube (part #13733)
    1. allow ten minutes for the alcohol from the case lube to dry before sizing the cases
  3. If you are still having difficulty, please E-mail Dillon's Technical Support staff or call 1-800-762-3845 or 602-948-8009
Return to Sizing Questions | Top of Page

Dents in cases after sizing

  1. Excessive sizing lube was used -- this applies only to cases with shoulders
    1. spread the lube evenly and lightly on cases
  2. If you are still having difficulty, please E-mail Dillon's Technical Support staff or call 1-800-762-3845 or 602-948-8009
Return to Sizing Questions | Top of Page

Decap pin is not working or is breaking

  1. Smaller caliber case may be stuck inside a larger case, media and/or polish has formed a hard mixture in the bottom of the case, or there is debris in the case
    1. examine cases before depriming. Make sure they are free of debris
  2. Berdan cases
    1. has one or two flash holes that are offset from the middle. Berdan cases cannot be reloaded and should be discarded
  3. Sizing Die is not adjusted properly
    1. pull the operating handle down all of the way and screw the sizing die down all of the way to the shellplate. Raise the handle and insert an unsized case into the shellplate at station one. Pull the handle down all of the way and tighten the die lock nut (part #516)
  4. Point of decap pin is squared off, rather than rounded
    1. pin gets stuck in anvil of primer and pulls it back up
    2. clean the brass build-up off the pin using steel wool
  5. Using non-Dillon dies that do not have a tapered opening
    1. screw the decapping assembly down further
  6. Burrs around the flash hole
    1. use a flash hole deburring/uniformer tool
  7. If you are still having difficulty, please E-mail Dillon's Technical Support staff or call 1-800-762-3845 or 602-948-8009
Return to Sizing Questions | Top of Page

Cases are not getting primers

  1. Dillon recommends standing up in front of the machine while operating it
  2. Be sure to have the machine mounted on a solid surface. If the bench moves or flexes this may result in priming problems. Again, be sure to be standing up to operate the machine
  3. No primer in the primer cup
  4. Using the wrong size primer for the caliber being loaded
    1. consult a loading or powder manual for the correct primer size for the desired caliber
  5. Primer cup (part # 525S or 525L) is upside down or is the wrong size
    1. the primer cup is gold for the small primers and silver for the large primers
  6. Primer seating punch (part # 524S or 524L) is the wrong size
    1. one seating punch is small and the other is large
  7. Primer seating punch (part # 524S or 524L) is not compressed and locked properly in place
    1. partially rotate the shellplate so that it covers the primer hole in the platform. Loosen the primer set screw about 1/4 turn. Leave the wrench in the set screw and push forward on the handle. Lastly, tighten the primer set screw
  8. If you are still having difficulty, please E-mail Dillon's Technical Support staff or call 1-800-762-3845 or 602-948-8009
Return to Primer Questions | Top of Page

Crushed, sideways, upside down or improperly seated primers

  1. It is important to be standing up rather than sitting down while operating the machine
    1. the Dillon strong mount (part # 22051) optimizes the machine's height for the best operation
  2. Not pushing the handle fully forward or hard enough
    1. make sure that full forward movement is not being blocked
  3. Locator buttons are missing or are the wrong size
    1. see the AT 500 instruction manual for the correct placement and size locator buttons for the caliber being loaded
  4. Using the wrong size primer for the caliber being loaded
    1. consult a loading or powder manual for the correct size primer for the desired caliber
    2. large rifle primers are .008" taller than large pistol primers. Do not substitute
  5. Index ball (part # 522) is stuck in a hole in the shellplate platform (part # 506)
    1. insert a small slotted screwdriver into the slot around the hole to remove the index ball
  6. Shellplate is too loose
    1. shellplate must turn freely, but not be too loose
    2. tighten down the shellplate bolt all of the way, then back it out 1/16 of a turn. Now tighten the shellplate bolt set screw on the left side of the shaft to hold adjustment
  7. Primer cup (part # 525S or 525L) is upside down or is the wrong size
    1. the primer cup is gold for the small primers and silver for the large primers
  8. Cartridge retaining spring (part # 533) needs adjusting
    1. adjust so that it just touches the case and then back off about the thickness of a business card. The cartridge retaining spring must hold the case centered without interfering with the movement of the shellplate
  9. Residue has formed under the primer cup (part # 525S or 525L)
    1. remove and soak all of the parts, with the exception of the plastic parts, in acetone or alcohol and then scrub them with a toothbrush
    2. a temporary fix is to rotate the primer cup (part # 525S or 525L) several times to free it
  10. Primer seating punch (part # 524S or 524L) is not compressed and locked properly in place
  11. Military primer pocket needs swaging
    1. use a swaging tool, such as the Dillon Super Swage 600, to modify the primer pocket to commercial specifications
  12. If you are still having difficulty, please E-mail Dillon's Technical Support staff or call 1-800-762-3845 or 602-948-8009
Return to Primer Questions | Top of Page

Spent primers are not dropping into the spent primer cup

  1. Spent primer catcher chute (part #557) is sticking
    1. spread out the sides of the primer catcher chute to prevent sticking
  2. Spent primer catcher-pin (part #558) is binding movement of the spent primer catcher chute (part #557)
    1. replace the cotter pin
  3. Spent primer catcher cup (part # 532) is missing
    1. consult the AT500 instruction manual for proper placement of the spent primer catcher cup
  4. If you are still having difficulty, please E-mail Dillon's Technical Support staff or call 1-800-762-3845 or 602-948-8009
Return to Primer Questions | Top of Page

Shellplate is not indexing smoothly

  1. Shellplate is too tight
    1. shellplate must turn freely, but not be too loose
    2. tighten down the shellplate bolt all of the way, then back out 1/16 of a turn. Now tighten the shellplate bolt set screw on the left side of the shaft to hold the adjustment
  2. Primers, powder or other debris is trapped under the shellplate
    1. keep the shellplate clean. Remove and soak in rubbing alcohol or in acetone
    2. when replacing the shellplate bolt (part #517), lube the bolt with a little all-purpose grease
  3. Cartridge retaining spring (part # 533) is restricting the shellplate's movement
    1. adjust so as to just touch the case and then back off about the thickness of a business card. The cartridge retaining spring must hold case centered without interfering with the movement of the shellplate
  4. If you are still having difficulty, please E-mail Dillon's Technical Support staff or call 1-800-762-3845 or 602-948-8009
Return to Shellplate Questions | Top of Page

Cases are misaligned or are not fitting into the shellplate

  1. Wrong shellplate for that caliber
    1. consult the AT 500 instruction manual for the correct size shellplate for the caliber being loaded
  2. Wrong case for that caliber shellplate
    1. check the case headstamp for caliber markings
  3. Shellplate is upside down
    1. number or letter in a circle must face up
  4. Locator buttons are missing or are the wrong size
    1. consult the AT 500 instruction manual for the correct placement and size locator buttons for the caliber being loaded
  5. Rim of the case is damaged or the case was shot in an open-bolt gun
    1. an example of an open-bolt gun would be a 9mm sub-machine gun
    2. discard any damaged cases
  6. Worn out case from overuse or from hot loads
    1. useful life of the case is over and it should be thrown away
  7. Debris has collected in the grooves of the shellplate
    1. clean out the debris with an awl or with a toothbrush
  8. If you are still having difficulty, please E-mail Dillon's Technical Support staff or call 1-800-762-3845 or 602-948-8009
Return to Shellplate Questions | Top of Page

Shellplate keeps tightening

  1. Brass-tipped set screw (part #505) is loose or missing
    1. consult the AT 500 instruction manual for proper adjustment
  2. If you are still having difficulty, please E-mail Dillon's Technical Support staff or call 1-800-762-3845 or 602-948-8009
Return to Shellplate Questions | Top of Page

Over-flared or under-flared cases

  1. No funnel is installed
    1. consult the AT 500 instruction manual for the proper funnel for the desired caliber
  2. Wrong funnel for desired caliber
    1. consult the AT 500 instruction manual for the proper funnel for the desired caliber
  3. Improper powder die (part #16629) adjustment
    1. consult the AT 500 instruction manual for the proper adjustment of the powder die
  4. Powder die set screw is loose
    1. powder funnel could be riding up or down in the powder die. Tighten the powder die set screw
  5. Variations in case length
    1. trim cases
  6. If you are still having difficulty, please E-mail Dillon's Technical Support staff or call 1-800-762-3845 or 602-948-8009
Return to Powder Measure Questions | Top of Page

Cases are sticking to the powder funnel

  1. New cases
    1. deburr the case mouth of new cases with a deburring tool
  2. Powder funnel is dirty
    1. soak funnel in rubbing alcohol or in acetone
    2. wipe with steel wool or Scotch-Brite® pad
  3. If you are still having difficulty, please E-mail Dillon's Technical Support staff or call 1-800-762-3845 or 602-948-8009
Return to Powder Measure Questions | Top of Page

Powder is spilling from the machine

  1. Operating the machine too fast
    1. this does not allow the powder a chance to dispense completely into the case
    2. smooth cycling of the handle, down all of the way and then up all of the way, works best
  2. Case is full
    1. this is common in 9mm
    2. index the shellplate more slowly
  3. Machine is not secured properly
    1. look for loose bolts or an unstable bench
  4. No primer in the case
  5. If you are still having difficulty, please E-mail Dillon's Technical Support staff or call 1-800-762-3845 or 602-948-8009
Return to Powder Measure Questions | Top of Page

Shaving lead or lube when seating the bullet

  1. Wrong size bullet
    1. make sure to use the correct bullet for the case being loaded
  2. Case is not belled enough
    1. increase the case bell by turning down the powder die. To do this, turn the die clockwise in 1/2 turn increments
  3. Using a combination seat and crimp die
    1. bullet gets crimped before being fully seated
    2. adjust the the seating stem depth first, then adjust the crimp after the seating depth is correct
  4. Cracked case mouth
    1. throw the case away
  5. If you are still having difficulty, please E-mail Dillon's Technical Support staff or call 1-800-762-3845 or 602-948-8009
Return to Bullet Seating Questions | Top of Page

Brass shavings fall when the bullet is seated

  1. New cases
    1. the symptom will usually go away after one or two firings
  2. Case mouth is worn or thinned out
    1. the case is worn out, and should be discarded
  3. Too much flare in case
    1. decrease the bell by turning the powder die upwards. To do this, turn the die counter clockwise in 1/4 turn increments
  4. If you are still having difficulty, please E-mail Dillon's Technical Support staff or call 1-800-762-3845 or 602-948-8009
Return to Bullet Seating Questions | Top of Page

Bullet is tilted after seating or the loaded round varies in overall length

  1. Bullet was not straight on the case prior to seating
  2. Case is belled too much or not enough
    1. set the bell so that the bullet sits on top of the case without falling off but not so much that the bullet falls into the case
  3. Wrong seating stem for that bullet or caliber
    1. make sure to use the correct seating stem for the desired caliber
    2. use the stem that makes the best contact with the bullet
  4. Using the wrong diameter bullet
    1. make sure that the bullet diameter is correct for the bore being used
    2. some brands and shapes of bullets give greater variation than others
  5. Using wrong locator buttons
    1. consult the AT 500 instruction manual for the right size locator buttons for the desired caliber
  6. No case in station two when tightening the powder die nut (part # 516)
    1. this leaves the bell uneven and slants the funnel
    2. after adjustment of the bell, put the case back into the shellplate, pull the handle down all of the way and then tighten everything up
  7. Variations in case wall thickness
    1. if case appears thicker than usual, chamfer the case mouth
    2. check the case length, it may need trimming
  8. If you are still having difficulty, please E-mail Dillon's Technical Support staff or call 1-800-762-3845 or 602-948-8009
Return to Bullet Seating Questions | Top of Page

Bullets are being deformed at the seating station

  1. Wrong seating stem for that bullet or caliber
    1. make sure to use the correct seating stem for the desired caliber
    2. use the stem that makes the best contact with the bullet
  2. Case is not belled enough
    1. increase the bell by turning down the powder die. To do this, turn the die clockwise in 1/2 turn increments
  3. Lead or wax has built up in the die
    1. soak the die in rubbing alcohol or in acetone
  4. Soft lead
    1. use Dillon hard cast bullets
  5. If you are still having difficulty, please E-mail Dillon's Technical Support staff or call 1-800-762-3845 or 602-948-8009
Return to Bullet Seating Questions | Top of Page

Bullet is too loose or too tight in the case

  1. New cases have not been sized
    1. new cases should always be sized
  2. Bullet is undersized
    1. check the bullet diameter with a pair of calipers
  3. Wrong size bullet for that caliber
    1. consult a loading or powder manual for the correct size bullet for the desired caliber
  4. Using wrong crimp die for that size case
    1. look on the die body for caliber identification
  5. Not going full stroke on the handle (part #511)
    1. pull the handle down all of the way and then push it up all of the way
  6. Over-belled case
    1. over-belling in station two will require an over-adjustment of the crimp die to take out the excessive flare
    2. set the bell so that the bullet sits on top of case without falling off, but not so much that the bullet falls into the case
  7. Over-crimping
    1. consult the AT 500 instruction manual for adjustment instructions
  8. Variations in case lengths
    1. trim cases
  9. If you are still having difficulty, please E-mail Dillon's Technical Support staff or call 1-800-762-3845 or 602-948-8009
Return to Bullet Seating Questions | Top of Page

Cartridges won't feed into the gun's chamber

  1. Over-all length of the cartridge is too long
    1. bullet is hitting the rifling
    2. consult a loading or powder manual for the over-all length specifications
  2. Too much flare has been left on the cases
    1. over-belling in station two will require over-adjustment of the crimp die to take out excessive flare
    2. set the bell so that the bullet sits on top of the case without falling off, but not so much that the bullet falls into the case
  3. Not enough or too much crimp
    1. consult the AT 500 instruction manual for the proper die adjustment
  4. Using range brass that has been shot in someone else's gun. Especially those with extra large or unsupported chambers
    1. start with new cases and shoot only in a known chamber
  5. Incorrect headspace
    1. purchase a headspace gage (Rifle)
    2. for proper use, see the case preparation manual
  6. If you are still having difficulty, please E-mail Dillon's Technical Support staff or call 1-800-762-3845 or 602-948-8009
Return to Miscellaneous Topics | Top of Page

Dies are too short

  1. Need Dillon lock rings (part #14067)
    1. three extra lock rings come with each machine
  2. There is no need to over-tighten--only one thread above the toolhead is sufficient enough to hold the dies
  3. Use Dillon Dies
  4. If you are still having difficulty, please E-mail Dillon's Technical Support staff or call 1-800-762-3845 or 602-948-8009
Return to Miscellaneous Topics | Top of Page

Handle movement is difficult

  1. Primers are trapped under the shellplate
    1. remove the shellplate and remove any trapped primers
  2. Main shaft is dirty or dry
    1. clean and lubricate the shaft and cylinder with 30 WT motor oil
  3. Link arms (part #503A or #503B) and/or upper link arm pins (part #515A or #515B) need to be greased
    1. use an all purpose grease. Do not use aerosol lubricants
  4. Frame (part #501) is marred where the shellplate“s brass-tipped set screw (part #505) was backed out too far
    1. consult the AT 500 instruction manual for proper adjustment
  5. If you are still having difficulty, please E-mail Dillon's Technical Support staff or call 1-800-762-3845 or 602-948-8009
Return to Miscellaneous Topics | Top of Page

Dillon Precision Products, Inc.
8009 E. Dillon's Way
Scottsdale, AZ 85260 U.S.A.

Call Toll Free 800-762-3845 or 602-948-8009 ° Fax 602-998-2786
Open 7-6 MST, M-F; 8-3 Sat.

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Last modified: December 18, 1998

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