Call 1-866-SANDISK. You shouldn’t be having this problem with a new unit.
Though my guess is that what’s happening is that it’s running into something from your library it can’t read. For instance, if there are giant embedded images in the tags, or long comments, or foreign characters, the Fuze’s tiny brain may not be able to handle them.
If you can connect to the computer again, take the whole library off and send it over in smaller chunks. That will help you find the problem files.
When the Fuze loads after you have added or removed music, it reads the ID3 tags, the electronic labels of the files, and makes a database: Artist, Album, etc. If it stumbles over a tag, annoying things happen.
I run all my albums through mp3tag to make them Fuze-friendly. It’s a free program.
Install mp3tag and have it add itself to context menus. (checkbox during install)
Change the default under Tools/Options/Tags/Mpeg to Write ID2v2.3 ISO-8859-1, the Fuze’s favorite format.
Highlight them all (in correct order, top to bottom) and under Tools, use the Auto-Numbering Wizard to Add leading zeros. Leading zeros will give you 01, 02, 03 as track number and make sure they play in order. It will also change the tag version to ID3v.23 because that’s how you told it to save them.
Under View, highlight files that might be giving you a problem and see if the album cover is imbedded. You don’t need the album cover in every file–just in the same folder, named, folder.jpg or album.jpg (sorry, .png or other graphic formats don’t get displayed by the Fuze). If you highlight all the files and the cover appears, click on the little floppy disc icon, and mp3tag will store one in the album folder as folder.xxx in the same image format (hopefully .jpg). Then click the X to take the images out of the tags. It will make the Fuze load much faster.
It takes just seconds per album, but if you have a big library that will take some time. See if you can isolate the problem files and just fix them–either before you send them over or in the copy that’s on the Fuze.
Once you’ve done your initial major loading of the Fuze, you’ll probably just be moving a few albums at a time, and at that point the mp3tag step is easy. Ideally you shouldn’t have to do this, but it’s the downside of the Fuze trying to handle many file formats, and the fact that mp3 tags aren’t all standardized. There’s human error, too–people dump a lot of useless junk into some ID3 tags, and the Fuze dutifully tries to read it all.