KM 6500 Staple Cassette Jam on FS-503

[BeachPrinter]

The staple cassettes in our FS-503 have consistently had a problem switching to a newly loaded staple roll. Usually after a reload it will keep going for a while (30-60 staples) and then it either misses, jams, or fails to advance the new staple roll enough to push the remaining old staples completely forward. If all the old staples left over from the first roll are removed, it quickly settles down and good stapling can resume.

This was our recent experience with a relatively new machine on which we were running our first stapling job of 30,000 2-sheet sets.

It looks like the clear plastic cover which keeps the staples in place on the flat part of the cassette, should pop off easily, and make it easier to remove the old staples, but we couldn't figure it out, and a few times had to pull the old staples out the front, one or a few at a time until the new roll was fully advanced.

Anyone know about the quirks of this cassette?

[flc-printing]

You have probably figured this out by now, but we have found a way to avoid this problem. After you have set the new roll in, and are slowly pulling the tab out, watch for the begining of the new staples. When the new staples are about 1/8" away from the old staples, stop the advancement of the new staples by pressing down on the roll. Continue pulling the tab out without letting the new staples touch the old ones. It's worked for us.