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Thread: How to fix those dreaded em0480 problems for good

  1. #1
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    How to fix those dreaded em0480 problems for good

    Short of throwing it in the bin because in its original state it really is sub standard... Remove bean hopper, top housing, top burr 4 screws in next housing remove it being careful not to lose the button for the safety micro switch. Undo the nut 10mm noting that it is a left hand thread so you need to turn it clockwise to undo it, remove bottom burr and shims and 3 part bearing assy, there is a rubber seal sitting on top of the shaft bearing you need to dig it out carefully without destroying it, you will notice from new these grinders have a lot of lateral movement in this shaft therefore resulting in an uneven grind so what we are doing is replacing this soft rubber seal with something a lot more substantial, what I did was machine up a piece of timber which is all I had but some nylon bush material would be excellent, if machined to a snug finish slid it down the shaft into the plastic housing, then you will have eliminated the shaft movement. Reassemble the bottom burr, bearing, shims, micro switch and housing with the four screws. The next stage is to make up a spacer between the top of this housing and the top section I used masking tape in a spirax effect across the top by sticking multiple overlapping strips until completely covered, then carefully cut out the recesses and around the outside of the housing with a stanley knife this is simply done and very effective. The last stage is to replace the top section, you will also notice that the top burr is also sloppy in the top plastic housing I also fixed this by wrapping masking tape around it until snug, the amount of times you go around will depend on how loose yours is... Thats about it... once you replace the bean hopper etc you will need to back your adjustment off quite a bit, you will find that the "clumping" problem will dissappear and you will have to dial in your grind settings as though it was a different machine.

    If you are prepared to make these mods to your em0480 you will find it to be quite a good grinder after all, had sunbeam just taken a bit more care in component moulding, casting and machining they would have produced an awesome grinder, overall it has great features but in its raw state is quite ordinary to say the least.

    Ray.

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    Re: How to fix those dreaded em0480 problems for g

    Oh, I just saw this detailed set of instructions for modifying the EM0480....I just dont have access to those skills and I wonder if Sunbeam would appreciate/respond to some of these excellent, first hand suggestions from users, for their manufacturing process in future? I am still puzzling over how the 10 machines at the Sunbeam workshop all performed on 10 with a really consistent espresso grind...and this has been noted by other persons on this site, who have also attended the Sunbeam workshops....
    Gail

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    Re: How to fix those dreaded em0480 problems for g

    Would you by any chance have step by step photos?
    Is there any already made seal that fits in straight away without modifications?
    And what do you mean by
    "The next stage is to make up a spacer between the top of this housing and the top section I used masking tape in a spirax effect across the top by sticking multiple overlapping strips until completely covered, then carefully cut out the recesses and around the outside of the housing with a stanley knife this is simply done and very effective."?

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    Re: How to fix those dreaded em0480 problems for g


    "I am still puzzling over how the 10 machines at the Sunbeam workshop all performed on 10 with a really consistent espresso grind"


    Simple, they just chuck em out and replace em after every session.


    Nice post Ray, when I had mine, most of my problems were caused by the loose fit of the upper burr in the plastic carrier.

    The lower burr still seemed stable, but then, the grinder was only 3 months old. The Nylon bush/washer suggestion is great solution.

    Now, your homework assignment is to work out a mod to decrease the step size.

    What about, filing down the existing "humps" that create the steps, then glue in a length of cable tie [saw tooth facing inwards] and then mod the spring loaded pointer to suit.

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    Re: How to fix those dreaded em0480 problems for g

    I never thought of the zip tie mod to reduce the step size but I tell ya that is a real possibility isnt it? Im going to take a look at that.

    Ray.

    P.s coffee kid I will try to find the time to pull it down again and take some photos, Im not very good at expressing myself with text, I may also take the opportunity to explore reubsters brain child of the zippie tie.

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    Re: How to fix those dreaded em0480 problems for g

    Ok coffee kid here it is I have taken some photos of it, I hope it helps...

    This should show you how I did the masking tape washer between the housings and then cut it out.

    Ray.


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    Re: How to fix those dreaded em0480 problems for g

    This is the exploded view of components from top to bottom note masking tape around top burr, also note that the amount of tape you use is directly relevant to the amount of play you have in your various components.


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    Re: How to fix those dreaded em0480 problems for g

    Ahh.. I get you sorta...
    Any pics on the last section and the thing you machined out of timber?
    Sorry...

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    Re: How to fix those dreaded em0480 problems for g

    This one shows the timber bush inserted into the plastic housing, I didnt try to remove it because it is an interferance fit and subject to cracking through the grain being timber, on the other hand if it was nylon bushing material I probably wouldnt have that problem. Note it is not too tight on the shaft.


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    Re: How to fix those dreaded em0480 problems for g

    Would there be a particular size that the nylon bushing can be bought from hardware store?
    Just would love to do this mod just dont have the timber to make it out of and dont know how:(

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    Re: How to fix those dreaded em0480 problems for g

    This is a very blurry pic of the removed seal from where I fitted the timber bush, I know I only did the mod last night but I think the machining dimentions were 10.5mm ID and 17.5 OD, but then again being a sunbeam yours could be different to mine. Ha Ha Ha.


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    Re: How to fix those dreaded em0480 problems for g

    No, I got the sunbeam thats why i wanna do it:P

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    Re: How to fix those dreaded em0480 problems for g

    Finally one for you Reubster by time I machine out the existing indents for the grind steps I would be better off leaving it stepless and thus an even greater improvement, so having said that while its apart its getting a quick trip to work for an appointment with the dremel tonight... No time like the present is there?

    Ray........


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    Re: How to fix those dreaded em0480 problems for g

    How did you wrap masking tape around the top carrier?
    I tried it and the top burr wouldnt fit into the holder.

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    Re: How to fix those dreaded em0480 problems for g

    Quote Originally Posted by Coffee Kid link=1183436456/0#11 date=1183462915
    No, I got the sunbeam thats why i wanna do it:P
    Sorry mate I was having a dig at sunbeam, if you have a set of "very nears" you could confirm my vaige recollections on the inside and outside diameters of the shaft and plastic housing recess.

    Ray.

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    Re: How to fix those dreaded em0480 problems for g

    Quote Originally Posted by Coffee Kid link=1183436456/0#13 date=1183463284
    How did you wrap masking tape around the top carrier?
    I tried it and the top burr wouldnt fit into the holder.
    The tape goes around the top burr and is directly relevant to the amount of play there is in it.

  17. #17
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    Re: How to fix those dreaded em0480 problems for g

    Maybe i put too much in...

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    Re: How to fix those dreaded em0480 problems for g

    The item on the left is the top housing next to it is the top burr it has about 2 layers of masking tape on it, yours may not be as flogged out as mine so maybe one layer will fix it.... Its all trial and error.... until its just right.
    Ray


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    Re: How to fix those dreaded em0480 problems for g

    Haha, wonder why... I wrapped like 4 layers on it ::)

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    Re: How to fix those dreaded em0480 problems for g

    Hey Reubster check this out.........

    Ha Ha now stepless em0480....... thanks for the idea man...

    Ray.


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    Re: How to fix those dreaded em0480 problems for g

    Huh? I dont see any difference:S

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    Re: How to fix those dreaded em0480 problems for g

    Heaps sorry for the lousy blurry pics mate.

    Ray.

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    Re: How to fix those dreaded em0480 problems for g

    Quote Originally Posted by Ray C link=1183436456/0#12 date=1183463126
    Finally one for you Reubster by time I machine out the existing indents for the grind steps I would be better off leaving it stepless and thus an even greater improvement, so having said that while its apart its getting a quick trip to work for an appointment with the dremel tonight... No time like the present is there?

    Ray........
    Compared to this pic I have removed the indents in the plastic housing with a dremel.

  24. #24
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    Re: How to fix those dreaded em0480 problems for g

    So what did you do to it?

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    Re: How to fix those dreaded em0480 problems for g

    Heres another photo with different camera settings I hope this is clearer, I actually ground the indents off the inside edge of the top housing.


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    Re: How to fix those dreaded em0480 problems for g

    Ahh, I see.... How do you secure it when its grinding? Doesnt it move around when its grinding?

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    Re: How to fix those dreaded em0480 problems for g

    not with the added masking tape between the two housings.

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    Re: How to fix those dreaded em0480 problems for g

    Just a matter of dialing it in now........

    Finally something I may be able to work with.....

    Thanks for the chat, Im outta here for now, Ray.

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    Re: How to fix those dreaded em0480 problems for g

    Just when you think youve got it sussed and after fixing all of the other "MANUFACTURING DEFECTS" you find one last one and a quite important one at that, where the top burr goes through the top housing and engages into the bottom screw there are two locaters at either side of the top burr which fit or supposed to anyway into the other housing are typically really sloppy and loose. A split match stick and masking tape once again has done a fine job, Ill post a pic........ Ray.

    P.s. the pic is of the top burr assy. (the other side is the same as this side) You can see the half thickness match stick taped next to the "under size" raised section of PLASTIC. I hope this is clear for you.


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    Re: How to fix those dreaded em0480 problems for g

    I couldnt help myself I was so excited that the piece of crap actually works, it sounds and performs exceptionally, I would put it up against anything. It dialled in at just over 15 on the setting bar with no extra spacers under the burr just the 2 standard shims it came with and absolutely no clumping.

    I pulled a double ethiopian sidamo latte and it was fantastic, I am so excited, coffee nirvana is that little bit closer, probably not the best thing to do at 1.30 in the morning I really dont know how Im going to sleep or get up when the day breaks, anyway Ill cross that bridge later...

    So heres the result. Im going to try to get some sleep. Ha Ha Ha.... I must be kidding...


  31. #31
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    Re: How to fix those dreaded em0480 problems for g

    Try Teflon tape for the burr carrier thread. [smiley=wink.gif]

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    Re: How to fix those dreaded em0480 problems for g

    Hey

    I havent used mine yet and am a bit concerned about doing all this and it blowing up and not having warranty. Should I wait until it starts to slip? Or make changes in 6 months. Or even better see how yours goes over the next few months. I know its not supposed to heat up too much but masking tape???? :)

    Great ideas though and smart thinking pity Sunbeam didnt do this :)

    Sue

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    Re: How to fix those dreaded em0480 problems for g

    Sueb.....................wait a little and see how it goes, if you dont want to mod it, Sunbeam will happily swap it.
    Im not sure where your coffee making skills are , but some of the above mods will make more sense once you have used the grinder for a bit and the improvements [and the reasons behing doing them] will be more noticeable once your coffee skills reach a certain level.

    Ray

    Nice work, Nice shot.

    When I was playing around with mine and trying to make it steppless, I siliconed some little strips of rubber between the "humps". It worked ok but the position of the collar wasnt very stable, ie a little bump and the grind setting would move. I then tried glued a rubber strip [cut down rubber band] over the whole length of the "humps" which made an improvement but I still found it unstable, hence my thinking on the cable tie.

    Just curious, how stable is position of your collar?

  34. #34
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    Re: How to fix those dreaded em0480 problems for g

    Ray, your mods are very crafty, and look like they will tighten the whole burr assembly up nicely, at least in the short term, but I would worry that the wear and tear that results in increasing sloppiness in the plastic parts of the assembly will have the same or worse effects on masking tape and wood, over time. I had my first sign of the upper burr sitting a bit deeper into its housing with my grinder (now espresso grind works at 11 whereas it used to be 14/15, and it is only about a month old). I pulled it apart as others have. As you have observed, the plastic does not offer a very strong support where the burr sits and the metal compresses it a little (very silly design!). I am wondering if it is possible that this happens early in the grinders life, as the burr and plastic assembly wears in with use, and that it might stabilise at 11 or thereabouts (for optimal espresso), which might explain the grinders used by sunbeam for their demo all working on 10-12. Maybe this is wishful thinking....

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    Re: How to fix those dreaded em0480 problems for g

    This is one of the best threads I have seen on this site. Well done Ray C.

    I may see if a friend of mine can machine some nylon bushes for this purpose (for a couple of other friends with EM480s).

    BTW Does you camera have a macro facility or can you zoom from further away whn taking the pics?

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    Re: How to fix those dreaded em0480 problems for g

    Kaanage; Im not the best photographer that is for sure, the manufacture of nylon bushes is an awesome idea.

    Dig; My grinder got down to 3 for an espresso grind hence the Deterioration didnt stop, my theory is that I can add more tape if need be in the future, all I can say is that it has NEVER worked this well from new.

    Ruebster; my collar with the tape gasket / spacer under it is currently working very well, should it wear some more and become loose again which is probably quite likely I will add some more to it. By the way great advice to Sue...

    Ray.

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    Re: How to fix those dreaded em0480 problems for g

    Quote Originally Posted by vicroamer link=1183436456/30#30 date=1183494761
    Try Teflon tape for the burr carrier thread. [smiley=wink.gif]
    Thanks mate I didnt explain myself very clearly, the problem wasnt with the thread being sloppy it was the plastic locating lugs being too small for the mating housing... "made that way from factory" I still cant work out why they would do that...anyway its going very well now 8-)

    Ray.

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    Re: How to fix those dreaded em0480 problems for g

    Thanks for the info!

    Well Ive tried the grinder. Hubby decided to have a look at the burrs before I started and then put it back together. So i try and a grind and even on the finest it comes out like wood shavings. I think crap Ive got a dud. Then Hubby says let me have a look he hadnt put it back together properly. Well now I have fine grind on 12. My first go so will play with the settings. Hopefully will be able to do the mods if and when it starts to play up :)

    Sue

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    Re: How to fix those dreaded em0480 problems for g

    Hmm... Does any of your grinders have burrs touching on the finest setting? mine does

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    Re: How to fix those dreaded em0480 problems for g

    I havent seen inside one of these grinders so cant comment from experience but replacing a seal with a bush concerns me. I expect the seal to be there to keep grinds out, which could build up in the motor to cause a short or worse. Maybe consider replacing that seal and dig deeper and check for bodgie bushes/bearings.

  41. #41
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    Re: How to fix those dreaded em0480 problems for g

    When brand new my burrs just touched when wound right down and something ressembling a fine espresso grind was about 12 to 14 depending on the beans. Just for the record this is my second em0480 the first one which was only a few months old died an agonising death, there was a horrible noise followed by a flash and then smoke, needless to say it worked no longer. They happily replaced it, there was no trouble there, you really cant complain about their customer service, I just dont think they will show the same level of service regarding the lack of quality manufacturing.
    Its obviously produced to a budget and thats what you get.

  42. #42
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    Re: How to fix those dreaded em0480 problems for g

    Quote Originally Posted by vicroamer link=1183436456/30#39 date=1183547375
    I havent seen inside one of these grinders so cant comment from experience but replacing a seal with a bush concerns me. I expect the seal to be there to keep grinds out, which could build up in the motor to cause a short or worse. Maybe consider replacing that seal and dig deeper and check for bodgie bushes/bearings.
    I tried that.. I started disassembling it from underneath and found it to be a nightmare, it is assembled in order of components with non detachable wiring etc... which means you have to butcher it quite a bit. I then studied the so called rubber seal on top of the shaft and found it to also be substandard with heaps of clearance and slop in it (flogged out so to speak) wouldnt keep rice out so a snug fitting solid bush was always going to be better than it was.

    Ray.

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    Re: How to fix those dreaded em0480 problems for g

    "I tried that.. I started disassembling it from underneath and found it to be a nightmare, it is assembled in order of components with non detachable wiring etc... which means you have to butcher it quite a bit. I then studied the so called rubber seal on top of the shaft and found it to also be substandard with heaps of clearance and slop in it (flogged out so to speak) wouldnt keep rice out so a snug fitting solid bush was always going to be better than it was.

    Ray."

    Fair enough Ray, sounds like your making a better fist of it than sunbeam.

  44. #44
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    Re: How to fix those dreaded em0480 problems for g

    Quote Originally Posted by Sueb link=1183436456/30#37 date=1183527712
    Thanks for the info!

    Well Ive tried the grinder. Hubby decided to have a look at the burrs before I started and then put it back together. So i try and a grind and even on the finest it comes out like wood shavings. I think crap Ive got a dud. Then Hubby says let me have a look he hadnt put it back together properly. Well now I have fine grind on 12. My first go so will play with the settings. Hopefully will be able to do the mods if and when it starts to play up :)

    Sue
    Hey Sue given some time to show some wear and tear you can always refer back to this thread for the information and how tos you may come up with better solutions and add them here yourself.


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    Re: How to fix those dreaded em0480 problems for g


    Might as well tell you of the mod I performed on my sunbeam...

    I have no problem with the grind settings from new. I grind 10-12 for fresh caf beans, and 6-7 for fresh Decaf beans.

    I was really annoyed with how non-positive the steps were. when placed on one setting, I could wiggle it an increment either side before meeting resistance. Turns out that the reason is the button on the back that is used to unlock the burr carrier also moonlights as the detent that creates the step increments.

    Now, this button has flat sides, and where it exits the housing, it is a reasonable fit. However, further inside, it is an 8mm wide slab of plastic in a 9mm wide hole. The detent is also at the back of the button, but on top. The effect is that the button rotates around the exit hole and allows the detent to move sideways. for a positive step engagement, this detent needs to be held firmly.

    The solution is to pull the button out and file the sides flat. Then find yourself some shim material to take up the gaps either side of the button. I used a micrometer to check various materials to find just the right thickness. I ended up using slightly different thickness shims on each side, as I didnt have shim that was exactly the right thickness when used on each side. I had proper brass shim on one side, and part of a plastic screw container from Bunnings on the other side.

    You wont get all the slop out, as you need to find a compromise between minimum clearance, and friction on the sides of the button. if its too tight, the button wont pop out again when pushed in.

    I also touched the file onto the top edge of the (male) semicircular detent, as it is normally a semicircle in a semicircle (ie single point contact). a good detent has two points of contact to prevent sideways movement.

    The end result is more positive, although still not fantastic. Id really like to feel and hear it click into position, and stay there when a bit of rotational force is applied.

  46. #46
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    EOI: Nylon 0480 bush

    Quote Originally Posted by Ray C link=1183436456/0#0 date=1183436456
    ... replacing this soft rubber seal with something a lot more substantial, what I did was machine up a piece of timber which is all I had but some nylon bush material would be excellent, if machined to a snug finish slid it down the shaft into the plastic housing, then you will have eliminated the shaft movement...
    I have the best part of a metre of excess nylon rod and a lathe and could probably machine something suitable up if anyones interested. Since I dont have this grinder Id have to know the exact specs on the bush and whether it makes substantial a difference enough to the performance of the grinder to make it something really worth having.

    How many would be interested in something like this, and for those who have done it, how worthwhile has it been to the grinders performance?

    Greg

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    Re: How to fix those dreaded em0480 problems for g

    Yes me I am getting so frustrated with this grinder! Mine is grinding too fine I think and just doesnt seem to change. Off to start another thread :0

    Sue

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    Re: EOI: Nylon 0480 bush

    Quote Originally Posted by Greg Pullman link=1183436456/45#45 date=1184368014
    Quote Originally Posted by Ray C link=1183436456/0#0 date=1183436456
    ... replacing this soft rubber seal with something a lot more substantial, what I did was machine up a piece of timber which is all I had but some nylon bush material would be excellent, if machined to a snug finish slid it down the shaft into the plastic housing, then you will have eliminated the shaft movement...
    I have the best part of a metre of excess nylon rod and a lathe and could probably machine something suitable up if anyones interested. Since I dont have this grinder Id have to know the exact specs on the bush and whether it makes substantial a difference enough to the performance of the grinder to make it something really worth having.

    How many would be interested in something like this, and for those who have done it, how worthwhile has it been to the grinders performance?

    Greg

    Greg

    be careful offering Nylon as a high speed bearing material. none of the materials mentioned so far are particularly good as rotating bearing materials, but I would actually back the timber over the nylon, as it will just burn due to the friction. The nylon will melt....

    I have one of these grinders and as mentioned, have had no problem with the grind settings. Hence I am loath to do a major dismantle of it in case I muck up the magic adjustment. However just popping the top and feeling the slack in the centre burr, the slack seems to be in a bearing lower down, not the top bearing. Also, I saw photos of someones in bits, and there is a ball thrust bearing as the top bearing. I havent had it apart to investigate, but Ill wager that bearing is doing a pretty good job of being a radial bearing as well.

    As you know I am an inveterate modifier, so its something I will investigate in time. For now, got to get on with my lecture...

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    Re: How to fix those dreaded em0480 problems for g

    Meetim. Have fun mate, I did, by the way mine is working better than it ever has and still is...........

    I would go as far to say that it is producing a grind worthy of the most astute coffee snob and being stepless is just a peach...... Ray.

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    Re: How to fix those dreaded em0480 problems for g

    Oh yer, there are heaps of different composition nylon bush materials to be had and are produced just for that purpose as nylon bushes, besides the 0480 is a fairly slow speed grinder.

    Ray...... :-?

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