Question about Sony Grand WEGA KDF-42WE655 42" Rear Projection HDTV

3 Answers

Melted plastic where the lamp is positioned

The area around the lamp is all melted .im worried that this is a fire hazard and could burn down my this a common problem or what

thanks in advance

Posted by on

  • 4 more comments 
  • Calvin c Mar 14, 2008

    Had the same problem, took it to a repair place that sony recomended, and they said the fan was bad, they fixed it, and been fine so far

  • shauna Kreger Mar 21, 2008

    sony wouldn't recogize as a problem. Contac the "US Consumer Product Commision". I did, and filed a safty concern.

  • Anonymous Mar 24, 2008

    The plastic around my "lamp" is also melted. Called for Warranty Service because of the pink splotches on the screen. Not only is the plastic melted, the plastic box the "lamp" is in is cracked beyond repair. I too amy afraid this is a fire hazard, never mind the fire retardancy, if it's hot enough to melt what's to say it wouldn't be hot enough to catch something on fire. I do know the front cover on the TV was as hot as "fire" and "Mama ain't happy". Paid $2500 for the TV exactly 3 years ago and now.....what a steal!!

  • Mohasa Mar 28, 2008

    I have the same issue, my lamp went out after almost 3 years of flawless performance. BUT, when I pulled out the bad lamp, I discovered that all the plastic around the housing is melted and covered by black and dark brown soot. The cover that you initially take off to remove lamp is badly melted and wont even go back on and line up. I have taken many pictures of this and am waiting for an answer from the repair service center on whether they have resolved similar issues or if Sony covers what is obviously a design flaw. My fan is in good working condition and I keep it clean. The thing is, a person would never know that this is happening unless they pull the lamp out and there is no need to do this unless it goes out. Now I am stuck with a $4000.00 dollar paper weight because as it turns out, my lamp is not bad, it just melted things so bad that the connections don't make contact anymore due to massive corrosion or heat related build up on the connections themselves so they don't make contact, at least not metal to metal contact. After talking to the technician tomorrow I will know which direction I need to go in.


  • Anonymous Apr 01, 2008


  • prhude Jul 11, 2008

    I also have a 2004 kdf-42we655 with the plastic melted and blackened around the lamp. I am going to call for service tomorrow. I am not expecting any help from sony. The TV still works, it is starting to get a little dim, which is why I opened to replace lamp.



3 Answers

  • Level 1:

    An expert who has achieved level 1.


    An expert that has over 10 points.


    An expert whose answer got voted for 2 times.

    Problem Solver:

    An expert who has answered 5 questions.

  • Contributor
  • 8 Answers

There's a thermal protect switch (thermalcouple) that should shut TV down near lamp. If TV works, I'd set a small fan in front of internal cooling fan vents and provide adaquate space for circulation. Maybe cool it down a few degrees.

Posted on Jul 24, 2008

  • billac Apr 13, 2009

    It's very important to keep air intake vents clean. Use a vacuum cleaner with soft clean brush attachment to remove as much dirt as possible. You might try Googling "Sony DLP Class Action Lawsuits"


  • Level 1:

    An expert who has achieved level 1.

  • Contributor
  • 1 Answer

Please dont buy sony products in future. I had same problem and I have through my tv in garbage.
Thanks Sony

Posted on Jul 14, 2008

  • Level 3:

    An expert who has achieved level 3 by getting 1000 points


    An expert that got 20 achievements.


    An expert that got 10 achievements.


    An expert that got 5 achievements.

  • Master
  • 2,336 Answers

I would suggest to call Sony if you have a safety concern about your TV. A fire hazzard is unlike because most if not all the electronics components or plastics used on TVs have a flame retardant that It will not burst into a flame.
Good Luck.

Posted on Feb 29, 2008

1 Suggested Answer

  • 2 Answers

SOURCE: I have freestanding Series 8 dishwasher. Lately during the filling cycle water hammer is occurring. How can this be resolved

Hi there,
Save hours of searching online or wasting money on unnecessary repairs by talking to a 6YA Expert who can help you resolve this issue over the phone in a minute or two.

Best thing about this new service is that you are never placed on hold and get to talk to real repairmen in the US.

Here's a link to this great service

Good luck!

Posted on Jan 02, 2017

Add Your Answer

Uploading: 0%


Complete. Click "Add" to insert your video. Add



Related Questions:

1 Answer

How to melt down plastic

go google and type in--- how to melt and work with plastic
a note of caution--- that when plastic is melting or burning it produces deadly cyanide based gasses (The main reason for such high numbers of deaths in plane crashes with fires burning the plastic interior seats and fittings and not from burns ) so it should only be done in the open air and with good ventilation

Nov 14, 2015 | Refrigerators


Damage or Fire Warning on Samsung DLP Television

I was reading some articles in a website and i found out that there is a problem with the Samsung DLP.

If you don't install firmly the connectors may cause damage to both the ballast and the lamp and maybe you can get small fire...

i will add a picture of the connector and the link to the blog.

so if you are installing your TV lamp do it the correct way so this wont happen..

good luck

this is a connector image..




Please read carefully! has identified a potential hazard that may severely damage your Samsung TV with lamp code BP96-01653A!
Samsung DLP lamp units, model BP96-01653A may fail due to improper insertion. We discovered this while doing some tests on these enclosures. If you don’t install the BP96-01653A firmly into the TV, the housing connector may cause damage to both the ballast and the lamp—or even worse a fire.
You’ll know immediately if there’s something wrong because as soon as you turn your television on, and there’s white smoke emanating from the back of your television.
You should shut your television off immediately and open your lamp door and pull out that lamp. Inspect it and hopefully, you’ve just burned the connectors to the ballast, and not the ballast itself. Our testing has only caused the connectors to burn or melt, but don’t take any chances—we’ve never seen a fire, but we also don’t rule out the possibility of fires either.
Here is a correct installation method and the reasons why a bad installation will cause the connectors to burn:
Regarding the installation of a BP96-01653A lamp unit into a Samsung DLP Television.
Step 1
Figure A – Open panel, lamp unit removed
You must install the lamp unit to fit snug with the ballast connector.
To do this, align the lamp unit with the female ballast connector facing down, on the bottom side of the enclosure, then slide the lamp unit until it snaps into place. Check to make sure the unit is firmly inside the television.
Step 2 install_images_bp96-01653a_02.jpg
Figure B – Snapping the lamp into place
Snap the wire brackets in tightly by lifting the bottom set up to meet with the top bracket. The wire bracket keeps the lamp and lamp enclosure seated properly to reduce the risk of fire.
when installed properly, the unit should sit secure and slightly elevated from the floor of the compartment.
Step 3 install_images_bp96-01653a_03.jpg
Figure C – Close back panel securely
Once the lamp is firmly secure, close the back panel to engage the blue lamp door sensor switch. Leaving the door open will prevent the television from starting up.

Important Damage or Fire Warning
Because of the nature of the ballast or lamp driver, there is a risk of damage or fire to your television set.
The ballast ignites the lamp with up to 20kV of electricity to arc the gas tube inside. If the ballast does not have a firm connection with the lamp unit, the arc will occur between the ballast connectors (from the ballast to the lamp), which may cause a fire, or melt your plastic connectors. Indications of this are a rapid clicking sound, a burning smell, and/or a non-functioning lamp. If you improperly install the lamp into your television causing a ballast or lamp failure, this may void your warranty for the television or the lamp product.

on Mar 23, 2010 | Televison & Video

1 Answer

GE Spacemaker XL1800 sparking from behind wave stirrer cover

Microwaves use a magnetron to generate microwave energy and direct it a rotating blade wheel to spread them around the inside of the oven. If there is any metal in the area to be heated, or any of the blades are bent, even a bit, the microwave energy can be reflected back up to the magnetron area. In this area there is now too much power and it sparks away, so it does not heat the item in the oven.
Because it is sparking it is now a safety hazard the sparks may melt and set fire to plastic parts in it. This is serious it could burn your house down. Bin this microwave and cut the cable off it to make sure no one else ever uses it.

Dec 20, 2013 | GE Profile Spacemaker JVM1871 Microwave...

2 Answers

LEW0050PQ dryer works but smells like burning

In many machines, those elements, which are manufactured by "robots", are very cheaply made.
Rather than risk a fire, perhaps an investment of 20 - 30 dollars for a new element might be a good idea.
If you decide to do this, take a second look around for what specifically is getting so hot it is melting.
Likely the loose wire inside the element is doing that problem.
I should guess it is out of it's place and is melting an adjacent wire outside the heating element.
God bless your efforts.

Oct 05, 2017 | Whirlpool GEW9250 Electric Dryer

1 Answer

The breaker itself does not seem to trip completely. The power will go off to the lights and outlets on the circuit for the breaker. When attempting to reset, the breaker is not in off position, but when...

It is a clear case of metal contacts getting heated/melted/burn out due to overload/short-circuit inside. Please get the circuit breakers replaced with a new one to avoid fire hazard.

Jul 31, 2010 | Electric Electrical Supplies

2 Answers

I was driving down the road when all of the sudden i smell burning plastic.I pulled over turned my radio down stepped out popped the hood .I didn;t see any problems i cranked my car and my radio was dead...

arent you still under warranty?! check the positive terminal of the battery(common gm issue). check the wiring at the starter motor and look for burned wires. if there is consider the warranty. BY THE WAY, IF YOU HAVE HEAVY SMOKE AGAIN, DO NOT "POP" THE HOOD! IT CAN CAUSE AN AIR FEED AND POSSIBLY IGNITE A FIRE IN YOUR FACE. ive put out car fires in iraq. its not fun getting or treating people for burns. let me know if you need further assistance. cheers

Jan 20, 2010 | 2007 Chevrolet Cobalt Coupe

1 Answer

I have a 4 yrs old kf-42we610. We had to replace the lamp each year since we have had it. Well the door and housing has finally melted to ruin the tv. Seems theses tv only last 4 yrs. Nice profit for Sony...

One should not look at the light emanating from the lamp area for sure.
Healthwise, the eyes are vulnerable, not much else.

I would search the web if this is a chronic problem and maybe there is a recall or class action regarding it.

It is important to not have any obstruction blocking cooling air around these units. Also the cooling fan and channels must be kept free of dust and the operation of the fan checked periodically.

Some of the engineering of this stuff I would say is marginal.

Nov 10, 2009 | Sony Televison & Video

2 Answers

Melted base of electric kettle FB 1735

Quit buying them, they are pieces of junk if the base keeps melting, that or you are using it beyond it's rated hourly heat time.

Sep 02, 2009 | Farberware (102105065) Electric Kettle

Not finding what you are looking for?
Sony Grand WEGA KDF-42WE655 42" Rear Projection HDTV Logo

255 people viewed this question

Ask a Question

Usually answered in minutes!

Top Sony Televison & Video Experts

The Knight
The Knight

Level 3 Expert

75756 Answers

Donald DCruz
Donald DCruz

Level 3 Expert

17130 Answers

Jerry Greenberg
Jerry Greenberg

Level 3 Expert

1689 Answers

Are you a Sony Televison and Video Expert? Answer questions, earn points and help others

Answer questions

Manuals & User Guides