How to Use and Care For Your

Moonlighter

TM

Kerosene Heater

Owner's Guide®

KERO:SUN

Specifications

QUICK REFERENCE
Specifications
Special Features
Safety Features
UnpackingAssembly
Serial Number
Fueling
Ventilation
Safety Reminders

To Extinguish the Flame
Troubleshooting

9

Cleaning the Glass Cover

10
10
11
14
14
16

Automatic Lighting
Lighting with a Match
Adjusting the Flame

Care of the Wick
Replacing Wick
Replacing IgniterParts and Service
Limited WarrantyThis includes heat produced b y the Moonlighter p lus
heat that would be generated if water of combLIAn
were condensed. This rating and " Heater Outp~
below should be used when making comparisons between heaters of different manufacture.

Heater Output: 8,200 BTU/hr., 2,020 kcal.
This is the heat produced by the Moonlighter, and is
the amount of heat delivered to the room. (The wick-ted
Kero-Sun heater is more than 99.9 % efficient.)

4
5
6
6
7
7
7
8
8

Lighting

Model: Moonlighter
Heater Rating: 8, 700 BTU/hr; 2,190 kcal. ·

2
2
2
3
3

Burning Time: 26-36 hours.

iBurning time is a functio n of the condition of the wick, l

the setting of the flame regulator knob, fuel quality andatmospheric conditions.

Typical Room Sizes:
17'(5.2m)

or approx. 288 sq . ft.

D EJ
17'(5.2 m)

24 '(7.3 m)

The area to be heated varies wi th outside air tempera·ture, insulation R factors and square footage of the win·
dows. The room sizes given above assume the Kero-Sunis the only heat source for the r oom.

Fuel Type: Kerosene
Fuel Tank Capacity: 1.7 U.S. gallons; 1.42 Imp.
gallons; 6.43 liters
Wick Type: Cotton (Do not burn dry)Batteries: 2 size D Cells (included)
Dimensions: Height, 16-7/8 in.; width, 16-1/4 in.;height, 430 mm; width , 412 mm.
Weight: 14 lbs.; 6.4 kg , empty

Safety Features
UL ListedShut-off Protection: Automatic shut-off extinguishes the flame if heater is jarred .
Wick-feed: Fuel remains below burner and is unpressurizej If flame goes out, fuel flow stops,
fuel CCl'lnot nod burner.
Low Cemer of · ~vity: Weight concentrated inhance of tip-over.
base, reducin
Rubber Seals: f.~.Jr , wick winder, fuel cap andothe ..·,ints sealed with oil-proof rubber to prevent leaks if tip-over occurs.
Heavy Steel Construction: For high strength anddurability.
High-efficiency: 99.9% combustion of kerosene
eliminates hazard from odor, smoke and othercombustion by-products when used according·
to instructions.

2

Special Features
Provides Heat, Light and Cooking:" Especially
useful during power failure or other emergency. (Optional frosted glass available for improved light diffusion.)Push-button Ignition: No matches required.
Fuel Gauge: Shows remaining fuel at a glance.
Avoids unnecessary filling or need to remove
filler cap to check level.
Hand-pump Siphon: Provided for spil l-free transfer of fuel.
Drip Tray: Protects floors and carpets.
Easy Service: No tools required to change wick or
to perform other simple maintenance.
Baked Enamel Finish: High gloss, heat-proof,
easy to clean.
Cooktop: Ideal for cooking where other fac ~es
are not available (cabin, vacation home, etc.).

Unpacking
Before discarding any packing materials, be sure to check the carton for
the following items: two batteries, warranty card, siphon, caution notice, drip
tray and dustproof ring.
Lift the heater out of the carton by its carrying handle.
NOTE: Be careful not to discard the wick guide; a 2-inch
plastic disk with a hole.
On the outside of the carton. look for a label with serial numbers. The
peel off portion of the label will be fastened to the side of the heater, as
described later.
To remove pad, spread ears of carrying handle and lift away handle.
Lift top plate support from retaining tabs and remove pad.
Reinstall top plate support, top plate and handle.

Assembly
BATTERY COVER

COVER THUMBSCREW

FOOT(4)

DUSTPROOF RING
TAB(4)

1. Install the Drip Tray
Place the drip tray on the floor.
Position dustproof ring in the center of the drip tray.
Lift the heater by its carrying handle and lower it onto the drip tray, fiW11g
the lip of the heater over the dustproof ring.
Note how the four feet slide into the four tabs. Grasp the fuel tank and turnthe heater until the feet lock into the tabs.
3

2. Tighten Cover Thumbscrews
Three thumbscrews around the bottom of the cover should be checked fortightness.

3. Install the Batteries
Remove the battery cover by sliding it up. Install the two size D cells in theholder according to the plus (+)and minus (-)markings shown on the cover.
Attach the wires from the battery cable to the terminals: red wire to " + ";white wire to"-". (If the battery cable won't reach t he terminals, pul l out thecable another half·inch from the heater.)Slide the battery cover back over the holder.
Batteries should be repiaced when theigniter coil no longer glows brightly.

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PLASTIC PACKING

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4. Tilt the CoverLift the cover by pushing up on thelatch. (The cover tilts back about 45
degrees.)
Remove the plastic packing from thewick area.

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CARDBOARD

FLAME

5. Engage the Safety Shut-Off Reset Lever
Press the lever down until it locks.

6. Locate Your Heater Away From Walls
Allow at least three feet of clearance between the heate r and the nearest
wall or vertical surface.

7. Check the WickI

As you turn the flame regulator knob back and forth, the wick should movefreely up and down.
Close the heater cover.

8. Lt:)vel the HeaterYour heater should be on a firm, level surface, preferably the floor.
A built-in level guide is provided to check if the heater is leve l. Find t hesmall chain at the rear, above the fuel tank. When the heater is level, thechain will lie in the approximate center of the red circle.

9. Register Your Serial Number
On the outside of the shipping carton, find a label with the serial number
for your heater. Remove the peel-off portion and press it to the rear o f thefuel tank, next to the battery cover. If you need replacement parts or service inthe future, please refer to this number.
Fill out and mail the warranty card.
4~;;JDBOARD

Fueling

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Warning
Do not refuel your heater while it ishot. First extinguish the flame andallow the cabinet to cool. Use only
pure kerosene. Ne'of!l..r use gasoline,
white gas, camp fuel or other flammable liquids. Use of such fuels canresult in an explosive fire and cause
severe injury.

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USE KEROSENE ONLY

Using the Siphon
To operate the siphon provided with your heater, insert
AI R VEN T KNOB
the straight tube into the
kerosene container. Insert
the siphon's flexible hose into the heater fuel tank. (Besure to push this ho se overthe clip inside the tank. T heclip holds the hose to reduce
poss ibility of a spill.)
For good siphoning, raise
the kerosene container
slightly higher than the levelof the heater fuel tank.
Note the knob at the topof the siphon; it control s an
air vent. Before siphoning ,close the vent by turning theknob clockwise. Squeeze thebulb vigorously six or seventimes, paus ing to allow thebulb to expand after eachsqueeze. (Once the kerosene
flows it 's not necessary tosqueeze the bulb.)
To avoid overfilling the tank , watch the fuel gauge. As the needle enters
the red zone, stop the flow of l<erosene by turning the air vent knob counterc lockwi se.
Remove the siphon slowly to allow excess kerosene to drain back into thecontainer.

KEROSENE

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For added convenience, a five-gallon
Kero-Sun fuel container is available
from your dealer. The siphon provided
with your heater fits snugly over the
opening of this container for easier
siphoning.

Ventilation
Before you light your heater, check tor a source of air. It may be a halt-inch
opening of a door to an adjoining room, or a window opened one-halt in ch.
Be sure to provide a source of air whenever the heater operates in t ig htly
confined areas, such as a bathroom or camper.
Avoid drafty areas or locations where
the opening of a door might create agust of air.

Safety Reminders
Before You Light Your Heater.
1. Use only water-clear, fresh , pure kerosene. Yellow or colored kerosene will smoke,
smell and burn inefficiently.
2. BURN ONLY KEROSENE in this heater. NEVER use gasoline, white gas, camp
stove or any other fuel. These fuels are extremely dangerous if used in kerosene
heaters.
3. Store fuel tar away from any heat source, in a can clearly marked KEROSENE. (Asuitable Kero-Sun con tainer is available from your dealer.)
4. Keep heater away from all burnable materials such as clothes, curtains, woods, etc.
5. Heater surfaces become hot. Keep children away.
6. Do not move, service or refill heater while it is burning or hot. Extinguish flame fin~t
and let heater cool.
7. Refuel heater outside when the cabinet is cool. Use the Kero-Sun siphon to prevent any spillage.
8. Provide adequate ventilation . The heater needs oxygen just as you do. Leaving adoor ajar to an adjacent room normally provides sufficient ventilation . In small, tightly
sealed areas, open a window slightly.
9. When turning heater ott, make sure the flame is completely extinguished, using
flame regulator knob.
10. Keep outside of heater tree of dust or spilled kerosene.
11 . Follow maintenance instructions for optimum performance .
12. Keep heater level. .
13. Keep cap on fuel port tightly secured .
14. Do not burn dry. See "Caution" in "Care of the Wick" section.
15. Use only in accordance with local ordinances and codes.
6~LightingIf the fuel tank has been empty forsome time, or the wick is new, wai t
about 15 minutes after fueling for the
wick to saturate.

FETY SHUT-OFF RESET LEVER
LIGHTING LEVE

1. Raise the Wick
Turn the flame regulator knob clockwise until it stops.
Recheck the safety shut-off reset lever; it should be down and locked.

2. Automatic Lighting
Press the lighting lever. While looking through the mica window, you
should see the igniter brush against the side of the wick. When a flame appears, release the lighting lever. In about 40 seconds, the flame will spreadcompletely around the wick.

3. Lighting With a Match
You should not have to light the heater with a match, but should it become
necessary, lift the latch and tilt back the cover to expose the wick. Touch alighted match to the wick. When lighting in this manner, don't allow burnedparts of the match to fall or remain on the wick.
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To restore your heater to automatic ignition, check for worn-out batteries or adefective igniter, as described later under " Trouble shooting."
A slight odor and occasionally some smoke after lighting a new heater isnormal and is caused by a preservative oil on metal parts. Odor and smoke
should disappear in a few minutes. For this reason , you may want to lightyour heater for the first time in a well -ventilated area, such as a porch.

Adjusting the Flame
1. Wait for the Burner to Reach Operating Temperature
Several minutes after lighting, heat will spread through the burner. Thenlook for these signs of efficient operation:

TOO LOWCORRECTTOO HIGH

Look through the mica w indow and check the height of the fl ame. It should
project about 3.4 -in. beyond the top disk of the flame spreader.

To Extinguish Flame
1. Turn the flame regulator knob counterclockwise un til it stops. (This requires about one half of a turn.)
NOTE:
6o not use the safety shut-off to extinguish the flame. Automatic shut-off
shoU.Id occur only when the heater isjarred or tipped. Some odor may be experienced when automatic shut off occurs.
2. Look to be sure flame is out.

8Troubleshooting
Here are common symptoms which may appear during operation of your heater.
Most are easily corrected, as shown below .

Symptom
Smoke or odor.

Cure

Cause
Flame spreader
not securely seated.

Lock in place.

Flickering or
dying flame.

Wick won 't ignite.

Flame regulator
jams.

Wick burns down
too fast.
High flame.

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Wick damaged byburning dry.

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Flame too high.

Reduce wick height.

8

Dirty wick.

Clean or trim wick.

10

Contamina ted fuel.

Drain tank, dry wick andrep lace with fresh, clean
kerosene .

-Flame too low.

Raise wick.

Wick coated with tar or
carbon.

Clean or trim wick.

Water in kerosene.

Empty tank, refill withclean fuel. Remove wick,
dry out on a sheet of newspaper. Re-install wick.

Out of fuel.

Check fuel gauge,
add fuel.

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Igniter won 't glow.

Replace batteries.
Replace igniter coil.

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14

Water in kerosene.

Empty tank. Remove wick,
dry out on sheet of newspaper. Re-install wick.
Refi II with clean fuel.

Excess tar on wick.

Clean wick.

Water in kerosene.

Empty tank, remove wick,
dry out on sheet of newspaper. Re-install wick.
Refill with clean fuel.

Qrain tank and replace
Kerosene contaminat ed
fuel with fresh , clean
with gasoline, paintthinner, denatured alcohol kerosene. Replace wick.
or other volatile substance. Refer to diagramon page 8.
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Cleaning the Glass CoverAllow the heater to cool completely.
Lift off the top plate and remove the carrying handle by pulling apart its
sides.
Note how the top cover is held by three U-clips. Using a pliers, straighten
the sides of the clips so they fall free. Lift off the top cover and the glass.
Do not use abrasive cleaners on the glass. Clean with soapy water and apaper towel.
When re-installing the glass cover, insert the U-clips, then twist their sides
to hold the top cover.

Care of the Wick
CAUTION:

Never allow your Moonlighter to burn
dry or run out of fuel. Burning thewick without kerosene will char thecotton fibers, permanently damaging
the wick.
A damaged wick will cause yourheater to burn improperly and may
cause it to smoke.

Wick Contamination
Signs that a wick needs attention are: tars accumu lating on the top edges;
the flame regulator binds or jams; a flickering or dying flame.

Remove Ash, Cinders, Soot
Before cleaning the wick, allow your heater to cool completely. Be su re thesafety shut-off lever is down and locked.
Unlatch the cover and tilt it up to expose the wick. The flame regulator
should be turned fully clockwise.
Remove flame spreader.
Grasp the flame spreader,turn it clockwise, then lift itout. The wick is now accessible for cleaning.
When reinstalling theflame spreader, turn itclockwise until it drops into
place. Check if the flame
spreader is locked in by pulling up. It should not lift out.
If residue is found on thewick, it can be removed by asmall brush (an old toothbrush, for example). Cinders
or soot in the burner area
may be vacuumed away.
Stubborn deposits on metal
portions of flame spreader
can be removed by scraping
gently.
Be sure to check burnercover for char and debris. To
remove this accumulation,lift out extinguisher ring.
Remove burner cover andshake it gently over piece ofnewspaper.

FLAME SPREADER'

10

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To Replace the Wick
Before disassembly of yo ur heater,allow it to cool completely.

OUTER COVER
FLAME SPR EADER

THUMBSCREW (3)~

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~EXTINGUISHEAAING..===;~

BURNER COVER

WING NUTSRETAINERS

1. Remove the Outer Cover
Loosen and remove the three thumbscrews holding the cover, then lift off
the cover with the carrying handle.

2. Lift Out Flame Spreader and Extinguisher Ring
These parts are removed easily if the wick is first turned to its lowest position (flame regulator knob counterclockwise). As you lift the flame spreader,turn it clockwise.

3. Disconnect Battery Cable
Remove the two battery wires from the top of the battery holder.

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Before the next step, press and lock thesafety shut-off reset lever. If the lever inadvertently springs closed during thefollowing steps, you 'll have difficulty
removing the remaining parts. Recheckthe lever for the down position.

4. Lift Off the Burner Cover
5. Remove the Wick Adjuster
This assembly is released by loosen ing three wing nuts, and turning thethree retainers to the side. Note: If the retainer to your right won't swing
around, loosen the wing nut and remove it completely. Lilt out the wick adjuster.

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FLAME REGULATOR KNOB

6. Remove the Old Wick
Turn the flame regulator
knob counterc lockwise unti l
you can grip the wick holder
and pull it out.
Fold in the wick until you
can free it from the holder.

7. Install the New Wick

RED LINE (BARELY VISIBLE)

Fold the new wick until
you can insert it into theholder. When the red line on
the wick is barely visible
along the top of the holder,
unfold the wick and press itaround the inner wall of theholder. This engages thewick against metal teeth inside the holder.

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FLAME REGU

8. Insert the Holder in the Gear Mechanism
WICK ADJUSTER

Push the holder into thewick adjuster, as shown;with the flame regulator
knob to your right, and the
double row of holes in theholder facing you.
Twist the holder back andforth until you feel it engage
the gear mechanism.
Check for the correct gear
action; as you turn the flame
regulator knob, the wickshould move up or down,with no slippage.

WICK ADJUSTER

9. Install the Wick Adjuster
To prevent the wick fromsnagging during reassembly,
temporarily place the plastic
wick guide into the top opening of the air tube.
IMPORTANT-Remove
wick guide before installingthe wick adjuster. If guide is
not removed, it will restrict
air flow and cause improper
combustion and may
smoke."
Lower the wick adjuster
onto the air tube (locating
the flame regulator knob between the fuel gauge andfiller cap). During this step,
check to see if the bottom of
the wick enters the tankevenly, without folding back.
If you cannot seat the wick adjuster,press the safety shut-off reset lever
to be sure it 's not blocking the wa y.
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10. Reassemble the Heater(Refer to the iliustration on page 3 .)Fasten the wick adjuster with three wing nuts and retainers.
Turn wick down and install the flame spreader (turn counterclockw ise).
Replace the extinguisher ring, with the wide rim down.
Install the burner cover.
Slide the wires onto the battery terminals (red to + ).
Push the safety shut-off reset lever down.
Install the flame spreader (turn clockwise).
Fasten the outer cover with three thumbscrews .
Before lighting a new wick for the
first time, allow 15 minutes for thematerial to saturate completely withkerosene.

Replacing the IgniterWhen the igniter no longer glows sufficiently to light the wick, check thebatteries. If replacement of batteries doesn't restore the glow, the igniter may
be burned out.
To c hange the igniter, start by disassemblin g the heater, as described in
Steps 1, 2; 3 and 4 in the preceding section; " To Replace the Wick. " This
releases the burner cover, which contains the igniter.

COIL

Be sure battery leads have been disconnected .
Press in the lighting lever and grasp the igniter with your other hand, as
shown.
To remove the igniter from the socket, press in and twist slig htly counterclockwise.
To install the new igniter, press it into the socket, while turning slightly
clockwise.
Reassemble the heater as described in Step 10 of the preceding section;" Reassemble the Heater. "Parts and Service
For parts and service, see your authorized KERO-SUN dealer. If additional
assistar;tce is needed, send a brief letter stating the nature of the problem,
the name and address of your KERO-SUN dealer, and your own address andtelephone number to:
Customer Service
KERO-SUN, Inc.
Kent, CT 06757

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2 -~---•oonlighter Parts List

Part
No.

0110700110070110u1011065011002000906005051005052005070005053005071005054000902
0903
,
5025
05026

000901005072011037000910000915011068005041005066

Ref.
No.

Name
COVER
OUTER
Outer cove r complete. handle
Carrymg
Pyrex mant lec cl ip

1.
2.
3.
4.
5.
6.

for coverTop plateThumbscrew

BURNER
Flame spreade:
Extinguisher rmg

7.
8.
9.

Extinguisher undlt xtinguisher lever
Burner cov er an e
Wick adjuster
Wick holder
Wing nut
Retainer
Cotton wick.
Rubber packmg

6

10.
11.
12.

7

13.
14.
15.
16.

IGNITER .
Igniter Coli
Ign iter unit

8

17.
18.

FUEL TANK lete
Fuel tank comp19.

ith chain
Fuel gauge
Fuel fil ler cap w
Battery cover

20.
21.
22.

DRIP TRAY. Drip tray .
Dustproof nng

23.
24.

16

15

22

15

~~~~~~$~~~~~~~~$~~~~~~
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KERO-SU N, INC.
Limited Warranty

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, under normal use and service. for
KERO-SUN, Inc warrants each heater sold by it io be free from defec ts in material and workmanshipbelow:
statedcor.ditions
and
terms
the
to
subject
purchase.
retailone year after the date of original~t icut 06757.
1. WARRANTOR. Th is Warranty is granted by KERO-SUN. Inc., Main Street. Kent, Connec~
to t he original re tai l purchaser.
2. PARTI ES TO WHOM WARRANTY IS EXTENDED. This Warranty shall be extended only~~~
as provided for herein.
3. PARTS COVERED. All produc ts and parts manufactured by or for KERO-SUN , Inc., except~~
Warranty:
thisbycovered
not
are
parts
4. PARTS NOT COVERED. The following
and siohons.
Normal wear and tear items, sucl1 as. but not limited to. wicks. batteries, igni ter coils,~
Warranty proves to be defective in matenal ~5. REMEDY. If, within the applicable warranty period. any product or part included in this·~~product or part.
and/or workmanship , then KERO-SUN, Inc. shall , at its option, repair or replace the defective
under
obligations
theofperformanceobtaintoorder
In
WARRANTY.
THIS
UNDER
6. PROCEDURE FOR OBTAINING PER FORMANCEof the defect) not ify any author- ~~' *:e. this Warranty, the origina l purchaser must promptly [in no event later than thirty (30) days after di scovery
defective part or product to an authorized KERO- .-...::
thereturnanddefecttheofCanadaorStatesUnitedtheindealerInc.
,
KERO-SUN,\J ized
will be al the expense of the original retail purSUN dealer. All transportatio n costs to and from the authori zed KERO-SUN , Inc. dea ler
chaser.
ty. a charge will be made for testing, handling. ~If the instrument or any part thereof is returned for any cause not covered by this Wa rran

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'"'- packing and/or any repa irs made.
part during transrt to or from the onginal retail &KERO-SUN. Inc. accept s no responsibility for any damage that occurs to the product or~~to\.
· ~ purchaser.
IN-AL PURCHASE DATE-SALE S INVOICEANY CLAIM MADE UNDER THIS WARRANTY MUST BE ACCOMPANI ED BY PROOF OF ORIGOR CANCELLED CHECK IS SATISFACTORY EVIDE NCE.
set forth above rs the sole and exclus ive ~~7. SOLE REMEDY. The remedy and liability ior any breach of warranty, express or implied,~
remedy and the limit of liability for any such breach.
or material of the heater without incurring any ~8. DESIGN CHANGES. KERO-SUN, Inc. reserves the right tq make changes in the design~ised.
advertordmanufacture
previously
productanyinchangessucl1
obligations to incorporate
f ailure toothers.
ofnegligence
e
t11
to
due
t
defec
any
to
extendnot
does
Warranty
This.
9. EXCLUSIONS AND IMPLIED WARRANTIES~
furnished with each new heater. unreason·
operate or maintain the heater in accordance with t he operating and maintenance inst ructions

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~ fuel other than good quality kerosene. All.. IMPLIED WARRANTIES, IF ANY, ARISING UNDER STATELAW IN CON NECTION WITH THE

THE DURATION OF THIS WRITT EN WARRANTY.
SALE BY KERO-SUN, Inc . OF ANY NEW INSTRUMENT ARE LIMITED IN DURATION TO
FITNESS OR OTHERWISE WHICH EXTEND BEYOND-~ THERE ARE NO WARRANTIES, EXPRESS OR IMPLIED, OR MERCHANTA BILITY.
OF ANY HEATER, LOSS OF TIME. INCONVET HIS WA RRAN TY, KERO-SUN, Inc. SHALL NOT BE RESPONSIBLE FOR LOSS OF USE
BUSINESS OR PROPERTY, WHETHER AS ATO
RESPECTWITH
DAMAGESENTIALCONSEQUOR
CIDENTALIN"I'\ NI ENCE OR OTHER.
OTHERWISE
OR
TORT,
IN
LIABILITYSTRICTE,
NEGLIGENC,
lti RESULT OF BREACH OF WARRANTYLASTS OR (b) THE EXCLUSION OR· ~ NOTE: SOME STATES DO NOT ALLOW (a) LIMITATIONS ON HOW LONG AN IMPLIED WARRANTYEXCLUSIONS
MAY NOT APPLY TO
OR
LIMITATION OF INCIDENTAL OR CO NSEQUENTIA L DAMAGES. SO THE ABOVE LIMITATIONS

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other wa.y vary the terms. conditions or exc!u·
10. NO VARIATION OF TERMS. No person has til e authority to orally, in writing. or in any
sions of this Warranty or to make any express warranties other than t hose contained herein.
other nghts whi ch vary from state to stat e.
11 . LEGAL RIGHTS. This Warranty gi ves you specific legal rights and you may al so have
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PORTABLE HEATER S!
!

Kero-Sun, Inc., Kent, CT 06757 (203) 927-4611

Rev. 1/81

This manual supersedes earlier editions.

(c) 1980, Kero·Sun, Inc.

Printed in Japan