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PolyJohn Comfort XLT PH04 Instructions And Parts

Flushing unit
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POLYJOHN
USA
PolyJohn Enterprises Corp
2500 Gaspar Ave.
Whiting, IN 46394
Phone: 800-292-1305
Fax: 219-659-0625
Web: www.polyjohn.com
Email: info@polyjohn.com
PH04 Comfort XLT™
Instructions and Parts Listing
USA PATENTS: 4,577,351, 4,637,299, 4,793,100, 4,831,671, 4,895,400,
SPECIFICATIONS
DIMENSION
Exterior Height
Exterior Width
Exterior Length
Door Frame Height(I.D.)
Door Frame Width(I.D.)
Tank Seat Height
Weight
Flush Tank Capacity
Side Panel Decal Area
Door Panel Decal Area
We recommend reading through the entire Assembly Instructions
prior to proceeding with installation, service or maintenance. All ref-
erences to left and right throughout this guide are as viewed from
the front.
POLYJOHN
WORLDWIDE
PolyJohn (UK) Ltd.
Equinox 1 Audby Lane
Wetherby, England LS22 7RD
Phone: 44 (0) 1937-583333
Fax: 44 (0) 1937-583322
Web: www.polyjohn.co.uk
Email: sales@polyjohn.co.uk
PH04 Comfort XLT Flushing - June 2019
Page 1 of 15
Flushing Unit
Des. 304,082 CANADIAN PATENT: 1311898
IMPERIAL
91 in
62 in
62 in
74 in
32 in
19 in
240 lb
45 gal
12" x 23"
30cm x 58cm
27" x 27"
POLYJOHN
CANADA
PolyJohn Canada
P .O. Box 2300
199 Forest Plain Rd.
Orillia, Ontario LV3 6S2
Phone: 800-465-9590
Fax: 705-325-8250
Web: www.polyjohncanada.ca
Email: info@polyjohncanada.ca
4,918,765
METRIC
231 cm
157 cm
157 cm
188 cm
81 cm
48 cm
108 kg
170 L
68cm x 68cm

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  • Page 1 POLYJOHN POLYJOHN POLYJOHN WORLDWIDE CANADA PolyJohn Enterprises Corp PolyJohn (UK) Ltd. PolyJohn Canada 2500 Gaspar Ave. Equinox 1 Audby Lane P .O. Box 2300 199 Forest Plain Rd.
  • Page 2 : / /www. p ol y j o hn. c om/pc- 0 00570/ http: / /www. p ol y j o hn. c om/ph03- 0 008r/ PH03-0008R - Roof PC-000570 Fly Screen http://www.polyjohn.com/pc-000100/ (28) PC-000100 - Rivet http://www.polyjohn.com/pc-000100/ PC-000100 - Rivet http://www.polyjohn.com/pc-000106/...

  • Page 3: Front Assembly

    PH03-0003 - Front Assembly http://www.polyjohn.com/ph03-0003/ PH01-0004 http://www.polyjohn.com/ph01-0004/ - Front Panel PC-000200 http://www.polyjohn.com/pc-000200/ Door Check Cable PC-000104 - Rivet (To Jamb) http://www.polyjohn.com/pc-000104/ http://www.polyjohn.com/pc-000105/ PC-000105 - Rivet (To Door) http://www.polyjohn.com/pc-000106/ PC-000106 - Washer http://www.polyjohn.com/pc-000168/ PC-000168 - Washer PC-000181 http://www.polyjohn.com/pc-000181/ - Cable Clip...
  • Page 4 : / /www. p ol y j o hn. c om/sg1- 0 013c/ SG1-0013C - Flapper Complete Contains the following parts http: / /www. p ol y j o hn. c om/PC- 0 00233/ PC-000233 http://www.polyjohn.com/sg1-0013/ SG1-0013 - Flapper Valve Nylon Lock Nut http://www.polyjohn.com/pc-100620/ PC-100620...
  • Page 5 : / /www. p ol y j o hn. c om/sg1- 0 013c/ SG1-0013C - Flapper Complete http: / /www. p ol y j o hn. c om/ch100- 0 60/ CH100-060 Contains the following parts http://www.polyjohn.com/sg1-0013/ SG1-0013 - Flapper Valve Discharge Hose, 1” x 60” http://www.polyjohn.com/pc-100620/ PC-100620 - Counterweight http://www.polyjohn.com/pc-000106/...
  • Page 6 FS3-0026*FF - Fleet Sink FS3-0028 http://www.polyjohn.com/fs3-0028 Flushing Model Anti-Siphon Tank PC-000415 http://www.polyjohn.com/pc-000415 1/4” Uniseal PC-000339 - Elbow http://www.polyjohn.com/pc-000339 PC-000581G - Sink Tap http://www.polyjohn.com/pc-000581g PC-000104 CT38-046 - Rivet http://www.polyjohn.com/pc-000104 http://www.polyjohn.com/ct38-046 PC-000106 - Washer Tube (pump to tap) http://www.polyjohn.com/pc-000106 PC-000225 - Catch Lock http://www.polyjohn.com/pc-000225...

  • Page 7: General Overview

    FULL SIZE SCALE FASTENER DRAWINGS (12) PC-000105 Rivet (123) PC-000106 (113) PC-000100 Rivet Small Flange Washer Large Flange, Short 3/16” Back-up (1) PC-000117 Rivet (4) PC-000102 Rivet Hollow Wall 3/4” Grip (29) PC-000123 Washer Small Flange, Short 1/4” x 5/8” Flat (3) PC-000104 Rivet (1) PC-000122 Screw Small Flange, Long...
  • Page 8 ASSEMBLY INSTRUCTIONS These assembly instructions are for foot flush and hand flush, recirculating and fresh flush systems. Some steps will not be needed for your particular configuration. Step 1. Foot Flush Pump Assembly for Recirculating and Fresh Flush (Continue to step 2 for Hand Flush Place a PC-000352 hose clamp on the end of a 60”...
  • Page 9 Step 3. Front Sub-Assembly to the Base Surrounds Lift the front sub-assembly and place the legs of the aluminum door jamb into the “pockets” of the base surround on each side of the door opening. Attach the front assembly to the front corner moldings by riveting into the pre-drilled holes using (18) PC-000100 rivets and (18) PC-000106 back-up washers as in Step 1.

  • Page 10: Step 5. Roof Assembly

    Step 4. Attaching the Wall Panels and Corner Moldings to the Base Surround For the side panels: Place a PC-000121 washer on a PC-000139 bolt and insert the bolt though the center hole in the left side panel and into the base surround.
  • Page 11 Step 6a. Foot Flush Waste Tank Installation Place the waste tank into position and insert the two hoses coming from the foot pump into the two holes in the back rib of the tank. Locate the discharge hose (the hose coming from the right side hole) and place a PC- 000352 clamp on the end.
  • Page 12 Step 8. Vent Stack Installation Slide the vent stack up through the 4” hole of the roof and down into the corresponding hole in the tank. Using a 13/64” drill bit, drill a hole through the boss on the tank and through the vent stack.
  • Page 13 Step 11. Sink Installation For Fresh Flush Sink: Place the sink assembly into the corner and tilt Two holes on right side, located 13-1/2” from right vertical rib. Top the sink out so that the intake hose coming from the tank can be con- hole 3”...
  • Page 14 Step 14. Toilet Paper Dispenser The double roll dispenser can be mounted in a location of your prefer- ence based upon the accessories you have in the unit. Level the dis- penser on the wall and use the four holes in the back of the dispenser as a guide to mark the location for drill holes.

  • Page 15: Cleaning And Maintenance

    Association International. Contact your area sales representative for further details. OUR MISSION STATEMENT “PolyJohn is a family owned, state of the art, plastics manufacturing company dedicated to providing its employees with a work environment committed to excellence, and its customers with innovative products, services and technology that meet or exceed their requirements.”...

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