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ManualsBrandsPOLYJOHN ManualsFlushing UnitPOLYJOHN PH04 Comfort XLT Flushing Unit

PH04 Comfort XLT Flushing - June 2019

Page 1 of 15

PH04 Comfort XLT™

Flushing Unit

Instructions and Parts Listing

USA PATENTS: 4,577,351, 4,637,299, 4,793,100, 4,831,671, 4,895,400,

4,918,765

Des. 304,082 CANADIAN PATENT: 1311898

SPECIFICATIONS

DIMENSION IMPERIAL METRIC

Exterior Height 91 in 231 cm

Exterior Width 62 in 157 cm

Exterior Length 62 in 157 cm

Door Frame Height(I.D.) 74 in 188 cm

Door Frame Width(I.D.) 32 in 81 cm

Tank Seat Height 19 in 48 cm

Weight 240 lb 108 kg

Flush Tank Capacity 45 gal 170 L

Side Panel Decal Area 12” x 23” 30cm x 58cm

Door Panel Decal Area 27” x 27” 68cm x 68cm

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

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

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

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

Summary of content (15 pages)

PAGE 1
PH04 Comfort XLT™ Flushing Unit Instructions and Parts Listing USA PATENTS: 4,577,351, 4,637,299, 4,793,100, 4,831,671, 4,895,400, 4,918,765 Des. 304,082 CANADIAN PATENT: 1311898 SPECIFICATIONS DIMENSION IMPERIAL Exterior Height 91 in Exterior Width 62 in Exterior Length 62 in Door Frame Height(I.D.) 74 in Door Frame Width(I.D.
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Comfort XLT - Flush Tank Parts Diagram PH03-0008R http: //www.polyjohn.com/ph03-0008r/- Roof (28) http://www.polyjohn.com/pc-000100/ PC-000100 - Rivet (28)http://www.polyjohn.com/pc-000106/ PC-000106 - Washer (6)httpPC-000570 ://www.polyjohn.com/pc-000570/- Fly Screen (9)http://www.polyjohn.com/pc-000100/ PC-000100 - Rivet (9)http://www.polyjohn.com/pc-000106/ PC-000106 - Washer PC-000531 http://www.polyjohn.com/pc-000531/- Vent Stack http://www.polyjohn.com/pc-000117/ (1) PC-000117 - Rivet http://www.
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http://www.polyjohn.com/ph03-0003/ - Front Assembly PH03-0003 http://www.polyjohn.com/ph01-0004/- Front Panel PH01-0004 http://www.polyjohn.com/pc-000200/- Door Check Cable PC-000200 (1)http://www.polyjohn.com/pc-000104/ PC-000104 - Rivet (To Jamb) (3)http://www.polyjohn.com/pc-000105/ PC-000105 - Rivet (To Door) (1)http://www.polyjohn.com/pc-000106/ PC-000106 - Washer (1)http://www.polyjohn.com/pc-000168/ PC-000168 - Washer http://www.polyjohn.
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http: FS3-0022* //www.polyjohn.com/fs3-0022/ Seat Base/Flush Bowl http: //www.polyjohn.com/pc-100612/ PC-100612 - Pivot Rod (2)http:PC-100151 //www.polyjohn.com/pc-100151/- Retailer Clip http: PC-100611 //www.polyjohn.com/pc-100611/ Flapper Pivot Rod http:PC-000591 //www.polyjohn.com/pc-000591/ Pump Handle PC-000593 http: //www.polyjohn.com/pc-- Cotter 000593/ Pin http:PC-100372B //www.polyjohn.com/PC-100372B/ Barbed Nozzle http:PC-000597 //www.polyjohn.
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PC-100612 - Pivot Rod http: //www.polyjohn.com/pc-100612/ (2)http:PC-100151 //www.polyjohn.com/pc-100151/- Retailer Clip http: FS3-0022* //www.polyjohn.com/fs3-0022/ Seat Base/Flush Bowl http: PC-100611 //www.polyjohn.com/pc-100611/ http:PC-100372B //www.polyjohn.com/PC-100372B/ Flapper Pivot Rod Barbed Nozzle SG1-0013C - Flapper Complete http://www.polyjohn.com/sg1-0013c/ http:CH100-060 //www.polyjohn.com/ch100-060/ Contains the following parts http://www.polyjohn.
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FS3-0026*FF - Fleet Sink Flushing Model FS3-0028 http://www.polyjohn.com/fs3-0028 Anti-Siphon Tank PC-000415 http://www.polyjohn.com/pc-000415 http://www.polyjohn.com/pc-000339 PC-000339 - Elbow 1/4” Uniseal PC-000581G http://www.polyjohn.com/pc-000581g - Sink Tap http://www.polyjohn.com/pc-000104 (2) PC-000104 - Rivet http://www.polyjohn.com/pc-000106 (2) PC-000106 - Washer CT38-046 http://www.polyjohn.com/ct38-046 Tube (pump to tap) http://www.polyjohn.
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FULL SIZE SCALE FASTENER DRAWINGS (12) PC-000105 Rivet Small Flange (113) PC-000100 Rivet Large Flange, Short (123) PC-000106 Washer 3/16” Back-up (1) PC-000117 Rivet Hollow Wall 3/4” Grip (4) PC-000102 Rivet Small Flange, Short (3) PC-000104 Rivet Small Flange, Long (29) PC-000123 Washer 1/4” x 5/8” Flat (1) PC-000122 Screw 1/4”-20 x 2-1/4” TrussHead (1) PC-000168 Washer 5/16” x 7/16” Flat (4) PC-000175 Screw 1/4”-20 x 1-1/2” Phillips (2) PC-000174 Bolt 1/4”-20 x 1-1/4” Hex Head (23) PC-000139 B
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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” long 1” diameter hose and push the end of the hose on the intake side of the foot pump. Tighten clamp and repeat for the discharge side of the pump.
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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. NOTE: (Make sure that you rivet from the outside of the front toward the corner.
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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. Place a PC-000123 washer on the inside along with a PC-000140 nut and tighten. Repeat this step for the other two side panels. Level the left side panel, and using the remaining holes in the side as a guide, drill 1/4” holes all the way through the base surround.
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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 PC000352 clamp on the end. Connect the hose to the nozzle mounted on the back of the flush bowl and tighten the clamp in place. For Recirculating Flush: Locate the intake hose (coming from the left side hole) and place a PC-000352 clamp on the end.
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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. Rivet into place with (1) PC-000117 rivet. Step 9.
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Step 11. Sink Installation Two holes on right side, located 13-1/2” from right vertical rib. Top hole 3” up from horizontal rib. Bottom hole located 34-1/2” from top of base. For Fresh Flush Sink: Place the sink assembly into the corner and tilt the sink out so that the intake hose coming from the tank can be connected to the back of the sink. Place a PC-000352 clamp over the end of the hose, install the hose on the fitting, and tighten the clamp in place.
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Step 14. Toilet Paper Dispenser The double roll dispenser can be mounted in a location of your preference based upon the accessories you have in the unit. Level the dispenser on the wall and use the four holes in the back of the dispenser as a guide to mark the location for drill holes. Drill four 13/64” holes into the drill spots just marked. Use awls to hold the T.P. Dispenser in place. From outside of the unit rivet in place using (4) PC-000100 rivets and (4) PC-000106 back-up washers on the inside.
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Step 16. Toilet Seat Installation Place the toilet seat on the top of the tank. Line up the holes in the hinge of the seat with the holes in the top of the tank. Insert the seat bolts through the seat hinge and through the tank. Lift open the seat, thread the plastic seat nuts on the ends of the bolts and tighten. Step 17. Optional Urinal Installation Insert the drain spigot of the urinal into the hole on the left top surface of the holding tank. Position the urinal so that it is level.