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PolyJohn Comfort XLT FLUSH Series Product Instructions

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Comfort XLT™ SERIES
PRODUCT INSTRUCTIONS
FLUSH MODELS
PH04-2000/2100 RECIRC HAND/FOOT
PH04-3000/3100 FRESH HAND/FOOT
Page 1 of 29
September 2023
there when you need us

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Summary of Contents for PolyJohn Comfort XLT FLUSH Series

  • Page 1 Comfort XLT™ SERIES PRODUCT INSTRUCTIONS FLUSH MODELS PH04-2000/2100 RECIRC HAND/FOOT there when you need us PH04-3000/3100 FRESH HAND/FOOT Page 1 of 29 September 2023...

  • Page 2: Product Specifications

    PRODUCT SPECIFICATIONS PH04 COMFORT XLT™ FLUSH SERIES 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...

  • Page 3: Product Overview

    The Comfort XLT® – Xtra Large Tank PolyJohn’s Comfort XLT portable toilet features all-new interior components PROs have been asking for. Designed with a large tank (capacity of 60 gallons) and a sloped, smooth tank top for easy cleaning, this unit is ideal for special events of all types including weddings, concerts, fairs, festivals, construction sites and parties where guests just want extra room.
  • Page 4 FULL SIZE SCALE PH04 COMFORT XLT™ FLUSH SERIES FASTENER DRAWINGS (1 13) PC-000100 Rivet (12) PC-000105 Rivet (123) PC-000106 Large Flange, Short Small Flange 3/16” Back-up Washer (30) PC-000123 (2) PC-000102 Rivet (2) PC-0001 17 Rivet 1/4” x 5/8” Flat Washer Small Flange, Short Hollow Wall 3/4”...
  • Page 5 ASSEMBLY INSTRUCTIONS PH04 COMFORT XLT™ FLUSH SERIES STEP 1: PREPARE THE BASE SURROUND FOR ATTACHING THE WALL PANELS Drill a 1/4” hole in center notch of base surround for mounting, centering, and leveling the first side panel. This will be repeated for other two side panels. STEP 2.
  • Page 6 ASSEMBLY INSTRUCTIONS PH04 COMFORT XLT™ FLUSH SERIES STEP 3: ATTACH THE WALL PANELS TO THE BASE SURROUND 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.
  • Page 7 ASSEMBLY INSTRUCTIONS PH04 COMFORT XLT™ FLUSH SERIES STEP 4. FRONT SUB-ASSEMBLY TO THE BASE SURROUNDS Lift the front sub-assembly and place the legs of the aluminum door jamb into the front of the base surround on each side of the door opening.
  • Page 8 ASSEMBLY INSTRUCTIONS PH04 COMFORT XLT™ FLUSH SERIES STEP 5. ATTACHING THE WALL PANELS AND CORNER MOLDINGS TO THE BASE SURROUND For the corner moldings: NOTE: (Be sure the corners are pushed tight against the base surround by pushing the corner at the rib in the center.) Start with the front corners first.
  • Page 9 ASSEMBLY INSTRUCTIONS PH04 COMFORT XLT™ FLUSH SERIES 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 7A. FOOT FLUSH PUMP ASSEMBLY FOR RECIRCULATING AND FRESH FLUSH (CONTINUE TO STEP 8 FOR HAND FLUSH) Place a PC-000352 hose clamp on the end of a 60”...
  • Page 10 ASSEMBLY INSTRUCTIONS PH04 COMFORT XLT™ FLUSH SERIES STEP 9. SINK INSTALLATION 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 located on the anti-siphon tank located on the back of the sink., and tighten the clamp in place.
  • Page 11 ASSEMBLY INSTRUCTIONS PH04 COMFORT XLT™ FLUSH SERIES STEP 10. FLY SCREEN INSTALLATION Each of the three sidewall panels has two vent screens. On the surface of each screen there is a date stamp symbol. The symbol goes toward the center of the sidewall panel, facing the inside.
  • Page 12 ASSEMBLY INSTRUCTIONS PH04 COMFORT XLT™ FLUSH SERIES STEP 13. DOOR CHECK CABLE Align the three holes of the metal bracket on the door check cable to the holes in the top inside center of the door so that the bracket angles toward the unit and the three holes line up with the holes in the bracket (as shown).
  • Page 13 ASSEMBLY INSTRUCTIONS PH04 COMFORT XLT™ FLUSH SERIES STEP 15. PAPER TOWEL DISPENSER INSTALLATION Open the Paper Towel dispenser by lifting out on the sides of the lid and lifting up. Place the dispenser in the location shown and using the holes as a drill guide, drill 4 - 13/64” holes through the side. Rivet in place using PC-000100 rivets from the outside with PC-000106 washers on the inside.
  • Page 14 ASSEMBLY INSTRUCTIONS PH04 COMFORT XLT™ FLUSH SERIES STEP 16. DOOR CLOSURE INSTALLATION Push the spring tube assembly into the hole in the center molded pocket of the door with the cable end towards the hinged side of the door. Insert the tabs of the door closure retainer clip into the 2 pre-drilled holes as shown below. Pivot the retainer clip into place while feeding the spring cable through the hole in the retainer clip.
  • Page 15 ASSEMBLY INSTRUCTIONS PH04 COMFORT XLT™ FLUSH SERIES STEP 17. 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.

  • Page 16: Parts Diagram

    - Fly Screen http: / /www. p ol y j o hn. c om/ph03- 0 008r/ PH03-0008R - Roof http://www.polyjohn.com/pc-000100/ (9) PC-000100 - Rivet http: / /www. p ol y j o hn. c om/pc- 0 00100/ (28) PC-000100 - Rivet http://www.polyjohn.com/pc-000106/...
  • Page 17 - SERIAL I.D. PLATE http: / /www.pol y j o hn.com/pc-000794/ http: / /www.pol y j o hn.com/pc-000108/ (2) PC-000108 - RIVETS PH03-0006RL http://www.polyjohn.com/ph03-0006RL/ DOOR w/HINGES (15) PC-000102 - RIVETS (DOOR) http://www.polyjohn.com/pc-000102/ http: / /www.pol y j o hn.com/pc-000102/ (15) PC-000104 - RIVETS (JAMB) http://www.polyjohn.com/pc-000104/...
  • Page 18 FLUSH SERIES CXLT BASE COMPLETE PH04-0001C - Static Tank/Hand Flush Tank PH04-0001CF - Foot Flush Tank PC-000140 - NUT, NYLON LOCK 1/4”-20 http://www.polyjohn.com/pc-000140/ - WASHER 1/4” x 5/8 PC-000123 http://www.polyjohn.com/pc-000123/ (23) PC-0001 17 - RIVET, LONG HOLLOW WALL http://www.polyjohn.com/pc-000117/ (20)
  • Page 19 PC-000592 Pump Handle Boot http: / /www. p ol y j o hn. c om/ft02- 0 011/ FT02-001 1 http://www.polyjohn.com/sg1-0013c/ SG1-0013C - Flapper Complete Prop Rod Contains the following parts http: / / www. p ol y j o hn. c om/sg1- 0 013/ SG1-0013 - Flapper Valve http: / /www.
  • Page 20 PC-10061 1 Barbed Nozzle Flapper Pivot Rod http: / /www. p ol y j o hn. c om/ch100- 0 60/ http://www.polyjohn.com/sg1-0013c/ CH100-060 http://www.polyjohn.com/sg1-0013c/ ht t p : / / www. p ol y j o hn. c om/sg1- 0 013c/ SG1-0013C - Flapper Complete Discharge Hose, 1”...
  • Page 21 Decal Not for Drinking http://www.polyjohn.com/pc-000782 PC-000783 http://www.polyjohn.com/pc-000783 Decal Transport PC-000790 http://www.polyjohn.com/pc-000790 Decal Foot Pump PC-000418 http: / /www.polyjohn.com/pc-000418 1” Uniseal PC-100421B http: / /www.pol y j o hn.com/pc-100421b PC-000417 Drain Body http://www.polyjohn.com/pc-000417 3/4” Uniseal PC-000241 http: / /www.pol y j o hn.com/pc-000241...
  • Page 22 (2) PC-000147 http://www.polyjohn.com/pc-0 FS3-0028 http://www.polyjohn.com/fs3-0028 Anti-Siphon Tank PC-000900 http://www.polyjohn.com/pc-000900 PC-000352 http://www.polyjohn.com/pc-000352 Hose Clamp #12 CT38-035 - Tube http: / /www.polyjohn.com/ct38-035 (Intake to Anti-Siphon) CH100-028 Hose 1” x 28” (2) PC-000417 http://www.polyjohn.com/pc-000417 3/4” Uniseal CH100-025 http://www.polyjohn.com/ch100-025 PC-000415 http://www.polyjohn.com/pc-000415 Hose 1” x 25”’...
  • Page 23 PARTS DIAGRAM PH04 COMFORT XLT™ FLUSH SERIES CXLT Fresh Flush Hose Connections Sink Tank to Anti-Siphon Tank Recirc Filter to Pump Inlet Sink Pump Outlet to Sink Tap Pump Outlet to Flush Bowl Sink Tank to Sink Pump Inlet Sink Bowl Drain Hose ** CHECK FOR LEAKS AT FOOT PUMP CONNECTIONS ** ** CHECK FOR LEAKS AT...

  • Page 24: Cleaning And Maintenance

    WHITING, IN 46394-2175 800-292-1305 www.polyjohn.com/supplies/pros-choice.html We highly recommend membership in the Portable Sanitation Association International (PSAI); the worldwide authority on portable sanitation services. The PSAI, “Portable Sanitation Industry Certification Program” manual contains a wealth of information on standards and service procedures.
  • Page 25 Chemical exposure typically occurs through inhalation, ingestion, or adsorption. PolyJohn products are not intended to be used in these methods. PolyJohn Corporation cannot foresee all uses of their products (both intended and unintended uses) and as a result has opted to provide a general warning of known chemical presence.

  • Page 26: Frequently Asked Questions

    fit? A: The new PolyJohn Urinal has been completely redesigned. The new design has been proven to be the best shape and form to keep splash- back to a minimum. The side walls are much higher and there is no lip on the inside. This will help keep the urinal clean. The entire urinal has smooth surfaces as well to aid in cleaning.
  • Page 27 That being said, there is always a very small chance that there is a manufacturing defect. If all other options have been ruled out, then please visit the PolyJohn Warranty page. Q: Where is the fill port? A: Most of our sinks fill ports are colored blue to indicate fresh water.

  • Page 28: Warranty

    PolyJohn Enterprises warrants our sinks, tanks, trailers and sanistands from the date of purchase. Any misuse or abuse of our products or failure to properly follow recommended procedures shall void this warranty. The warranty is a 1 year limited warranty and a 90 day limited warranty for components thereof.
  • Page 29 OUR MISSION STATEMENT PH04 COMFORT XLT™ SERIES “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.”...

This manual is also suitable for:

Ph04-2000Ph04-2100Ph04-3000Ph04-3100

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