PolyJohn Comfort Inn PH03 User manual

PH03 Comfort Inn - September 2008
Page 1 of 12
PH03 Comfort Inn™
Assembly Instructions
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
®
POLYJOHN
®
POLYJOHN
USA
PolyJohn Enterprises Corp
2500 Gaspar Ave.
Whiting, IN 46394
Phone: [phone]
Fax: [phone]
www.polyjohn.com
[email protected]
POLYJOHN
WORLDWIDE
PolyJohn (UK) Ltd.
Equinox 1 Audby Lane
Wetherby, England LS22 7RD
Phone: [phone]
Fax: [phone]
[email protected].uk
POLYJOHN
CANADA
PolyJohn Canada
P.O. Box 2300
199 Forest Plain Rd.
Orillia, Ontario LV3 6S2
Phone: [phone]
Fax: [phone]
[email protected]
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
Static Tank Capacity 33 gal 125 L
Recirc Tank Capacity 22 gal 83.6 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 references to left
and right throughout this guide are as viewed from the front.

PH03 Comfort XL - Parts - March 2012
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PH03-0008R - Roof (28) PC-000100 - Rivet (28) PC-000106 - Washer
(3) PJ03-0002 - Side Panel (15) PC-000121 - Washer (15) PC-000123 - Washer (15) PC-000139 - Bolt (15) PC-000140 - Nut
PC-000490 - T.P. Dispenser PC-000760 - Rod PC-000205M - Lock (4) PC-000100 - Rivet (4) PC-000106 - Washer
PH01-0010 - Corner Panel (72) PC-000100 - Rivet (72) PC-000106 - Washer (8) PC-000121 - Washer (8) PC-000123 - Washer (8) PC-000139 - Bolt (8) PC-000140 - Nut
(6) PC-000570 - Fly Screen (9) PC-000100 - Rivet (9) PC-000106 - Washer
PH03-0001C - Floor Complete
PH03-0001R - Right Base Surround
PH03-0001L - Left Base Surround
PH03-0002 - Floor Plate
(21) PC-000117 - Rivet
(23) PC-000121 - Washer
(2) PC-000174 - Bolt
(2) PC-000123 - Washer
(2) PC-000140 - Nylon Lock Nut
PH01-0003 - Comfort XL Front Assembly (See Front Assembly Exploded View)
PH03-0009 - Waste Holding Tank (4) PC-000103 - Rivet
(
4
)
PC-000106 - Washer
PC-000204 Toilet Seat
PC-000531 - Vent Stack
(1) PC-000117 - Rivet
(3) PH03-0020 - Heavy Duty Grab Bar (24) PC-000105 - Rivet (24) PC-000106 - Washer

PH03 Comfort XL - Parts - March 2012
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PH01-0006 - Door w/Hinges
(5) PC-000170 - Hinges
(15) PC-000104 - Rivet (to jamb)
(2) PC-000104 - Rivet (to door)
(2) PC-000106 - Washer (to door)
(15) PC-000102 - Rivet (to door)
PH01-0004 - Front Panel
(2) PC-000105 - Rivet
(2) PC-000121 - Washer
PH03-0005 - Door Jamb
(10) PC-000104 - Rivet (jamb to panel)
(4) PC-000175 - Screw 1/4”-20 x 1.5”
(2) PC-000174 - Bolt 1/4“-20 x 1.25”
(6) PC-000140 - Nylon Lock Nut 1/4“-20
(6) PC-000123 - Washer 1/4” x 5/8”
**PC-000200 - Door Cable
(3) PC-000105 - Rivet (to door)
(1) PC-000104 - Rivet (to jamb)
(1) PC-000168 - Washer
(1) PC-000106 - Washer
**PC-000223 - Handle
(2) PC-000104 - Rivet
**PC-000800 Door
Spring Closure
**PC-000806 - Door Closure Clip
(2) PC-000105 - Rivet
**SG1-0031 - Slide Latch Cover Plate
(4) PC-000105 - Rivet
(4) PC-000106 - Washer
**SG1-0030 - Slide Latch
**SA1-0017 U-Type Handle
(2) PC-100796 Rubber Grommet
**PC-000181 - Cable Clip
(2) PC-000102 - Rivet
NOT SHOWN
PC-000794 - Serial I.D. Plate
(2) PC-000108 - Rivet
** Items are not included with PH01-0003 Front Assembly.
Parts bag PH03-0206 is available for replacement purposes.
PH01-0003 Front Assembly

PH03 Comfort XL - Parts - March 2012
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PH03-0009R
Tank
FT02-0011 Prop Rod
PC-000232 Screw
PC-000233 Nut
CH100-014
Hose 1”x14”
PC-100372B Nozzle
(2) PC-000102 Rivet
(2) PC-000106 Washer
PF01-1000
Filter Complete
FS3-0022P
Bowl/Lid Pewter
(4) PC-000352
Hose Clamp
CH100-020 Hose
1”x20”
PC-000590
Flush Tank Pump
PC-100611 Shaft
SG1-0013Cup Flapper Valve
PC-100620 Counterweight
(2) PC-000155 Screw
(2) PC-000233 Nut
PC-000591
Pump Handle
PC-000593 Cotter Pin
(2) PC-000235
Shoulder Bolt
PC-000592
Pump HandleBoot
PC-000597
Pump Cover
**NOT SHOWN
PC-000786 Decal -Flush Tank
Optional Recirculating Flush System - Exploded View

PH03 Comfort Inn - September 2008
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• Please follow directions in the sequence they are presented. It is suggested you read through the entire assembly
instructions prior to proceeding.
• Proper handling is required, especially structures that have at oors with minimal foundations. Dropping this unit
during transport and site set-up may cause structural damage or misalignment of the front assembly and door.
• Position on clear level ground, shims may be used under the oor to aid in leveling, or the door may be out of
alignment.
• The PH03 Model restroom assembly will require two people.
• All drilling with 13/64” and 1/4” drill bits. All rivet holes drilled 13/64” dia.
• All references to left, right, front and rear throughout the entire assembly instructions are as viewed from the front
of the restroom.
• Use 1/4” disposable shim strips on all four diagonal corners during assembly to allow for thermal expansion and
contraction of the walls when exposed to weather extremes.
GENERAL OVERVIEW
ASSEMBLY INSTRUCTIONS
Locate three wall panels and four corner panels. Choose
one of the wall panels to be the rear panel and add a cor-
ner molding to each side of the rear panel wall using (9) PC-
000100 rivets and (9) PC-000106 back-up washers. Rivet in
the center holes rst, then to the top, and back down to the
bottom. Follow this procedure for both of the side wall pan-
els connecting them to both rear corners. Repeat, as well
for both of the front corner moldings. NOTE: (Make sure to
rivet corner moldings from the outside in, this gives a good vi-
sual appearance.) Place 1/4” thick shim strips on each of the
corners of the base surround. Lift the three wall panels and
four corner moldings sub-assembly and wrap them around
the base, resting the corners on the 1/4” shims.
Step 1. Three Wall Panels and Four Corner Mold-
ing Sub-Assembly
PC-000106 Washer
54 Used in this step
PC-000100 Rivet
54 Used in this step
~~Tools Required for Assembly~~
•13/64” Drill Bit • 1/4” Drill Bit • Tapered Awls
• Rivet Gun 3/16” nose piece • Phillips Screwdriver • Hammer
• Tape Measure • 7/16” Wrench • Vise-Grips