PolyJohn Comfort XLT PH04 Parts list manual

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: [phone]
Fax: [phone]
Web: www.polyjohn.com
Email: [email protected]
POLYJOHN
WORLDWIDE
PolyJohn (UK) Ltd.
Equinox 1 Audby Lane
Wetherby, England LS22 7RD
Phone: [phone]
Fax: [phone]
Web: www.polyjohn.co.uk
Email: [email protected]
POLYJOHN
CANADA
PolyJohn Canada
P.O. Box 2300
199 Forest Plain Rd.
Orillia, Ontario LV3 6S2
Phone: [phone]
Fax: [phone]
Web: www.polyjohncanada.ca
Email: [email protected]

PC-000490 - T.P. Dispenser
PC-000760 - Rod
PC-000205M - Lock
(4) PC-000100 - Rivet
(4) PC-000106 - Washer
(6) PC-000570 - Fly Screen
(9) PC-000100 - Rivet
(9) 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
PSD1-1000 - Soap Dispenser
(3) PC-000105 - Rivet
PH03-0008R - Roof
(28) PC-000100 - Rivet
(28) PC-000106 - Washer
PC-000531 - Vent Stack
(1) PC-000117 - Rivet
PC-000495 - Urinal (Optional)
(2) PC-000102 - Rivet
(2) PC-000106 - Washer
(3) PJ03-0002 - Side Panel
(15) PC-000121 - Washer
(15) PC-000123 - Washer
(15) PC-000139 - Bolt
(15) PC-000140 - Nut
PH03-0003 - Comfort XL
Front Assembly
(See Front Assembly Exploded View)
(2) PC-000174 - 1-1/4” Screw
(4) PC-000175 - 1-1/2” Screw
(6) PC-000123 - Washer
(6) PC-000140 - Nylon Lock Nut
PC-000204
Toilet Seat
PH04-0001C - Floor Complete
PH03-0001 - Base Surround
PH04-0001T - Tank Support
PH04-0002 - Floor Plate
(25) PC-000117 - Rivet
(20) PC-000121 - Washer
(2) PC-000174 - Screw
(2) PC-000123 - Washer
(2) PC-000140 - Nylon Lock Nut
TD04-1000 - Paper Towel
Dispenser
(4) PC-000100 - Rivet
(4) PC-000106 - Washer
PH04-0025 - Sink Surround
(3) PC-000105 - Rivet
FS3-0026PC - Static Sink OR
FS3-0026PFF - Fresh Flush Sink
(3) PC-000103 - Rivet
(3) PC-000106 - Washer
PH04-0009RFC - Recirc Foot Flush Tank or
PH04-0009RHC - Recirc Hand Flush Tank or
PH04-0009FFC - Fresh Foot Flush Tank or
PH04-0009FHC - Fresh Hand Flush Tank
(5) PC-000105 - Rivet
(5) PC-000106 - Washer
PH04-0024C - Foot Pump Housing w/pump
PH04-0024- Foot Pump Hosing
PC-000606 - Foot Pump
PC-000604 - Rubber Cover
(6) PC-000106 - Washer
(6) PC-000231 - Screw
(1) PC-000105 - Rivet
PH04-0001CF - Floor Complete-Foot Flush
PH03-0001 - Base Surround
PH04-0001TF - Tank Support - Foot Flush
PH04-0002 - Floor Plate
(25) PC-000117 - Rivet
(20) PC-000121 - Washer
(2) PC-000174 - Screw
(2) PC-000123 - Washer
(2) PC-000140 - Nylon Lock Nut
Comfort XLT - Flush Tank Parts Diagram
http://www.polyjohn.com/pj03-0002/
http://www.polyjohn.com/pc-000121/
http://www.polyjohn.com/pc-000123/
http://www.polyjohn.com/pc-000139/
http://www.polyjohn.com/pc-000140/
http://www.polyjohn.com/ph01-0010/
http://www.polyjohn.com/pc-000100/
http://www.polyjohn.com/pc-000106/
http://www.polyjohn.com/pc-000121/
http://www.polyjohn.com/pc-000123/
http://www.polyjohn.com/pc-000139/
http://www.polyjohn.com/pc-000140/
http://www.polyjohn.com/pc-000570/
http://www.polyjohn.com/pc-000100/
http://www.polyjohn.com/pc-000106/
http://www.polyjohn.com/pc-000490/
http://www.polyjohn.com/pc-000106/
http://www.polyjohn.com/pc-000100/
http://www.polyjohn.com/pc-000205m/
http://www.polyjohn.com/pc-000760/
http://www.polyjohn.com/ph03-0008r/
http://www.polyjohn.com/pc-000100/
http://www.polyjohn.com/pc-000106/
http://www.polyjohn.com/pc-000531/
http://www.polyjohn.com/pc-000117/
http://www.polyjohn.com/ph03-0003/
http://www.polyjohn.com/pc-000174/
http://www.polyjohn.com/pc-000175/
http://www.polyjohn.com/pc-000123/
http://www.polyjohn.com/pc-000140/
http://www.polyjohn.com/pc-000204/
http://www.polyjohn.com/ph04-0001c/
http://www.polyjohn.com/ph03-0001/
http://www.polyjohn.com/ph04-0001t/
http://www.polyjohn.com/ph04-0002/
http://www.polyjohn.com/pc-000117/
http://www.polyjohn.com/pc-000121/
http://www.polyjohn.com/pc-000174/
http://www.polyjohn.com/pc-000123/
http://www.polyjohn.com/pc-000140/
http://www.polyjohn.com/pc-000102/
http://www.polyjohn.com/pc-000106/
http://www.polyjohn.com/pc-000495/
http://www.polyjohn.com/psd1-1000/
http://www.polyjohn.com/pc-000105/
http://www.polyjohn.com/TD04-1000/
http://www.polyjohn.com/pc-000100/
http://www.polyjohn.com/pc-000106/
http://www.polyjohn.com/ph04-0025/
http://www.polyjohn.com/pc-000105/
http://www.polyjohn.com/FS3-0026PC/
http://www.polyjohn.com/pc-000103/
http://www.polyjohn.com/pc-000106/
http://www.polyjohn.com/FS3-0026PFF/
http://www.polyjohn.com/PH04-0009RFC/
http://www.polyjohn.com/pc-000105/
http://www.polyjohn.com/pc-000106/
http://www.polyjohn.com/PH04-0009RHC/
http://www.polyjohn.com/ph04-002C/
http://www.polyjohn.com/pc-000606/
http://www.polyjohn.com/pc-000604/
http://www.polyjohn.com/pc-000106/
http://www.polyjohn.com/pc-000231/
http://www.polyjohn.com/pc-000105/
http://www.polyjohn.com/ph04-0024/
http://www.polyjohn.com/ph04-0001cf/
http://www.polyjohn.com/ph03-0001/
http://www.polyjohn.com/ph04-0001tf/
http://www.polyjohn.com/ph04-0002/
http://www.polyjohn.com/pc-000117/
http://www.polyjohn.com/pc-000121/
http://www.polyjohn.com/pc-000174/
http://www.polyjohn.com/pc-000123/
http://www.polyjohn.com/pc-000140/
http://www.polyjohn.com/PH04-0009FFC/
http://www.polyjohn.com/PH04-0009FHC/

PH04 Comfort XLT Flushing - June 2019
Page 3 of 15
http://www.polyjohn.com/pc-000108/
http://www.polyjohn.com/pc-000105/
http://www.polyjohn.com/pc-000806/
http://www.polyjohn.com/pc-000181/
http://www.polyjohn.com/pc-000800/
http://www.polyjohn.com/pc-000223/
http://www.polyjohn.com/pc-000104/
http://www.polyjohn.com/pc-000574c/
http://www.polyjohn.com/pc-000121/
http://www.polyjohn.com/pc-000122/
http://www.polyjohn.com/pc-000140/
http://www.polyjohn.com/ph03-0006/
http://www.polyjohn.com/pc-000102/
http://www.polyjohn.com/pc-000104/
http://www.polyjohn.com/pc-000170/
http://www.polyjohn.com/pc-000794/
http://www.polyjohn.com/pc-000108/
http://www.polyjohn.com/ph03-0005/
http://www.polyjohn.com/pc-000104/
http://www.polyjohn.com/pc-000174/
http://www.polyjohn.com/pc-000175/
http://www.polyjohn.com/pc-000140/
http://www.polyjohn.com/pc-000123/
http://www.polyjohn.com/pc-000200/
http://www.polyjohn.com/pc-000104/
http://www.polyjohn.com/pc-000105/
http://www.polyjohn.com/pc-000106/
http://www.polyjohn.com/pc-000168/
http://www.polyjohn.com/ph01-0004/
http://www.polyjohn.com/ph03-0003/
PC-000200 - Door Check Cable
(1) PC-000104 - Rivet (To Jamb)
(3) PC-000105 - Rivet (To Door)
(1) PC-000106 - Washer
(1) PC-000168 - Washer
PC-000181 - Cable Clip
(2) PC-000108 - Rivets
PC-000806 - Spring Retainer
(2) PC-000105 - Rivets
PC-000800 - Spring Assembly
PC-000223 - Handle
(2) PC-000104 - Rivets
PC-000574C - Rotary Latch w/Decal
(2) PC-000121 - Washers
(1) PC-000122 - Screw
(1) PC-000140 - Nylon Lock Nut
PH03-0006 - Door w/Hinges
(15) PC-000102 - Rivets (Hinge to Door)
(15) PC-000104 - Rivets (Hinge to Jamb)
(5) PC-000170 - Hinges
PH03-0005- Door Jamb
(10) PC-000104 - Rivets
(2) PC-000174 - Screw
(4) PC-000175 - Screw
(1) PC-000140 - Nylon Lock Nut
(4) PC-000123 - Washer
Not Shown
PC-000794 - Serial I.D. Plate
(2) PC-000108 - Rivets
PH01-0004 - Front Panel
PH03-0003 - Front Assembly

PH04 Comfort XLT Flushing - June 2019
Page 4 of 15
http://www.polyjohn.com/pc-000593/
http://www.polyjohn.com/pc-100611/
http://www.polyjohn.com/pc-000591/
http://www.polyjohn.com/pc-000597/
http://www.polyjohn.com/pc-000592/
http://www.polyjohn.com/ch100-020/
http://www.polyjohn.com/ch100-036/
http://www.polyjohn.com/pc-000590/
http://www.polyjohn.com/pc-100151/
http://www.polyjohn.com/PC-100372B/
http://www.polyjohn.com/pc-100612/
http://www.polyjohn.com/ph04-0009f/
http://www.polyjohn.com/ch100-014/
http://www.polyjohn.com/pf01-1000/
http://www.polyjohn.com/fs3-0022/
http://www.polyjohn.com/PC-000233/
http://www.polyjohn.com/PC-000232/
http://www.polyjohn.com/ft02-0011/
http://www.polyjohn.com/PC-000352/
http://www.polyjohn.com/sg1-0013c/
http://www.polyjohn.com/sg1-0013/
http://www.polyjohn.com/pc-100620/
http://www.polyjohn.com/pc-000106/
http://www.polyjohn.com/pc-100137/
http://www.polyjohn.com/pc-100138/
PC-100611
Flapper Pivot Rod
PC-000592
Pump Handle Boot
PC-000597
Pump Cover
PC-000591
Pump Handle
PC-000593 - Cotter Pin
Used in the
Recirculating Flush only
CH100-036
Fresh Water Intake
Hose, 1” x 36”
(Used in the Fresh Flush only)
CH100-020
Recirculating Intake
Hose, 1” x 20”
SG1-0013C - Flapper Complete
Contains the following parts
SG1-0013 - Flapper Valve
PC-100620 - Counterweight
(4) PC-000106 - Washer
(2) PC-100137 - Screw
(2) PC-100138 - Nylon Lock Nut
CH100-014
Hose, 1” x 14”
PC-100372B
Barbed Nozzle
PC-000590
Flush Tank Pump
FS3-0022*
Seat Base/Flush Bowl
PH04-0009F
Comfort XLT Flush Tank
PF01-1000
Plastic Filter
PC-000233
Nylon Lock Nut
PC-000232
Screw
FT02-0011
Prop Rod
(4) PC-000352
#12 Hose Clamp
PC-100612 - Pivot Rod
(2) PC-100151 - Retailer Clip

PH04 Comfort XLT Flushing - June 2019
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http://www.polyjohn.com/pc-100611/
http://www.polyjohn.com/pc-000106/
http://www.polyjohn.com/pc-000604/
http://www.polyjohn.com/ph04-0024/
http://www.polyjohn.com/pc-000231/
http://www.polyjohn.com/ch100-060/
http://www.polyjohn.com/pc-000606/
http://www.polyjohn.com/pc-100151/
http://www.polyjohn.com/PC-100372B/
http://www.polyjohn.com/pc-100612/
http://www.polyjohn.com/ph04-0009f/
http://www.polyjohn.com/ch100-060/
http://www.polyjohn.com/pf01-1000/
http://www.polyjohn.com/fs3-0022/
http://www.polyjohn.com/PC-000233/
http://www.polyjohn.com/PC-000232/
http://www.polyjohn.com/ft02-0011/
http://www.polyjohn.com/PC-000352/
http://www.polyjohn.com/sg1-0013c/
http://www.polyjohn.com/sg1-0013/
http://www.polyjohn.com/pc-100620/
http://www.polyjohn.com/pc-000106/
http://www.polyjohn.com/pc-100137/
http://www.polyjohn.com/pc-100138/
http://www.polyjohn.com/ph04-0009f/
http://www.polyjohn.com/ph04-0024C/
PC-100611
Flapper Pivot Rod
PH04-0024
Foot Pump Housing
PC-000604
Pump Cover
(6)PC-000106 - Washer
Used in the
Recirculating Flush only
CH100-060
Intake Hose, 1” x 60”
(Same hose used for
Fresh Flush and
Recirculating Systems)
(6)PC-000231 - Screw
SG1-0013C - Flapper Complete
Contains the following parts
SG1-0013 - Flapper Valve
PC-100620 - Counterweight
(4) PC-000106 - Washer
(2) PC-100137 - Screw
(2) PC-100138 - Nylon Lock Nut
CH100-060
Discharge Hose, 1” x 60”
PC-100372B
Barbed Nozzle
PC-000606
Flush Tank Foot Pump
FS3-0022*
Seat Base/Flush Bowl
PH04-0009F
Comfort XLT Flush Tank
PF01-1000
Plastic Filter
PC-000233
Nylon Lock Nut
PC-000232
Screw
FT02-0011
Prop Rod
(4) PC-000352
#12 Hose Clamp
PC-100612 - Pivot Rod
(2) PC-100151 - Retailer Clip
PH04-0001TF
Foot Flush Tank Riser
PH04-0024C
Foot Pump
Housing Complete

PH04 Comfort XLT Flushing - June 2019
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Fasteners for Bowl
(2) PC-000107 - Rivet
(2) PC-000106 - Washer
PC-000310 -
Rubber Washer
PC-000224 - Locking Clip
(2) PC-000110 - Rivet
(2) PC-000111 - Washer
PC-000581G - Sink Tap
(2) PC-000104 - Rivet
(2) PC-000106 - Washer
PC-000225 - Catch Lock
(2) PC-000110 - Rivet
(2) PC-000111 - Washer
FS3-0026*FF - Fleet Sink
Flushing Model
PC-000308
Sink Strainer
PC-000415
1/4” Uniseal
CT38-046
Tube (pump to tap)
PC-000339 - Elbow
FS3-0028
Anti-Siphon Tank
(4) PC-000352
Hose Clamp #12
PC-100324 - Fitting
CH100-025
Hose 1” x 25”
(Used On Fleet)
(2) PC-000417
3/4” Uniseal
To Pump
PC-000339 - Elbow
PC-000600 -Foot Pump
(4) PC-000102 - Rivet
(4) PC-000106 - Washer
PC-000417
3/4” Uniseal
CH075-028 - Drain Hose
PC-000351 - #10 Hose Clamp
PC-000322 - Elbow
PC-000305
Plastic Filter
**NOT SHOWN
PC-000782 - Decal Not for Drinking
PC-000783 - Decal Transport
PC-000790 - Decal Foot Pump
CT38-0065
Tube (tank to pump)
FS3-0052 - Foot Pump Plate
(2) PC-000147 - Screw
PC-000418
1” Uniseal
PC-100421B
Drain Body
PC-100421P
Drain Plug
PC-000241
O-Ring
Updated 6-05-2019
PC-000415
1/4” Uniseal
CT38-035 - Tube
(Intake to Anti-Siphon)
CH100-036
Hose 1” x 36”
(Used On CXLT hand flush)
CH100-060
Hose 1” x 60”
(Used On CXLT foot flush)
Fresh
Flush
Only
http://www.polyjohn.com/ct38-046
http://www.polyjohn.com/pc-000415
http://www.polyjohn.com/pc-000339
http://www.polyjohn.com/pc-000581g
http://www.polyjohn.com/pc-000104
http://www.polyjohn.com/pc-000106
http://www.polyjohn.com/pc-000225
http://www.polyjohn.com/pc-000110
http://www.polyjohn.com/pc-000111
http://www.polyjohn.com/pc-000111
http://www.polyjohn.com/pc-000110
http://www.polyjohn.com/pc-000310
http://www.polyjohn.com/pc-000224
http://www.polyjohn.com/pc-000417
http://www.polyjohn.com/pc-000600
http://www.polyjohn.com/pc-000102
http://www.polyjohn.com/pc-000106
http://www.polyjohn.com/pc-000147
http://www.polyjohn.com/fs3-0052
http://www.polyjohn.com/fs3-0028
http://www.polyjohn.com/pc-100324
http://www.polyjohn.com/pc-000417
http://www.polyjohn.com/pc-000352
http://www.polyjohn.com/ch100-025
http://www.polyjohn.com/pc-100421P
http://www.polyjohn.com/pc-000241
http://www.polyjohn.com/PC-000305
http://www.polyjohn.com/pc-000339
http://www.polyjohn.com/pc-100421b
http://www.polyjohn.com/pc-000418
http://www.polyjohn.com/pc-000351
http://www.polyjohn.com/ch075-028
http://www.polyjohn.com/pc-000322
http://www.polyjohn.com/pc-000107
http://www.polyjohn.com/pc-000106
http://www.polyjohn.com/pc-000308
http://www.polyjohn.com/ct38-0065
http://www.polyjohn.com/pc-000415
http://www.polyjohn.com/ct38-035
http://www.polyjohn.com/pc-000782
http://www.polyjohn.com/pc-000783
http://www.polyjohn.com/pc-000790
http://www.polyjohn.com/ch100-036
http://www.polyjohn.com/ch100-060

PH04 Comfort XLT Flushing - June 2019
Page 7 of 15
•Please follow directions in the sequence they are presented. It is suggested you read through the entire as-
sembly 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 PH04 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.
GENERAL OVERVIEW
(12) PC-000105 Rivet
Small Flange
FULL SIZE SCALE FASTENER DRAWINGS
(3) PC-000104 Rivet
Small Flange, Long
(123) PC-000106
Washer
3/16” Back-up
(1) PC-000117 Rivet
Hollow Wall 3/4” Grip
(27) PC-000121 Washer
1/4” x 1-1/4” Fender
(29) PC-000123 Washer
1/4” x 5/8” Flat
(30) PC-000140
Nut 1/4”-20 Nylok
(4) PC-000175 Screw
1/4”-20 x 1-1/2” Phillips
(1) PC-000168 Washer
5/16” x 7/16” Flat
(113) PC-000100 Rivet
Large Flange, Short
~~Tools Required for Assembly~~
(23) PC-000139 Bolt
1/4”-20 x 1” Hex Head
(1) PC-000122 Screw
1/4”-20 x 2-1/4”TrussHead
(2) PC-000174 Bolt
1/4”-20 x 1-1/4” Hex Head
• 13/64” Drill Bit • 1/4” Drill Bit • Tapered Awls
• Rivet Gun w/ 3/16” nose piece • Phillips & Slotted Screwdriver • Hammer
• Tape Measure • (2) 7/16” Wrenches • Vise-Grips (Locking Pliers)
(4) PC-000102 Rivet
Small Flange, Short
(1) PC-000147 Screw
#10 x 3/4” Phillips Head

PH04 Comfort XLT Flushing - June 2019
Page 8 of 15
ASSEMBLY INSTRUCTIONS
These assembly instructions are for foot ush and hand ush, recirculating and fresh
ush systems. Some steps will not be needed for your particular conguration.
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. Slip
the other ends of the hoses through the rectangular
cutout in the front of the tank riser that is mount-
ed to the oor plate. Feed the ends of the hoses
through the cutout towards the rear of the tank
riser. Tilt the foot pump housing assembly into the
front cutout. Raise the oor plate assembly so that
you can drill a 13/64” hole through the underside of
the oor (in the counterbore located under the foot
pump assembly) and into the foot pump assembly.
Fasten in place using a PC-000117 rivet.
PC-000117 Rivet
1 Used in this step
Locate three wall panels and four corner panels. Choose one of
the wall panels to be the rear panel and add a corner 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 pro-
cedure for both of the side wall panels 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 visual appearance.) Lift
the three wall panels and four corner moldings sub-assembly
and wrap them around the base, resting the corners on the
1/4” raised areas molded into the top of the base.
Step 2. Three Wall Panels and Four Corner Molding Sub-Assembly
PC-000106 Washer
54 Used in this step
PC-000100 Rivet
54 Used in this step

PH04 Comfort XLT Flushing - June 2019
Page 9 of 15
PC-000106 Washer
18 Used in this step PC-000123 Washer
6 Used in this step
PC-000140 Nut
6 Used in this step
PC-000175 Screw
4 Used in this step
PC-000100 Rivet
18 Used in this step
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.) For shipping
purposes, there is a zip tie holding the holding the
door closed with the front assembly. Cut this tie o
and install a PC-000107 rivet into the hole in the door
jamb. Grab one side of the front assembly and pull
tightly into the“pocket” of the base surround and place
a pair of vise-grips onto the base surround holding the
front sub-assembly. Locate the three pre-drilled holes
in the bottom of the door jamb, using a 1/4” drill bit, drill
into those holes all the way through the base surround. Insert
into the two bottom holes (2) PC-000175 screws with (2) PC-000123
washers with (2) PC-000140 lock-nuts. DO NOT TIGHTEN TO THE END OF
THE THREAD, TIGHTEN JUST SO THE LOCK-NUT IS JUST FLUSH AT THE END OF
THE SCREW.Insert into the top hole (1) PC-000174 bolt with (1) PC-000123 washer and (1)
PC-000140 lock-nut. DO NOT TIGHTEN TO THE END OF THE THREAD, TIGHTEN JUST SO THE
LOCK-NUT IS JUST FLUSH AT THE END OF THE SCREW. Repeat this for the other side of the front sub-assembly.
PC-000174 Bolt
2 Used in this step

PH04 Comfort XLT Flushing - June 2019
Page 10 of 15
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 pan-
els. 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.
Fasten the side to the base using the same method as for the
center hole. Repeat this for the rest of the sides. 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 rst. From the
inside of the unit, locate the two recesses in the front inside cor-
ners of the base surround. Drill a 1/4” hole through the centers of
these recesses and through the corner panel. Fasten in place using
the PC-000121 washers and PC-000139 bolts on the ouside with the
PC-000123 washers and PC-000140 nuts on the inside. Tighten in place.
Repeat these steps for the remaining corner panels.
Step 4. Attaching the Wall Panels and Corner Moldings to the Base Surround
PC-000121 Washer
23 Used in this step
s
and
rjamb.
his
rom
a
al corner mouldings have a centre rib. On each
les through the corner mouldings and roof. Make sure
outside flanges of the corner moulding and in line
. Rivet from the outside flanges, using PC-000100
Step 5. Roof Assembly
NOTE: (The front and three wall panels are supplied with pre-
drilled holes at the top center of each panel. The roof is sup-
plied with dimple spots along each of the eight edges.) Use a
13/64” drill bit. Drill holes in the center dimple spots of the
roof. IMPORTANT - BE SURE TO ALIGN THE HOLE FOR THE
VENT STACK IN THE ROOF WITH THE HOLE IN THE TANK.
Start with the front of the unit: The roof needs to be aligned
with the center hole in the jamb. When aligning the roof to
the front assembly, apply pressure to the left corner mold-
ing, this will cause the door to move up and down within the
aluminum door jamb. Before installing the rivets in this area
square up the door to the jamb. Someone on the outside
will rivet PC-000100 rivets through each of the four center
holes of the roof to the wall panels, while another person
places PC-000106 back-up washers on the rivet stems from
inside the unit. Proceed with the corner moldings: Using a
13/64” drill bit, drill holes in the center on both sides of the
rib and then rivet into place as above. For the wall panels:
Hold the roof rmly against the wall panels. Using a 13/64”
bit, drill through the remaining dimple spots of the roof into
the wall panels. The person on the outside will again rivet
the PC-000100 rivets through the drilled holes, while from
inside, someone will place PC-000106 back-up washers on
the rivet stems.
PC-000106 Washer
28 Used in this step
PC-000100 Rivet
28 Used in this step
PC-000139 Bolt
23 Used in this step PC-000123 Washer
23 Used in this step
PC-000140 Nut
23 Used in this step

PH04 Comfort XLT Flushing - June 2019
Page 11 of 15
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. Connect the hose to the nozzle mounted on the back of the ush 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. Insert the plastic lter assembly into the end of the hose and tighten the
clamp in place. For Fresh Flush: Take the intake hose (coming from the left side hole) and push it through the
hole on the right side of the tank, leaving no slack inside the tank.
Step 6b. Waste Tank Installation (all ushing styles)
On the outside of the unit measure and
mark drill spots. All holes will be 17-3/4” up
from the top of the base surround. For the
rear wall panel make a mark above each
‘corner’ in the bottom rib. Make another
mark half way between those two. For the
corner molding, make a mark on each side of
the center rib, centered in the at area. On the
left wall panel, make a mark above the ‘corner’ of
the bottom rib and another 13-1/2” towards the front.
Position the waste tank in the left rear corner on the tank
supports of the base surround. While inside one person
holds the tank in the proper position, using a 13/64” bit,
someone on the outside will drill through the 7 spots
just marked. CAUTION: WHEN DRILLING HOLES, ES-
PECIALLY THE REAR PANEL, BE SURE TO DRILL ONLY
THROUGH THE FIRST WALL OF THE TANK. Place
a PC-000106 back-up washer on the body of the
PC-000105 rivet and rivet in place. Repeat this
for the remaining 6 holes.
PC-000106 Washer
7 Used in this step
17-3/4”
11-1/2”
2-1/2”
13-1/2”
2-1/2”
PC-000105 Rivet
7 Used in this step
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.
For each of the sidewalls, insert into the vent
slot one screen from each side and overlap the
center holes of the screens (at the date stamp
symbol). IMPORTANT - MAKE SURE BOTH
SCREENS ARE CENTERED IN THE VENT SLOT.
From inside the unit using a 13/64” drill bit, drill
a hole through the center hole of the screen and
into each of the side walls. From the outside riv-
et a PC-000100 rivet into the center hole with a
PC-000106 back-up washer on the inside. From
inside the unit using the holes at the ends of
the screens as guides, drill holes through to the
wall panels. From the outside rivet the screens
in place with PC-000100 rivets and PC-000106
back-up washers on the inside.
Step 7. Fly Screen Installation
PC-000100 Rivet
9 Used in this step
PC-000106 Washer
9 Used in this step

PH04 Comfort XLT Flushing - June 2019
Page 12 of 15
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 8. Vent Stack Installation
PC-000117 Rivet
1 Used in this step
Mark the hole locations on the front of the door for the door handle by measuring up from
the bottom of the door by 31-1/2” and measuring in from the side of the
door by 1/2”. This is the location for the bottom mounting hole. Using a
drill with a 13/64” drill bit, drill a hole through the plastic of the door and
the rst wall of the steel door pillar. Rivet the door handle to the door using
a PC-000104 rivet through the bottom hole of the handle. Making sure
the handle is straight on the door, use the very top hole of the handle
as a drill guide and drill a 13/64” hole through only the outside wall
of the steel door pillar. Rivet in place using a PC-000104 rivet. To
mount the rotary latch, insert the PC-000122 Screw through a PC-
000121 washer and into the front of the door. Place the rotary latch,
another PC-000121 washer on the end of the screw and fasten in place
using a PC-000140 lock nut. Adjust the tightness of the screw to adjust
the ease of the latch movement.
Step 9. Door Handle and Rotary Latch
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). Rivet into place using (3) PC-000105 rivets. From the outside of the unit, insert a PC-000104 rivet
into the pre-drilled hole at the top of the door opening of the door jamb. Place the looped end of the door
check cable on the end of the rivet followed by (1) PC-000168 washer and (1) PC-000106 back-up washer.
Rivet in place.
Step 10 . Door Check Cable
PC-000104 Rivet
1 Used in this step
PC-000168 Washer
1 Used in this step
PC-000105 Rivet
3 Used in this step
PC-000106 Washer
1 Used in this step
PC-000104 Rivet
2 Used in this step
Drill hole
1/2” away
from the side
of the door
and 31-1/2”
from the
bottom
of the door
PC-000121 Washer
2 Used in this step
PC-000122 Screw
1 Used in this step
PC-000140 Nut
1 Used in this step

PH04 Comfort XLT Flushing - June 2019
Page 13 of 15
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 con-
nected to the back of the sink. Place a PC-000352 clamp over the
end of the hose, install the hose on the tting, and tighten the
clamp in place.
For All Sink Installation: Place the sink assembly into the
corner, inserting the sink drain hose into the correspond-
ing hole in the tank. With someone holding the sink tight
in the corner, have another person drill 5 - 13/64” holes
in the locations shown in the gure to the left. Be sure to
drill only through the side wall and only one wall of the sink
surround. Fasten in place using a PC-000106 washer on
the end of a PC-000105 rivet and rivet in place. Place a
PC-000147 screw through the hole in the sink foot pump
mounting plate and screw into the oor plate.
Step 11. Sink Installation
Two holes located on
corner, 34-1/2” from top of base,
centered in at areas
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.
One hole on rear panel
located 34-1/2”from top of base,
centered on vertical rib.
13-1/2”
11-1/2”
PC-000106 Washer
5 Used in this step
PC-000105 Rivet
5 Used in this step
PC-000147 Screw
1 Used in this step
Step 12. Soap Dispenser Installation
Remove the mounting plate from the soap dispenser: To do this, start by turning the
lid of the dispenser counterclockwise and remove. Then, push in the locking
tab at the rear of the dispenser and push up on the soap container,
separating the container from the mounting plate. Using the
mounting plate as a drill guide, drill 3 - 13/64” holes into the sink
surround in the location shown to the right. Rivet in place using
3 - PC-000105 rivets. Reassemble the dispenser.
Step13. 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 riv-
ets from the outside with PC-000106 washers on the inside.
PC-000100 Rivet
4 Used in this step
PC-000105 Rivet
3 Used in this step
PC-000106 Washer
4 Used in this step

PH04 Comfort XLT Flushing - June 2019
Page 14 of 15
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. 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.
PC-000100 Rivet
4 Used in this step
PC-000106 Washer
4 Used in this step
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. Rivet into place
with (2) PC-000105 rivets. Line up the cable clip in the center of the door jamb to the door closure retainer clip. From
inside the unit using a 13/64” bit, drill two holes into one side of the door jamb only. Rivet the cable clip to the door
jamb using (2) PC-000108 rivets. On the inside of the unit, place the top of a hammer against the cable clip. Place the
ball end of the spring cable in the claw of the hammer. Open the door while holding the hammer in position. Hold the
door open with your foot and clamp a vice-grip pliers on the cable where it comes out of the door. BE SURE TO CLAMP
DOWN TIGHT. Remove the cable from the claw of the hammer, close the door and place the end of the cable into the
slot of the cable clip. Open the door and remove the vice-grips.
Step 15. Door Closure Installation
PC-000105 Rivet
2 Used in this step
1
2
PC-000108 Rivet
2 Used in this step

PH04 Comfort XLT Flushing - June 2019
Page 15 of 15
We highly recommend membership in the Portable Sanitation Association International (PSAI); the world-
wide authority on portable sanitation services. The PSAI, “Portable Sanitation Industry Certication Program”
manual contains a wealth of information of standards and service procedures. For more information contact
the PSAI:
PORTABLE SANITATION ASSOCIATION INTERNATIONAL
7800 METRO PARKWAY, SUITE 104
BLOOMINGTON, MINNESOTA 55425 USA
800-822-3020 / 612-854-8300 (FAX: [phone])
www.psai.org
PolyJohn Enterprises Corporation publishes a series of technical manuals of guides for the Portable Sanita-
tion Association International. Contact your area sales representative for further details.
For a source of cleaning, deodorizing, and paper products contact:
POLYJOHN
2500 GASPAR AVE.
WHITING, IN 46394-2175
800-292-1305
“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.”
OUR MISSION STATEMENT
Look for us on the Web @ www.PolyJohn.com
THANK YOU FOR PURCHASING POLYJOHN PRODUCTS!
• Use a mild soap to clean all surfaces and component parts.
• Minor scratches and abrasions can be lightly sanded or scrubbed with a mild abrasive cleaner (such as
“Soft Scrub”) that contains calcium carbonate, hypochlorate bleach, and detergents. Be sure to follow the
cleaning product directions since these ingredients may cause hazardous gases when mixed with other
chemicals. Rinse the cleaned areas and buff with a conventional wax.
• Some light scratches may also be hidden by using an industrial hot air gun.
• To keep the interior smelling fresh, spray with deodorant spray
CLEANING AND MAINTENANCE
Insert the drain spigot of the urinal into the hole on the left top surface of the holding tank. Position the uri-
nal so that it is level. There are two holes at the top of the urinal. Drill 13/64” holes through those holes and
through the side wall panel. From inside of the restroom one person will rivet through the drilled holes with
PC-000102 rivets, while another person outside the restroom places PC000106 back-up washers on the rivet
stems.
Step 17. Optional Urinal 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 16. Toilet Seat Installation