PolyJohn FS3-3, FS3-2, FS3 Fleet Series Assembly Manual

FS3 Fleet™ Series

Fresh Flush Model

Assembly Manual

U.S. PATENTS: 5,500,960 - 5,500,962 - 5,560,050 - 6,199,222 D 360,471

SPECIFICATIONS

DIMENSION IMPERIAL METRIC

Exterior Height 91 in 231 cm

Interior Height 83 in 211 cm

Exterior Width 47 in 119 cm

Interior Width 45.7 in 116 cm

Exterior Length (Runner Base) 48 in 122 cm

Exterior Length (Optional
Signature Style Handle Base) 47 in 119 cm

Interior Length 43 in 109 cm

Weight - Flush 243 lb. 110 kg

Door Frame Height (ID) 75 in 191 cm

Door Frame Width (ID) 26 in 66 cm

Side Panel Decal Area 6 in X 37 in 15 cm X 94 cm

Door Decal Area 22.5 in X 29 in 57 cm X 74 cm

Seat Height 19.5 in 49.5 cm

POLYJOHN

USA

PolyJohn Enterprises Corp.

2500 Gaspar Ave.

Whiting, IN 46394

Phone: [phone]

Fax: [phone]
www.polyjohn.com
[e-mail]

POLYJOHN

WORLDWIDE

PolyJohn (UK) Ltd.

Equinox 1 Audby Lane

Wetherby, England LS22 7RD

Phone: [phone]

Fax: [phone]

www.polyjohn.co.uk

[e-mail]

FS3-3 Assembly July 2016

Page 1 of 16

POLYJOHN

CANADA

PolyJohn Canada

P.O. Box 2300

199 Forest Plain Rd.

Orillia, Ontario LV3 6S2

Phone: [phone]

Fax: [phone]
www.polyjohncanada.ca
[e-mail]

FS1-0004* Rear Panel

(4) PC-000192 Sems Screw

FS1-0062 Left Rear Extrusion

(9) PC-000104 Rivet

FS1-0061 Top Rear Extrusion

(5) PC-000104 Rivet

(3) SG1-0037 Inner Screen

(3) SG1-0038 Outer Screen

(6) PC-000102 Rivet

(6) PC-000106 Washer

FS1-0063 Right Rear Extrusion

(9) PC-000104 Rivet

PC-000490 T.P. Dispenser

PC-000760 Rod

PC-000205M Lock

(4) PC-000100 Rivet

(4) PC-000106 Washer

PSD1-1000 Soap

Dispenser

(3) PC-000102 Rivet

(3) PC-000106 Washer

TD04-1000 Paper

Towel Dispenser

(4) PC-000102 Rivet

(4) PC-000106 Washer

FS3-0002* Side w/Hatch

PC-100451 Hatch w/Cover

(4) PC-000102 Rivet

(3) PC-000106 Washer

(1) PC-000110 Rivet

(1) PC-000111 Washer

(5) PC-000192 Sems Screw

PC-100146 Cable Tether

FS3-0026*F Fresh Flush Sink

(2) PC-000103 Rivet

(2) PC-000106 Washer

(1) PC-000158 Screw

FS3-0025*C Flush Waste Tank

(4) PC-000103 Rivet

(4) PC-000106 Washer

PC-000604 Rubber Cover

PC-000606 Foot Pump

* Must Specify Color

(6) PC-000106 Washer

(6) PC-000231 Screw

FS3-0018FC Base Complete

FS3-0018 Handle/Runner Base

FS3-0019 Handle Signature Style Base (Optional)

FS3-0085F Flush Style Floor

(8) PC-000117 Rivet

FS1-0007* Roof Panel

SG1-0080G Vent Stack

(1) PC-000117 Rivet

(4) PC-000100 Rivet

(4) PC-000106 Washer

(4) PC-000121 Washer

FS1-0002* Side Panel

(5) PC-000192 Lag Screw

(2) SG1-0035 Large Screen

(2) PC-000102 Rivet

(2) PC-000106 Washer

PC-000204 Toilet Seat

(2) PC-000101 Rivet

(2) PC-000106 Washer

PJN3-0009* Urinal

TM01-0003 Mirror

PC-000367 Push-In Fastener

FS3-0003* Front Assembly

(17) PC-000104 Rivet

(2) PC-000159 1/4-20 x 3-1/2” Screw

(2) PC-000175 1/4-20 x 1-1/2“ Screw

(4) PC-000123 Washer

(4) PC-000140 Nylock Nut

-FS3-0060 Door Jamb

-PC-100787 Serial I.D. Plate

-(2) PC-000108 Rivet

-FS1-0005*C Complete Door

--FS1-0005* Fleet Door

--(3)PC-100170 Hinge Assembly

--(6) PC-000116 Rivet

--(3) PC-000160 5/16” x 3/4” Bolt

--(3) PC-000161 5/16” Flat Washer

--(3) SG1-0037 Inner Screen

--(3) SG1-0038 Outer Screen

FS3-3 Assembly July 2016

Page 2 of 16

--(6) PC-000104 Rivet

--(6) PC-000106 Washer

FS1-0034* Door Panel Cover

(4) PC-000158 Screw

(2) PC-000147 Screw

SG1-0032 Retain Plate

PC-000800 Spring Assembly

PC-000223 Hover Handle

(2) PC-000104 Rivet

PC-000181S Spring Clip

(2) PC-000104 Rivet

SG1-0030 Slide Latch

SG1-0031C Slide Latch Cover Plate

SG1-0031 Slide Cover Plate

SA1-0017 Handle U Bolt

(2) PC-100796 Grommet

PC-000233

v

10-32 Nylon Lock Nut

PC-000352

#12 Hose Clamp

CH100-065 - Hose

1" I.D. x 65" Long

To Foot Pump

PC-000232

Screw

FT02-0011

Prop Rod

PC-100372B
Barbed Nozzle

(2) PC-000235 - Bolt

(2) PC-000102 - Rivet
(2) PC-000106 - Washer

FS3-0022*
Seat Base/Flush Bowl

PC-100611
Flapper Pivot Rod

SG1-0013
Cup Flapper Valve

(2) PC-000233 - Nut

PC-100620
Flapper Counterweight

(2) PC-000155 - Screw

PC-000304
Secondary Filter

PC-000303
Primary Filter

CH100-025

1" I.D. x 25" Long

FS3-0025*
Fleet Flush Tank

Fresh Flush

Tank Assembly

FS3-3 Assembly July 2016

Page 3 of 16

PC-000416
1/2” Uniseal

PC-000328
3/4” Barb x 1” Barbed Fitting

* Must Specify Color

To 3-Way Val
on Sink

CH100-050

1” x 50” Hose

CH100-028

CH100-025

Hose 1” x 25”’

Hose 1” x 28”

Pump

To Foot

Waste Tank

To Bottom of

PC-000415

1/4” Uniseal

CT38-046

(pump to tap)

Tube 3/8” x 46”

PC-000305

Plastic Filter

CT38-0065

Tube 3/8” x 6.5”

PC-000308

Sink Strainer

3/4” Mpt x 1” Hose

(2) PC-000901 - Fitting

PC-000339 - Elbow

Female 3/8” Tube X 3/8” Mpt

(tank to pump)

PC-000900 - Fitting

3/4” Mpt x 1” Barb

(2) PC-000147 - Screw

PC-100213 - Bracket

Fasteners for Bowl

PC-000903 - Valve

3-Way 3/4” Npt

(2) PC-000107 - Rivet

(2) PC-000106 - Washer

PC-000322

(4) PC-000352

Hose Clamp #12

3/4” Fpt x 3/4” Barb

PC-000417

3/4” Uniseal

PC-100316 - Elbow

PC-000370 - Bushing

1/2” Spigot x 1/8” Fpt

PC-000418

1” Uniseal

CH075-028 - Drain Hose 3/4” x 28”

PC-000351 - #10 Hose Clamp

1” Barb x 1” Barb

PC-000241

PC-100421B

Drain Body

O-Ring

**NOT SHOWN

PC-000782 - Decal Not for Drinking

PC-000783 - Decal Transport

PC-000790 - Decal Foot Pump

PC-100421P

Drain Plug

Updated 7-18-2016

PC-000339 - Elbow

Female 3/8” Tube x 3/8” Mpt

Flushing Model

FS3-0026CF - Fleet Sink

(2) PC-000104 - Rivet

(2) PC-000106 - Washer

PC-000581G - Sink Tap

PC-000225 - Catch Lock

(2) PC-000110 - Rivet

(2) PC-000111 - Washer

PC-000310 -

Rubber Washer

1” x 2“ x .031”

(2) PC-000110 - Rivet

(2) PC-000111 - Washer

PC-000224 - Locking Clip

FS3-3 Assembly July 2016

Page 4 of 16

PC-000417

3/4” Uniseal

PC-000600 - Foot Pump

(4) PC-000102 - Rivet

(4) PC-000106 - Washer

(2) PC-000147 - Screw

FS3-0052 - Foot Pump Plate

GENERAL OVERVIEW

•These instructions are for restrooms shipped unassembled. Please retain these instructions for maintenance and repair purposes.

•The FS3-3 Model restroom assembly will require two people.

•All references to left, right, front and rear are as viewed from the front of the restroom.

•Review the entire instruction manual prior to assembly.

•Please follow the instructions in the order they are presented.

•When using air operated screw drivers or impact wrenches, be sure that the torque setting does not exceed 28 inch pounds.
Also, when using a battery-operated drill, set it to the lowest torque setting.

•We strongly suggest that these restrooms, as with all portable structures, be transported and handled with care. Dropping the
restroom when loading and unloading could cause damage to the door jamb and other components.

~~TOOLS REQUIRED FOR ASSEMBLY!~~

• Rivet Gun • Standard Slotted Screwdriver • Phillips Crosshead Screwdriver • Vise-Grips • Pliers

• (2) Tapered Awls • Drill with a 13/64” Drill Bit • Socket Wrench with a 7/16” socket

FULL SCALE FASTENER DRAWINGS

(8) PC-000100 - Rivet

(2) PC-000101 - Rivet

(9) PC-000102 - Rivet

(6) PC-000103 - Rivet

(42) PC-000104 - Rivet

(4) PC-000140 Lock Nut

(31) PC-000106 - Washer

(4) PC-000123 - Washer

(4) PC-000121 - Washer

(2) PC-000147

3/4” Phillips Self

Tapping Screw

(5) PC-000158

1-1/2” Phillips Self

Tapping Screw

(6) PC-000231

10-32 x 1-1/2” Screw

(1) PC-000117 - Rivet

(2) PC-000175 Screw

(14) PC-000192 Sems

(4) PC-000367 - Nylon

Push-In Fastener

(2) PC-000159 - Screw

FS3-3 Assembly July 2016

Page 5 of 16

Step 1: Pump Installation

Place the PC-000604 rubber dust cover over the top of
the pump and from the underside of the base, place the
pump up into the hole in the  oor. Line up the holes in
the  oor with the threaded inserts in the pump making
sure that the barbed  ttings of the pump point toward
the holes drilled in the base (as shown on the left). Finish
installation of the pump by tightening in place using (6)
PC-000231 screws with (6) PC-000106 washers behind the
heads of the screws.

Step 2: Tank-Sink Installation

Place the tank into the opening of the base. Locate the 1” reinforced
hose coming out of the hole at the back of the waste tank. Pull about 3
feet of this hose out of the hole and route this hose down through the
opening in-between the waste tank and the base. Place the sink on
the base, lining up the 1/2” drain pipe, inserting into the corresponding
hole in the tank. Insert the ends of the two hoses into the slot, reaching
underneath the base to pull out the slack.

Step 3: Sidewall Panels to Rear Extrusions and Rear Wall Panel

PC-000231 Screw

(6) Used in this step

PC-000106 Washer

(6) Used in this step

Right Rear Extrusion

Rear Panel

PC-000104 Rivet

PC-000104 Rivet

(16) Used in this step

Right Side

FS3-3 Assembly July 2016

Page 6 of 16

Slide a plastic rear extrusion onto each side of the rear panel making
sure that the mitered ends are towards the top of the rear panel

(where the  y screens are, and the ribbed side of the extrusions are
facing toward the outside of the restroom). Line up the holes in the

rear extrusions with the holes in the rear wall panels. Insert awls
into the center holes. Slide the right side wall panel (with hatch
in corner) into the corresponding slot of the rear extrusion and
remove the awl from that rear extrusion. Line up all of the holes
and rivet from the inside, the rear extrusions, rear wall panel and
side wall panel together using small  ange, rivets, PC-000104. DO

NOT RIVET THE TOP HOLE IN EITHER OF THE EXTRUSIONS AT
THIS TIME. Remove the awl in the left extrusion and rivet together

the left side wall panel, left rear extrusion, and rear panel, leaving
the top hole for later.

Step 4: Sidewall Panels to Door Jamb

Insert the edge of the left side panel into the slot on the left side of the door jamb. Line up the holes in the jamb with the corresponding
holes in the side panel. Rivet the second and third holes from the bottom as well as the top two holes using (4) PC-000104 rivets (as

shown on the left). Using holes in the jamb as a guide, drill three 13/64” holes into the side
panel. Rivet the PC-000181 cable clip at the center two holes of the jamb using (2) PC-000104
rivets. Rivet the bottom hole using the same rivet. Wrap
the cabana around the base of the unit resting the bottom
edge of the sides on the ledge around the base. Slide the
edge of the right side wall panel into the slot in the jamb.
Line up the holes in the side panel with the corresponding
holes in the jamb and rivet in place using (4) PC-000104
rivets. DO NOT RIVET THE SECOND HOLE FROM THE TOP
AT THIS TIME. Using a drill with a 13/64” drill bit, drill out
the third hole from the top as well as the bottom hole. Rivet
the bottom hole using a PC-000104 rivet. The PC-000223
grab handle gets attached to the jamb using (2) PC-000104
rivets at the second and third hole locations.

PC-000104 Rivet
(14) Used in this step

Step 5: Cabana to Base

Insert (2) PC-000175 screws through the holes at the very bottom of the jamb, and (2) PC­000159 screws through the holes second from the bottom and into the slots in the base. On
the back-side of the unit, center the rear panel on the base. Fasten the rear panel
to the base using (4) PC-000192 sems. Gently lay the unit on it’s back. Place (4)
PC-000123 washers and (4) PC-000140 nuts on the PC-000159 amd PC-000175
screws at the front of the base, but DO NOT TIGHTEN AT THIS TIME. Close
the door and tighten the PC-000175 screws (making sure that there is a 1/4” gap
between the latch side of the door and the jamb). Open the door and tighten the
pc-000159 screws.

PC-000123 Washers
and PC-000140 Nuts

1/4” Gap Between
Door and Jamb

PC-000123 - Washer
(4) Used in this step

PC-000175 - Screw
(2) Used in this step

PC-000140 Lock Nut
(4) Used in this step

PC-000192 Sems
(4) Used in this step

FS3-3 Assembly July 2016

Page 7 of 16

PC-000159 - Screw
(2) Used in this step

Step 6: Hose Connections

Route the hose coming from the rear of the
waste tank through the 1-3/8” dia. hole in the
base, (located closest to the right-hand side of
the base). Place a PC-000352 hose clamp on
the end of the hose and push the end of this
hose onto the discharge side of the pump.
Tighten the clamp. Place a PC-000352 hose
clamp on the end of the hose coming from the
right-hand side of the slot in the  oor. Push the
end of this hose on the  tting at the bottom of
the waste tank, and tighten the clamp. Route
the remaining hose over the other hoses and
through the 1-3/8” hole in the base. Place
a PC-000352 hose clamp on the end of the
hose, push the hose onto the intake side of the
pump, and tighten the hose clamp.

from sink (fresh)

handle direction
arrow up = fresh

arrow down = recirc

In From 3-Way Valve

Out T o Waste Tank Bowl

to pump

inlet

from waste

tank (recirc)

Step 7: Cabana to Base (Continued)

Carefully stand the unit upright. Starting
with the left of the unit, drive a PC-000192
sems screw through the pre-drilled hole in
the front of the side panel. BE SURE NOT

TO OVERTIGHTEN AND STRIP OUT THE
PLASTIC. Continue around the left side of

the unit, until you reach the rear extrusion.
Repeat this process with the right side of the
unit, starting with the front.

PC-000192 Sems

(10) Used in this step

8

7

6

FS3-3 Assembly July 2016

Page 8 of 16

9 1

5

3

4

13

12

11

10

14

2

Step 8: Tank Installation

On the inside of the unit, pull the tank forward in the
opening of the  oor. Locate the dimples in the lower
portion of the rear and left wall panels. Drill four 13/64”
holes through the dimples and into the back of the tank.
Rivet from outside the restroom using (4) PC-000103
rivets with (4) PC-000106 back-up washers on the inside
of the tank.

PC-000103 Rivet
(4) Used in this step

Step 9: Sink Installation

With someone on the inside holding the sink tightly in
the corner, locate the dimples on the outside of the unit.
They will be found on the middle portion of the rear and
the right wall panels. Using a drill with a 13/64” drill bit,
drill two holes through the side/rear and into the sink.
Open up the sink. To do this, insert a long thin object
(the key for the lock on the T.P. Dispenser works well) into
the 1/4” hole directly below the bottom of the sink lid,
and while pushing down on the front of the lid of the
sink, push the (key) in to release the catch, and lift up
the lid. From the outside of the unit, rivet in place using
(2) PC-000103 rivets with (2) PC-000106 washers on
the inside of the sink. Fasten the bottom of the sink in
by driving a PC-000158 screw through the hole in the
aluminum foot pump plate and into the  oor plate of
the base.

PC-000106 Washer

(4) Used in this step

INSERT KEY

FS3-3 Assembly July 2016

Page 9 of 16

PC-000103 Rivet

(2) Used in this step

PC-000106 Washer

(2) Used in this step

PC-000158 Screw

(1) Used in this step

Step 10: Screen Installation

Take a SG1-0035 large  y screen and place the bottom
curved  anges onto the top of the right side panel (as
shown on the right). Tilt the top of the  y screen up into
place. Using the hole in the bottom, middle  ange as a
guide, drill a 13/64” hole through the side panel. Rivet
in place using a PC-000102 rivet from the inside with
a PC-000106 back-up washer on the outside. Repeat
this step with the left side.

PC-000102 Rivet
(2) Used in this step

Step 11: Roof Installation

Place the FS1-0061 top extrusion on the top edge of
the rear panel so that the miters line up with the left
and right extrusions, and that the grooved surface is
facing the outside. Place the roof on the top of the
unit with the arch in the roof going into the groove in
the top of the jamb. Put the rear edge of the roof in
the groove in the top rear extrusion. With someone
pushing down on the back of the roof, use the holes
in the rear extrusion as a drill guide, drill  ve 13/64”
holes into the roof. MAKE SURE TO ONLY DRILL

THROUGH THE ROOF AND NOT THROUGH THE
BACK OF THE TOP REAR EXTRUSION. Rivet the

top holes in both the left and right rear extrusions as
well as the  ve holes of the top rear extrusion using
(7) PC-000104 rivets. Push down on the front of the
roof while using the holes in the jamb as a drill guide,
drill  ve 13/64” holes through the roof. Rivet in place
using (5) PC-000104 rivets. Locate the holes in the
top of each of the side panels. Push out on the top
of the side panel, and using a 13/64” drill bit, drill a
hole through the hole in the top of the side, and through the roof. Rivet in place using a PC-000100 rivet on the inside
with a PC-000121 washer and a PC-000106 back-up washer on the topside of the roof. Repeat for remaining three holes.

PC-000106 Washer

(2) Used in this step

PC-000104 Rivet

(12) Used in this step

PC-000121 Washer

(4) Used in this step

FS3-3 Assembly July 2016

Page 10 of 16

PC-000100 Rivet

(4) Used in this step

PC-000106 Washer

(4) Used in this step

Step 12: Vent Stack Installation

Force the vent stack up through hole in roof then down
into the corresponding hole in the tank. Drill a 13/64”
hole through the boss in the tank and into the vent stack.
Rivet (as shown) using a PC-000117 rivet.

PC-000117 Rivet

(1) Used in this step

Step 13: Spring Installation

From the front of the door, insert the cable end of the spring assembly into the
1/2” hole in the door. Make sure that the 1/2” boss in the end cap of the spring
assembly is pushed through the hole. On the inside of the unit, place the top
of a hammer against the PC-000181S spring cable clip (as shown on the right).
Place the end of the spring cable in the claw of the hammer.

Step 14: Optional Lock Installation

Place the tip of a screwdriver in the lock area of the Door Trim Panel
(as shown on the right). Strike the handle end of the screwdriver with a
hammer to “knockout” the plastic  lling the hole for the lock. Remove
the nut from the end of the lock, and insert the lock through the hole
of the Door Trim Panel from the outside. Re-insert the nut back on the
lock and tighten down. Insert the key and turn the lock to the right and
remove the key (this is the locked position which is needed at this point

to check the lock for proper installation with the Slide Latch mechanism
which is installed in the next step). NOTE: Turning the key upright is the

neutral or normal use position which allows the Slide Latch to move
into the “Open/In-Use” position when persons are inside the restroom.
Turning the key to the left is the open position and the key can not be
removed until either in the “Open/In-Use” or “Locked” position.

Open the door while holding the hammer in position. Hold the door open
with your foot, and clamp a vice-grips 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.

FS3-3 Assembly July 2016

Page 11 of 16

Step 15: Door Panel /Slide Latch Installation

Snap the Unisex Indicator Plate into the back of the Door Trim Panel. Place the Door
Trim Panel into the recess in the front of the door. While holding the Door Trim
Panel in position, place the Slide Latch and Slide Latch Cover Plate on the inside
of the door and line up the holes of the Slide Latch Cover Plate, the Door, and the
Door Trim Panel. Insert (4) PC-000158 screws and tighten. NOTE: These screws

should be tightened to the point where they will interfere with the sliding action
of the Slide Latch and then backed o slightly, leaving enough friction to prevent
the Slide Latch from sliding into the “In-Use/Open” position when the door shuts. The
U Shaped handle prevents persons from inadvertently moving the
slide latch to the “In-Use” position when exiting the
restroom. Insert the  ip “Male-Female” Indicator

Plate into the slot on the top edge of the Door
Trim Panel (above where the Unisex Indicator Plate
is located). Insert (2) PC-000147 screws into the
holes toward the hinged side of the door, line up
with the holes in the Door Trim Panel, and tighten.
If the optional lock is installed, unlock the lock by
inserting the key into the lock and turning to the
left and back to the upright position which is the
neutral or normal use position and remove the
key (this allows the Slide Latch to move into the

“Open/In-Use” position when persons are inside
the restroom). Turn the key to the right and remove
the key for the locked position. Turning the key to
the left indicates the open position and the key can
not be removed until either in the “Open/In-Use”
or “Locked” positon. IMPORTANT: The punched

1/4” hole in the center of the Slide Latch where
the “In-Use/Open” stamp is imprinted complies
with code enabling the door to be unlocked from
outside the restroom in the event of distress
and a person inside were unable to unlock the
door. A POINTED OBJECT INSERTED INTO THE
HOLE AND MOVING THE SLIDE LATCH TO THE
LEFT WILL ALLOW THE DOOR TO BE OPENED
PROVIDING THE DOOR HAS NOT BEEN LOCKED
WITH THE KEY.

PC-000158 Screw

(4) Used in this step

PC-000147 Screw

(2) Used in this step

Step 16: Mirror Installation

Peel the protective cover from the front of the mirror. Place the mirror in
the recess in the door, and fasten in place using the plastic push-in fasteners
provided.

Step 17: 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 hinges of the seat and through the seat base. Lift open the seat base, thread the plastic
seat nuts on the ends of the bolts and tighten.

PC-000367 - Push-In Fastener

(4) Used in this step

FS3-3 Assembly July 2016

Page 12 of 16

Step 18: Optional Urinal Installation

Insert the drain spigot into the hole in the tank (as shown). Make
sure that the top of the urinal is level and drill two 13/64” holes
in the center of each of the recess’ through the top of the urinal
and through the side panel. Rivet in place using (2) PC-000101
rivets from the inside of the unit with (2) PC-000106 back- up
washers on the outside.

PC-000101 Rivet

(2) Used in this step

PC-000106 Washer
(2) Used in this step

PC-000100 Rivet

(4) Used in this step

Step 19: Toilet Paper Dispenser

There are four dimples in the rear panel for the Toilet Paper Dispenser location. From the outside, drill four 13/64” holes
through the rear panel. Line up the holes in the rear panel with the holes in the back of the dispenser, and rivet in place
from the outside using (4) PC-000100 rivets with (4) PC-000106 back-washers on the inside.

Step 20: Soap and Paper Towel Dispenser

Remove the lid of the Soap Dispenser by turning the lid
counter-clockwise and lifting o . Remove the backing plate
from the dispenser by pushing back on the tab at the top,
and sliding the backing plate down. Place the backing plate
up against the side wall on the third rib down from the top.
Line up the bottom of the backing plate with the bottom of
the rib, and using the top of the three mounting holes as a
guide, drill three 13/64” holes through the side panel. Rivet
in place from the outside using (3) PC-000102 rivets with
(3) PC-000106 back-up washers on the inside. Place the
body of the soap dispenser on the backing plate, and turn
the lid back on. Open up the Paper Towel Dispenser. Place
the dispenser on the top and second ribs (as shown on the
right). Using the mounting holes as a drill guide, drill four
13/64” holes through the side panel. Rivet in place using (4)
PC-000102 rivets from the outside with PC-000106 back-up
washers on the inside.

PC-000106 Washer

(4) Used in this step

Mount the TP
and Soap
Dispensers here

PC-000102 Rivet
(7) Used in this step

PC-000106 Washer
(7) Used in this step

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GENERAL USE AND MAINTENANCE

Opening The Sink

The sink holds the fresh water for hand wash as well as for the fresh
water  ushing operation of the waste tank. The lid of the sink is
hinged and locked with a keyless lock for ease of accessibility. To
unlock the sink, insert a long thin object (the key for the lock on the
T.P. Dispenser works well) into the 1/4” hole directly below the bottom
of the sink lid, and while pushing down on the front of the lid of the
sink, push the (key) in to release the catch, and lift up the lid.

INSERT KEY

Switching from Fresh Water Flush to Recirculating Flush / Recirculating Flush to Fresh Flush modes

This unit can be converted from fresh water  ush to recirculating  ush with just a  ip of the lever on the 3-way valve. The
3-way valve is located in the right rear corner of the unit, in the back of the sink. The hatch in the corner protects the valve
from being tampered with. To change from fresh  ush to recirculating mode, and vice versa, open the hatch, and turn the
yellow handle of the valve in the opposite direction of where it currently is. The unit is in fresh water  ush mode when the
handle is pointing up, and is in recirculating mode when the handle is pointing down. Replace the hatch when completed.

Locking/Unlocking the Unit (Optional)

If this unit is equipped with an optional exterior lock, it can be locked to prevent unwanted usage in the evening or weekend
hours when no one is on site. This is done by turning the lock to the right and removing the key. When it comes time to
unlock the unit, insert the key and turn all the way to the left, and then back to the upright position.

Winterizing the unit

Start winterizing the unit by opening up the drain plug on the sink, and making sure it is completely drained. Reinstall
the drain plug. Pump the foot pump on the sink several times until there is nothing but air coming out of the sink tap.
Pump out the contents of the waste tank. Clean the inside of the tank with a pressure washer or hose Pump the foot
pump to run the fesh water through the pump and hoses. Pump out the waste tank again and pump the foot pump
several times while doing so to be sure that no water remains in the hoses or pump.

Remove the cover from the soap dispenser. push the locking tab on the mounting plate towards the wall, and slide the
soap dispenser body up and o the mounting plate. Pour any left over soap into your soap container and thoroughly
rinse out the soap dispenser body with warm water. Place the soap dispenser body back on the mounting plate, and
reinstall the lid.

Trouble Shooting

PUMP WILL NOT RETURN UP WHEN PRESSED DOWN WHEN UNIT IS IN FRESH WATER FLUSH MODE: The hoses that go

from the sink to the tank and pump are reversed. Carefully lay the unit on it’s back. Loosen the clamp holding the hose on
the bottom of the sink as well as the clamp holding the hose on the intake port of the pump. Remove these hoses and place
the hose that was going to the tank to the intake port of the pump, and place the hose that was going from the intake port
of the pump onto the  tting on the bottom of the waste tank. Tighten the clamps, stand the unit back up and retest.

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GENERAL STATISTICS AND USEFUL TECHNICAL INFORMATION

ITEM STANDARD METRIC

FRESH WATER 1 gal 3.785 ltr
One gal 128  . oz 3,780 ml
One qt 32  . oz 946.35 ml
One gal 8.33 lb 3.77 kg
SEWAGE
One gal 10.20 lb 4.62 kg

Feces per person per day* .5 lb (26.12  . oz) .23 kg (772.4 ml)
Urine per person per day* 1 qt (32  . oz) .95 ltr

Non-Flush Tank Use & Capacity - (120 uses)
60 gal < 5 gal charge = 55 gal 7,040  . oz 208,200 ml

Flush Tank Use & Capacity - (75 uses)
40 gal < 5 gal charge = 35 gal 4,480  . oz 132,500 ml
Average person urination at special events = 8

- 10  . oz (237 - 296 ml)

Sink Tank Use & Capacity - (400 uses)
20 gal 2,560  . oz 75.7 ltr
Sink foot pump dispenses 2 oz per stroke 6  . oz / average 177.44 ml / average
* per Portable Sanitation Association International (PSAI)
NOTES:

9  . oz / average 266 ml / average

Weather conditions and consumption of foods, liquids and alcoholic beverages can in­crease usage by 30 to 40%.

“Conservative” usage calculations based upon each user producing 59  . oz of waste and
dispensing 6  . oz for hand washing.

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CLEANING AND MAINTENANCE

• Use a mild soap to clean all surfaces and component parts.

• The mirror is acrylic, do not use solvent cleaners, use only a mild liquid soap. To maintain a gloss, use a  annel cloth with a good
plastic cleaner or polish (such as “Johnson’s Pledge”).

• 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 area and bu 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 the interior with a deodorant spray.

For a source of cleaning, deodorizing and paper products contact:

COOPER’S OWN

2500 GASPAR AVE.

WHITING, IN 46394-2175

800-292-1305

www.polyjohn.com/products/supplies/cooper-s-own/

We highly recommend membership in the Portable Sanitation Association International (PSAI); the worldwide authority on portable
sanitation services. The PSAI, “Portable Sanitation Industry Certi cation Program” manual contains a wealth of information on standards
and service procedures. For more information contact the PSAI:

PORTABLE SANITATION ASSOCIATION INTERNATIONAL (PSAI)

7800 METRO PARKWAY, SUITE 104

BLOOMINGTON, MINNESOTA 55425 USA

800-822-3020 / 612-854-8300 FAX [phone]

www.psai.org

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.”

THANK YOU FOR PURCHASING POLYJOHN PRODUCTS!

Look for us on the web @PolyJohn.com

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