Hangar 9 Saratoga 40 User manual

Specications
Wingspan: ........................................................... 64.2 in (1630mm)
Length: ............................................................49.25 in (1251.8mm)
Wing Area: ................................................694 sq in (44.77 sq dm)
Weight: .................................................. 5.5–6.25 lb (2.49–2.83 kg)
Radio: .......................................................4-channel w/4–5 servos
Engine: ..................... .40–52 2-stroke; .56–82 4-stroke; Power 46
Saratoga 40
Assembly Manual

2 Hangar 9 Saratoga Assembly Manual
Table of Contents
Contents of Kit and Parts Layout ......................................2
Included Hardware............................................................3
Using the Manual..............................................................3
UltraCote Covering Colors ................................................3
Before Starting Assembly .................................................3
Radio Systems Requirements...........................................4
Recommended Setup–2-Stroke Glow...............................4
Recommended Setup–4-Stroke Glow...............................4
Recommended Setup–Electric Power (EP).......................4
Field Equipment Required.................................................4
Optional Field Equipment..................................................4
Additional Required Tools .................................................4
Additional Required Adhesives .........................................4
FS One..........................................................................................................................................................4
Important Information Regarding
Warranty Information..................................................4
Landing Gear Installation..................................................5
Tail Installation..................................................................7
Servo Installation..............................................................8
Aileron Servo Installation................................................13
2-Stroke Engine Installation............................................16
4-Stroke Engine Installation............................................20
Cowling Installation ........................................................24
EP Version Motor and Cowling Installation.....................27
\Final Assembly...............................................................31
Optional Float Installation ...............................................32
Center of Gravity.............................................................34
Control Throws ...............................................................34
Flight Preparations..........................................................35
Maintaining Your Model..................................................35
Safety Do’s and Don’ts for Pilots....................................36
Daily Flight Checks..........................................................36
Age requirements............................................................36
Safety, Precautions and Warnings ..................................36
Warranty Information......................................................37
CE Compliance Information for the European Union ......38
2009 Official Academy of
Model Aeronautics Safety Code ................................38
Building and Flying Notes ...............................................39
Replacement Parts
1. HAN4821 Fuselage without hatch
2. HAN4822 Right Wing with Aileron
3. HAN4823 Left Wing with Aileron
4. HAN4824 Tail Set
5. HAN4825 Painted Cowling and Clear Cowling
Template
6. HAN4826 Top Hatch
7. HAN4827 Anodized Wing Tube Set
8. HAN4828 Aluminum Landing Gear
9. HAN4829 Wheel Pant Set (right and left)
10. HAN4830 Windshield
11. HAN4831 Pushrod Set
12. HAN4144 21/4-inch Spinner (yellow)
13. HAN40M Motor Mount: Universal, 40-Size
14. HAN1986 Fuel Tank, 11oz
15. HAN305 23/4-inch H9 wheels
16. HAN4042 Replacement Tailwheel:
.40 Tail Wheel Assembly
17. HAN3611 Nylon Control Horn (5)
18. HAN3610 2-56 Nylon Clevis (5)
19. HAN320 Nylon Wing Bolt, 21/2-inch*
20. HAN8303 Pilot Bust
21. HAN4743 48mm EP Engine Standoff
* Will need to be cut down to 1-inch (25mm) for use with
this model
Contents of Kit and Parts Layout
1
20
19
18
16
17
17
2
3
4
5
6
7
8
9
10
11
12
13
21
14
15

3Hangar 9 Saratoga Assembly Manual
Included Hardware
PACKAGED IN KIT
Fuselage (1)
Left Wing with aileron & control horn (1)
Right Wing with aileron & control horn (1)
Vertical fin with rudder & control horn (1)
Horizontal stab with elevator & control horn (1)
Top hatch (1)
Cowl with clear template (1)
Canopy (1)
Painted aluminum landing gear (1)
Wheel pants (pair) (2)
3/4 x 16-inch anodized wing tube (1)
1/4 x 4-inch anodized wing tube (1)
LANDING GEAR BAG
Float mounting block (1)
Wheel axle, 13/16-inch (2)
Wheel collar, 11/64-inch (4)
3mm x 5mm machine screw for wheel collars (4)
#4 self-tapping wood screw (8)
4-40 x 3/8-inch socket head cap screws (2)
8-32 x 3/4-inch machine screws for landing gear (3)
#8 flat washers for landing gear (3)
Nylon landing gear straps for float mount (4)
Hangar 9 23/4-inch wheels (2)
#4 flat washers (2)
ELEVATOR BAG
Nylon Clevis (1)
Pushrod keeper (1)
Silicone clevis retainer (1)
#4 flat fender washers for bolt-on tail (2)
Nylon insert lock nuts for bolt-on tail (2)
RUDDER BAG
Nylon clevis (1)
Pushrod keeper (1)
Silicone clevis retainer (1)
MOTOR MOUNT BAG
Cast aluminum motor mount (1)
8-32 x 1-inch machine screws (4)
8-32 x 3/4-inch machine screws (4)
8-32 x 21/4-inch machine screws (4)
#8 flat washers (8)
8-32 nylon insert lock nuts (4)
17/8-inch (48mm) EP standoffs (4)
WING BAG
45/8-inch pushrod with L bend (aileron) (2)
1/4-20 x 1-inch nylon wing bolts (2)
Nylon clevis (2)
Pushrod keeper (2)
Silicone clevis retainer (2)
COWL BAG
4-40 x 1/2-inch socket head cap screw for cowl (4)
21/4-inch spinner (yellow) (1)
#4 washers for cowl (4)
Silicone tubing (4)
3mm x 10mm sheet metal screw (2)
FUSELAGE BAG
23-inch pushrod with L bend (elevator) (1)
231/2-inch pushrod with L bend (rudder) (1)
161/2-inch throttle pushrod (1)
Nylon clevis (1)
Pushrod keeper (1)
Silicone clevis retainer (1)
Plywood throttle pushrod support (1)
12-inch throttle pushrod housing (1)
4-40 x 3/8-inch socket head screw (3)
#4 washer (3)
MISCELLANEOUS BAG
Velcro battery strap (2)
1.5mm hex wrench (1)
Foam radio holder (3)
Pilot figure (1)
Using the Manual
This manual is divided into sections to help make assembly
easier to understand, and to provide breaks between each
major section. In addition, check boxes have been placed
next to each step to keep track of each step completed.
Steps with a single box () are performed once, while steps
with two boxes () indicate that the step will require
repeating, such as for a right or left wing panel, two servos,
etc. Remember to take your time and follow the directions.
UltraCote® Covering Colors
• Dark Yellow HANU889
• Black HANU874
• White HANU870
• 2-inch squares, Black/White HANU941
Before Starting Assembly
Before beginning the assembly of your model, remove
each part from its bag for inspection. Closely inspect the
fuselage, wing panels, rudder and stabilizer for damage. If
you find any damaged or missing parts, contact the place of
purchase.
If you find any wrinkles in the covering, use a heat gun or
covering iron to remove them. Use caution while working
around areas where the colors overlap to prevent separating
the colors.
HAN100 – Heat Gun
HAN150 – Covering Glove
HAN101 – Sealing Iron
HAN141 – Sealing Iron Sock

The Spektrum trademark is used with permission
of Bachmann Industries, Inc.
4 Hangar 9 Saratoga Assembly Manual
Radio Systems Requirements
Spektrum Radio System
• DX6i 6-channel radio or greater with receiver
(SPM6600)
• JRPS821 DS821 Digital Sport Servo (5)
(4 required for EP version)
• JSP98110 6-inch Servo Extension (2)
• JSP98020 Y-Harness or JSP98110 6-inch Servo
Extension (2) for receiver to aileron servos
• Receiver Battery, 2700mAh
• Deluxe Chargeswitch (JRPA004)
Optional
• JSP98020 Y-Harness or JSP98110 6-inch
Servo Extension to connect the float rudder
servo to the receiver.
Recommended Setup–2-Stroke Glow
• Evolution® .46NX with Muffler (EVOE0461)
• Evolution Propeller 11 x 5 (EVO11050) to
11 x 6 (EVO11060)
Recommended Setup–4-Stroke Glow
• Saito™.82 AAC w/Muffler (SAIE082AGK or SAIE082A)
• Evolution Propeller 13 x 8 (EVO13080) or
14 x 6 (EVO14060)
Recommended Setup–
Electric Power (EP)
• E-flite®Power 46 BL Outrunner Motor (EFLM4046A)
• 60-Amp Pro Switch-Mode BEC Brushless ESC
(EFLA1060)
• Thunder Power 4S 3850–4500mAh Li-Po Battery Pack
• APC Propeller 13x6.5-inch (APC13065E) to
14x7 (APC14070E)
Field Equipment Required
• Fuel (15% recommended)
• Propeller
• Long Reach Glow Plug Wrench (HAN2510)
• Metered Glow Driver w/Ni-Cd & Charger (HAN7101)
• 2-Cycle Sport Plug (EVOGP1)
• Manual Fuel Pump (HAN118)
Optional Field Equipment
• Selfstick weights, 6 oz (HAN3626)
• PowerPro 12V Starter (HAN161)
• 12V 7Ah Sealed Battery (HAN102)
• Power Panel (HAN106)
• Blue Block After Run Oil (EVOX1000)
• Cleaner and towels
Additional Required Tools
Drill File
Pin drill Pliers
Ruler Scissors
Side cutters Flat blade screwdriver
Medium grit sandpaper Metric propeller reamer
Hobby knife with #11 blade
Phillips screwdriver: #1, #2
Z-bend Pliers (HAN119)
Box wrench to fit propeller nut
Box end or open end wrench: 1/4-inch, 7/16-inch,
1/2-inch
Hex wrench or ball driver: 3/32-inch
Drill bit: 5/64-inch (2mm), 5/32-inch (4mm)
Additional Required Adhesives
Canopy Glue (PAAPT56)
Medium CA (PAAPT02)
Thin CA (PAAPT08)
Zap-A-Dap-A-Goo (PAAPT12)
Threadlock (PAAPT42)
30-Minute Epoxy (HAN8002)
FS One®
With FS One (HANS2000) you get more than photorealistic
fields, gorgeous skies and realistic-looking aircraft. You get
incredibly advanced aerodynamic modeling that simulates
every possible aspect of real-world flight.
The first Hangar Pack (HANS4010) will add even more
aircraft to FS One. This latest edition includes ten new planes
and helis from your favorite brands, including Hangar 9,
E-flite and Align. You’ll be able to fly aircraft that are only
available on FS One such as the T-REX, Blade CX2, Blade CP
Pro, Hangar 9 P-51 and F-22 PTS. And as always, with the
Hangar Pack, you still get all the same great features that
you did with the original aircraft.
HANS2008 HANS4010
Important Information
Regarding Warranty Information
Please read our Warranty and Liability Limitations section on
Page 37 before building this product. If you as the purchaser
or user are not prepared to accept the liability associated
with the use of this Product, you are advised to return this
Product immediately in new and unused condition to the
place of purchase.

5Hangar 9 Saratoga Assembly Manual
Landing Gear Installation
Required Parts
Fuselage Main landing gear
#4 washer (2) #8 washer (3)
Wheel axle with nut (2) Wheel pant (right and left)
4-40 x 3/8-inch socket head screw (2)
11/64-inch wheel collar (4)
23/4-inch (70mm) wheel (2)
3mm x 5mm machine screw (4)
8-32 x 3/4-inch machine screw (3)
Tools and Adhesives
Phillips screwdriver: #2 Threadlock
File
Box wrench: 7/16-inch, 1/2-inch
Ball driver or hex wrench: 3/32-inch
If you are planning to install floats, you can skip the
installation of the fixed gear and begin by attaching the
tail in the following section of the manual.
Step 1
Locate and open the bag marked Landing Gear. In the bag
are the parts for both the land-based landing gear and float
installation. Set aside the forward float mount, four landing
gear straps and eight #4 x 1/2-inch sheet metal screws. Keep
these in case you will be installing the floats at a later date.
Step 2
Locate three 8-32 x 3/4-inch machine screws and three #8
washers. Slide the washers onto the screws.
Step 3
Place a drop of threadlock on each screw. Secure the landing
gear on the fuselage using the three screws and a #2 Phillips
screwdriver.
Step 4
Locate the wheel axle and remove the nut. Slide the threaded
end of the axle into the large hole in the landing gear. Make
sure the axle faces outward. Thread the nut back onto
the axle. Use 1/2-inch (nut) and 7/16-inch (axle) box end
wrenches to tighten the nut to secure the axle.
Note: Make sure the hex on the axle is positioned as
shown or you will have difficulty installing the wheel
pants later.

6 Hangar 9 Saratoga Assembly Manual
Step 5
Use a file to make flat areas on the bottom of the axle. This
is necessary so the setscrews from the wheel collars have
a surface to bite onto. This will help keep the wheel collars
from vibrating loose in flight.
Step 6
Place a drop of threadlock on a 3mm x 5mm machine screw.
Thread the screw into one of the 11/64-inch wheel collars.
Slide the wheel collar onto the axle as shown. Do not tighten
the screw at this time.
Step 7
Open the bag containing the main 23/4-inch (70mm) wheels.
Slide one of the wheels onto the axle. Prepare a second
wheel collar as described in Step 6 and slide it onto the axle.
Position the wheel collar flush with the end of the axle and
use a #2 Phillips screwdriver to tighten the screw, securing
the wheel collar to the axle. The screw will be tightened
down onto the flat made in Step 5.
Step 8
First, slide the wheel against the outer wheel collar. Next
slide the wheel collar next to the landing gear so it is almost
touching the wheel. Use a #1 Phillips screwdriver to tighten
the screw and secure the wheel collar to the axle. The
position of the wheel will be fine-tuned later in this section of
the manual.
Step 9
Slide one of the wheel pants over the wheel and into position
on the landing gear. Note there is a right and left wheel pant
during the installation. Slide a #4 washer onto a 4-40 x 3/8-
inch socket head machine screw. Place a drop of threadlock
on the screw then use a 3/32-inch hex wrench to tighten the
screw, securing the wheel pant to the landing gear.

7Hangar 9 Saratoga Assembly Manual
Step 10
Repeat Steps 4 through 9 to install the remaining wheel and
wheel pant.
Step 11
Position the wheels so ther are centered side to side inside
the wheel pant. You will need to loosen the wheel collasrs
to do so. Also make sure the wheel can rotate freely
without binding.
Hint: Apply a small drop of lightweight oil to help to
allow the wheels to roll smoothly.
Tail Installation
Required Parts
Fuselage assembly Vertical stabilizer
Horizontal stabilizer Nylon clevis
Silicone clevis retainer 4-40 lock nut (2)
#4 fender washer (2) Pushrod keeper
Tools and Adhesives
Box wrench or nut driver: 1/4-inch
Step 1
Locate the bag marked elevator. Use scissors to cut open
the bag and place the parts in a tray for use in assembly.
The clevis and clevis retainer shown will be used later in the
manual when installing the elevator and rudder linkages.
Step 2
Locate the vertical fin and horizontal stabilizer assemblies.
Slide the threaded rods from the vertical fin through the
holes in the horizontal stabilizer. Make sure the control horn
from the elevator faces down, away from the top of the fin/
rudder.
Note: You may need to move the rudder to the left to
allow the rudder control horn the clear the elevator.

8 Hangar 9 Saratoga Assembly Manual
Step 3
Insert the threaded rods from the fin into the holes in the
rear of the fuselage. The tail assembly will sit tight against
the fuselage when installed.
Step 4
Slide a #4 washer on each of the threaded rods. Use a
1/4-inch box wrench or nut driver to tighten the 4-40 lock
nuts on the threaded rods. Use care not to over-tighten the
nuts and accidentally crush the fuselage.
Servo Installation
Required Parts
Fuselage assembly Servo (3, 2 for electric)
Hook and loop strap Receiver
Receiver battery Switch harness
Foam padding Pushrod keeper (2)
Clevis (2) Clevis retainer (2)
231/2-inch (597mm) pushrod wire
23-inch (584mm) pushrod wire
Y-Harness (1) or 6-inch (152mm) servo extension (2)
Tools and Adhesives
Phillips screwdriver: #1 Thin CA
Scissors Ruler
Hobby knife with #11 blade Pin drill
Drill bit: 5/64-inch (2mm) Pliers
Step 1
Insert the rubber grommets and brass eyelets into the
servos. Prepare three servos (two for electric-powered
model) at this time.

9Hangar 9 Saratoga Assembly Manual
Step 2
Use a #1 Phillips screwdriver to thread the servo mounting
screws into the pre-drilled holes in the servo tray then
remove the screw. Apply 2–3 drops of thin CA into each of
the holes to harden the surrounding wood.
Step 3
Use a #1 Phillips screwdriver to install the screws that hold
the servos in position in the fuselage. If you are building the
electric version, you do not have to install the throttle servo.
Note the direction of the servos in the image below. Route
the leads from the servos forward into the receiver/receiver
battery compartment.
Step 4
Open the bag marked Miscellaneous. Remove one of the
hook and loop straps and insert it through the strap supports
inside the fuselage.

10 Hangar 9 Saratoga Assembly Manual
Step 5
Measure and cut a 31/4-inch piece of foam from the supplied
foam blocks using scissors.
Step 6
Move the servo leads away from the battery compartment
and back over the servos. Insert the piece of foam into the
battery compartment. Make sure the hook and loop strap is
centered after installing the foam as shown in the photo.
Step 7
Use a hobby knife with a #11 blade to remove the covering
from your particular switch mounting hole. Mount the
switch in the fuselage using the hardware provided with
your switch.
Step 8
Place the receiver battery in the fuselage, then place the
remaining piece of foam on the battery. Make sure to plug
the battery into the switch harness at this time.
Step 9
Plug the servos, extension(s) or Y-harness for the aileron
servos and the switch harness into the receiver.
Step 10
Place the receiver on the foam. Tuck all the servo leads
under the servo tray so they will not interfere with the
operation of the servos.