Hangar 9 Saratoga 40 Assembly Manual Download Page 9 | Manualshive

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Hangar 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.

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Summary of Contents for Saratoga 40

Page 1: ... 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 ...

Page 2: ...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 C...

Page 3: ... 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 sc...

Page 4: ...1000 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 i...

Page 5: ... 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 landi...

Page 6: ...ar 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...

Page 7: ...levis 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 horizon...

Page 8: ...ntally 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 ...

Page 9: ...se 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 st...

Page 10: ...fe 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 ser...

Page 11: ...orns from the elevator and rudder servos Step 13 With the radio system on center the rudder and elevator servos Make sure all sub trims if using a computer radio have been set to 0 Install a 180 degree servo arm on the rudder and elevator servos so they are perpendicular to the fuselage centerline Step 14 Use a pin drill and 5 64 inch 2mm drill bit to enlarge the hole in the servo arm that is 9 16...

Page 12: ... servo arm Step 17 Slide the pushrod keeper onto the pushrod wire from underneath the servo Rotate the keeper and snap it onto the pushrod wire using pliers to secure the pushrod wire to the servo horn Step 18 Install a pushrod keeper to secure the rudder and elevator pushrods at this time Step 19 Slide a clevis retainer on a clevis Thread the clevis on the elevator pushrod a few turns so it will ...

Page 13: ... Repeat Steps 18 and 19 to connect the rudder pushrod to the center hole of the rudder control horn Aileron Servo Installation Required Parts Wing panel right and left Servo w hardware 2 Clevis 2 Clevis retainer 2 Pushrod keeper 2 45 8 inch 117mm pushrod wire 6 inch 152mm servo extension 2 Tools and Adhesives Phillips screwdriver 1 Thin CA Drill bit 5 64 inch 2mm Pin drill Step 1 Insert the rubber...

Page 14: ...to the center of the wing Once at the center guide it through the hole on the bottom of the wing as shown in the photo Step 6 Place the servo into the opening with the output of the servo facing the aileron Use the four screws provided with your servo and a 1 Phillips screwdriver to secure the servo in the wing Step 7 Use a pin drill and 5 64 inch 2mm drill bit to enlarge the hole in the servo arm...

Page 15: ... servo arm Step 11 Slide the clevis retainer onto the clevis Thread the clevis on the pushrod wire a few turn to get it started and secure Step 12 With the radio system plugged in and on check that the aileron servo is centered Thread the clevis on the pushrod wire so when the clevis is connected to the center hole of the control horn the aileron is centered and in alignment with the trailing edge...

Page 16: ...h machine screws for the Electric Power EP version as they will not be used in the engine installation Step 2 Slide a 8 washer onto each of the 8 32 x 3 4 inch machine screws Apply a drop of threadlock on each screw Step 3 Slide the screws into the motor mount as shown Step 4 Attach the mount to the fuselage using the screws prepared in the previous step and a 2 Phillips screwdriver Use 30 minute ...

Page 17: ... firewall Step 8 Locate the last two 8 32 x 1 inch machine screws 8 washers and 8 32 lock nuts Slide a washer on each screw and then pass the screw through the engine mount plate and engine mount Thread the lock nut onto the screw Step 9 Using a 2 Phillips screwdriver tighten the screws evenly to clamp the engine in position on the engine mount Step 10 Use a piece of medium grit sandpaper to rough...

Page 18: ...tem to move the throttle servo to the low position Use a felt tipped pen to mark the pushrod where it crosses the servo arm as shown Step 16 Use the radio system to move the throttle servo to the fully open position Move the throttle pushrod to move the carburetor to the fully open position Check that the mark made in the last step is still aligned with the hole in the servo arm used in the last s...

Page 19: ...o remove any unused arm so they will not interfere with the operation of the throttle servo Step 19 Insert the bend on the pushrod wire into the hole of the servo arm Slide the pushrod keeper on the wire then rotate it so it secures the connection between the pushrod and servo arm Note The bend on the pushrod wire goes up through the servo arm to prevent any binding between the pushrod wire connec...

Page 20: ... Clevis retainer Pushrod keeper 8 32 x 1 inch machine screw 4 8 32 x 3 4 inch machine screw 4 161 2 inch 419mm throttle pushrod wire 12 inch 305mm throttle pushrod housing Tools and Adhesives Phillips screwdriver 2 Threadlock Medium grit sandpaper Ruler Side cutters Pliers Z bend pliers Medium CA 30 minute epoxy Drill bit 5 64 inch 2mm 5 32 inch 4mm Step 1 Open the bag marked Motor Mount Set aside...

Page 21: ...l Note that the arches on the engine mount plates face to the centerline of the fuselage Thread an 8 32 lock nut on each screw Do not tighten the nut simply thread it on until the screw hits the nylon insert in the nut Step 7 Check the position of the needle valve in relation to the engine If it does not match the photo below you may need to remove the carburetor and rotate it so the needle valve ...

Page 22: ...andpaper to roughen one end of the 12 inch 305mm throttle pushrod housing This is necessary for the CA to stick to the tube when it is installed in the fuselage Step 14 Slide the pushrod housing into the hole in the firewall and into the fuselage The end of the tube sanded in the previous step will be almost flush with the firewall Do not glue the tube at this time Step 15 Use side cutters to trim...

Page 23: ... low position Use a felt tipped pen to mark the pushrod where it crosses the middle hole of the carburetor arm as shown Step 19 Use the radio system to move the throttle servo to the fully open position Move the throttle pushrod to move the carburetor to the fully open position Check that the mark made in the last step is still aligned with the hole in the carburetor arm used in the last step or b...

Page 24: ...her 5 Spinner cone Spinner backplate Propeller Fuel tubing 4 3mm x 10mm sheet metal screw 2 4 40 x 1 2 inch socket head screw 4 4 40 x 3 8 inch socket head screw Tools and Adhesives Phillips screwdriver 2 Ball driver or hex wrench 3 32 inch Step 1 Use the hardware provided with your engine to attach the muffler to the engine Note To position the muffler on your Saito closer to the fuselage purchas...

Page 25: ...r the clear cowl has been trimmed and fit you can them slide it over the painted cowl and transfer the outlines to the painted cowl Step 6 Remove the hatch from the bottom of the fuselage Pass a tie strap through the slots in the sides of the fuselage as shown Step 7 Inspect the fuel tank to determine the location of the vent and clunk lines as shown in the drawing below The vent line must face to...

Page 26: ...he covering on the hatch Use a 4 40 x 3 8 inch socket head screw and 4 washer to secure the hatch to the fuselage Use a 3 32 inch ball driver or hex wrench to tighten the screw Step 11 Use medium CA to glue the plywood pushrod support to the side of the fuselage Apply CA to the pushrod where it passes through the firewall and through the support at this time as well Step 12 Prepare the four 4 40 x...

Page 27: ...4 17 8 inch 48mm standoffs 4 8 32 x 21 2 inch machine screws 4 3mm x 10mm sheet metal screw 2 4 40 x 1 2 inch socket head screw 4 4 40 x 3 8 inch socket head screw 2 Tools and Adhesives Drill bit 5 32 inch 4mm Drill Phillips screwdriver 1 2 Threadlock Hobby knife with 11 blade Metric propeller reamer Ball driver or hex wrench 3 32 inch Step 1 Use a hobby knife and 11 blade to cut the supports to o...

Page 28: ...w and EP versions Make sure to install the mount at an angle as shown The hardware for the glow mount will not match up to the EP blind nut installation Step 5 Use hook and loop tape to attach the speed control to the battery tray as shown Note that the ESC is mounted to the bottom of the battery tray Step 6 Remove the hatch from the bottom of the fuselage and set it aside Step 7 Insert the hook a...

Page 29: ... will not interfere with the operation of the motor Step 11 Prepare the four 4 40 x inch socket head screws by sliding a 4 washer on each screw then a inch piece of fuel tubing on the screw The fuel tubing keeps the screws from vibrating loose without the need for threadlock Step 12 Use the screws from the previous step to secure the cowl to the fuselage The screws are tightened using a 3 32 ball ...

Page 30: ...propeller reamer Step 15 Slide the backplate assembly on the motor shaft Leave a gap of 3 32 inch 2mm between the cowl and spinner backplate Tighten the spinner nut to secure the adapter to the motor shaft Step 16 Install the spinner cone using the two 3mm x 10mm sheet metals screws and a 1 Phillips screwdriver Step 17 Use a hobby knife to remove the covering from the opening in the hatch before p...

Page 31: ...reen to the canopy hatch Make sure to position the windscreen so the hatch pin can still be operated Step 3 Insert the wing tubes into one of the wing panels Slide the tubes in until they stop Do not force the tubes in farther than they can easily slide Step 4 Slide the remaining wing panel onto the tubes and tight against the opposite wing panel Step 5 Connect the leads from the aileron servos to...

Page 32: ...ves Zap A Dap A Goo Threadlock Phillips screwdriver 2 Thin CA Hobby knife with 11 blade Before starting the installation of your floats you will need to assemble them according to the float manual Step 1 Locate the float mount adapter four landing gear straps and eight 4 x 1 2 inch sheet metal screws Step 2 Remove the landing gear from the fuselage Use the hardware from the landing gear to attach ...

Page 33: ...ew channel to operate the float servo The other option is to plug a Y harness into the rudder channel of the receiver The rudder servo inside the fuselage will plug into one of the leads from the Y harness while the float rudder servo will plug into the remaining lead Step 7 Use a hobby knife with a 11 blade to cut a hole in the fuselage big enough to fit the end of the servo extension or Y harnes...

Page 34: ... rudder should also move right Reverse the direction of the servo at the transmitter if necessary Step 2 Check the movement of the elevator with the radio system Moving the elevator stick toward the bottom of the transmitter will make the airplane elevator move up Step 3 Check the movement of the ailerons with the radio system Moving the aileron stick right will make the right aileron move up and ...

Page 35: ...e engine If not remove the spinner and use a crescent wrench to tighten it back down If you have had any not so great landings you will want to inspect the propeller for any damage Small nicks and scratches can quickly become fractures causing the propeller to be unsafe for flight Always carry a few spare propellers so a damaged propeller can be replaced at the field increasing your flying time pe...

Page 36: ...your expanded scale voltmeter Step 2 Check all hardware linkages screws nuts and bolts prior to each day s flight Be sure that binding does not occur and that all parts are properly secured Step 3 Ensure that all surfaces are moving in the proper manner Step 4 Perform a ground range check before each day s flying session Step 5 Prior to starting your aircraft turn off your transmitter then turn it...

Page 37: ...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 Law These Terms are governed by Illinois law without regard to conflict of law principals Safety Precautions This is a sophisticated hobby Product and not a toy It must be operated with caution and common sense and requ...

Page 38: ...nt by handing it over to a designated collection point for the recycling of waste electrical and electronic equipment The separate collection and recycling of your waste equipment at the time of disposal will help to conserve natural resources and ensure that it is recycled in a manner that protects human health and the environment For more information about where you can drop off your waste equip...

Page 39: ... properly licensed by the FCC are authorized to operate equipment on Amateur Band frequencies 6 I will not knowingly operate my model aircraft within three 3 miles of any preexisting flying site without a frequency management agreement A frequencymanagement agreement may be an allocation of frequencies for each site a day use agreement between sites or testing which determines that no interference...

Page 40: ...13819 2009 Horizon Hobby Inc 4105 Fieldstone Road Champaign Illinois 61822 877 504 0233 horizonhobby com Hangar 9 com ...

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