6-in-1 DIY Educational Solar Toy Kit

Welcome and Important Information

Thank you for purchasing this Merlin Product. Please read the instruction manual carefully before using the product. The documentation provided will allow you to fully enjoy all the features this unit has to offer. Please save this manual for future reference.

The following items are enclosed in the box. Please note that this product contains small plastic items that can easily be swallowed by children. Adult supervision is recommended when having children assemble this product.

Included Parts:

• Gear with Shaft (Green)
• Gear (Orange)
• Round Shaft
• Gear with Shaft (Purple)
• Solar Panel
• Motor with Connectors
• Adhesive Tape
• Sponge
• Eyes
• Wing
• Rubber Band
• Rubber Belt

Additional Recycled Items Required:

• Scissors
• Pencil
• Colored Box
• CD/DVD discs
• Soda Can (330-355 ml)
• Plastic Bottle (500-600 ml)
• Plastic Bottle (any size)
• Soda Can or Plastic Bottle (for drummer)
• Two cans of equal size
• Stiff paper or thick cardboard

Tools You May Need:

• Diagonal Cutter
• Scissors
• Pencil

Core Module Assembly

For the assembly of all the different toys, two main modules need to be assembled first: the Gearbox and the Solar Module.

Hint: Use a small side cutter to remove individual pieces from the main plastic assembly. Cut off any burrs for smoother edges.

1. Gearbox Assembly

The gearbox drives the different toys.

Step a: Motor Installation

Fit the motor into its slot as shown in figures 1 and 2. Be careful not to put the motor in skew, as it can damage the plastic parts. [Diagram Description: Figure 1 and 2 show the motor being inserted into a specific housing within the gearbox base. Arrows indicate the correct orientation and placement.]

Step b: Terminal Placement and Wiring

Place the black and red terminals in their positions and route the wires. [Diagram Description: Top and side views illustrate the placement of black and red wire terminals and how the motor wires should be routed.]

Step c: Gear Installation and Lid

Slide the gears into their places as shown in figures 4 and 5. Lock them in place by putting on the lid as shown in figure 6. [Diagram Description: Figures 4, 5, and 6 show the sequence of sliding gears onto shafts and then securing the gearbox with its lid.]

Step d: Side Covers

Add the two side covers to complete the gearbox. The final product should look like figure 8. [Diagram Description: Figure 8 shows the completed gearbox with side covers attached.]

2. Solar Module Assembly

The Solar module provides power to the gearbox and makes the toy come alive.

Step a: Solar Cell Placement

Place the adhesive pads (P8) on the plastic module (A16) and then place the solar cell (P6) onto it. Be careful to feed the wires through the provided gap. Remove the protective film that covers the solar cell. [Diagram Description: A side view shows adhesive pads being applied to a plastic module, followed by the solar cell being placed on top, with wires routed through a gap.]

Step b: Wire Stripping

The final step in assembling the solar module is removing the ends off the wires. The wires are already partially stripped for safety. While holding the wire and the stripped piece, twist the stripped piece and gently pull it off. It should come off easily. Remove both pieces of stripped ends. [Diagram Description: Shows how to twist and pull off the protective insulation from the pre-stripped wire ends.]

3. Merging of the Solar and Gearbox Modules

Now that the Gearbox and Solar Modules are completed, they can be put together to start making the toys.

Step a: Gearbox Orientation

It is very important to orientate the gearbox module correctly. In the lower right corner of the gearbox is a directional arrow pointing to the right. Have this arrow on your right-hand side when performing this connection. [Diagram Description: Shows the gearbox with a directional arrow highlighted in the lower right corner.]

Step b: Wire Connection (Polarity)

Observe the (+) and (-) symbols on the gearbox module. Line up the green wire from the solar module to the (-) terminal and the white wire to the (+) terminal of the gearbox module. [Diagram Description: Illustrates the gearbox terminals marked with '+' and '-' and the solar module wires (green and white) being aligned correctly.]

Step c: Securing Connections

Bend over the spring terminal on the gearbox module and insert the wires (observing correct colors) through them to protrude out the other side. Release the spring terminal gently. The wires from the solar module should be securely in place for a good connection. If they are loose, repeat the process until they are firmly in place. Ensure the wires do not touch each other, as this will cause a short circuit and the motor will not turn. [Diagram Description: Shows how to bend the spring terminal, insert the wires, and release the terminal to secure the connection. A warning about wires touching is also depicted.]

Step d: Completed Modules

The completed Solar and Gearbox Modules should look like the picture below. If everything is properly assembled, the main gear will turn when taken into sunlight. [Diagram Description: Shows the fully assembled and connected Solar Module and Gearbox Module. A note indicates that the main gear should spin in sunlight.]

Different Toy Assembly Instructions

1. CD Racer

This Toy uses old, unused CD or DVD discs to build.

Recycled Parts Required:

• Old CD/DVD discs
• Solar Module
• Gear Box

Assembly and Play:

Step a: Initial Assembly

Start by assembling the parts as shown in figure 1-3. [Diagram Description: Figures 1-3 show the initial assembly of parts for the CD Racer.]

Step b: Connecting Modules and Wheels

Connect the Solar module to the Gearbox, making careful note of the polarity of the wires and the orientation of the Gearbox. After this assembly, add the brackets that hold the CD wheels in place. [Diagram Description: Shows the Solar Module connected to the Gearbox, and brackets being attached for the CD wheels.]

Step c: Wheel Assembly

Assemble the wheel bushes and add the CD to form the wheel assembly. [Diagram Description: Illustrates assembling bushes and attaching them to the CD discs to create wheels.]

Step d: Final Assembly

Now, put all the modules together to form your racer. The modules clip together easily. When completed, the CD racer should look like the one in Figure 14. Let's go racing! [Diagram Description: Figure 14 shows the fully assembled CD Racer with CDs acting as wheels.]

Step e: Disassemble

This unit can be disassembled. If this is done, please follow these instructions to carefully remove the CDs from the bushing. [Diagram Description: Shows how to carefully detach the CD wheels from the assembly.]

2. Walking Robot

To make the walking robot, you will need an empty soda can of capacity between 330 and 355ml.

Recycled Parts Required:

• Soda Can (330-355 ml)
• Gear Box
• Solar Module
• Various plastic parts

Assembly & Play:

Step a: Robot Body and Module Attachment

Start by assembling the body for the robot. This will house the can, and the arms will be attached to it. Attach the Gearbox module to these parts. [Diagram Description: Shows the initial assembly of the robot's body parts and the attachment of the Gearbox module.]

Step b: Bushes and Main Body

Assemble the bushes and attach them to the main body. [Diagram Description: Illustrates attaching bushes to the robot's main body.]

Step c: Rubber Band and Can Insertion

The next step is to attach the rubber band and insert the old soda can. [Diagram Description: Shows attaching a rubber band and placing the soda can inside the robot's body.]

Step d: Eyes and Solar Module Connection

Now it is time to place the eyes on your robot and then hook up the Solar module. Connect the wires: GREEN WIRE to the (-) terminal (CONNECT) and WHITE WIRE to the (+) terminal (CONNECT) of the Gearbox. [Diagram Description: Shows placing eyes on the robot and connecting the Solar Module wires to the Gearbox terminals, noting polarity.]

Step e: Legs and Final Assembly

The final step is to assemble the legs and attach them to the rest of the robot. The completed robot (figure 17) can now be placed in a sunny area where it will start walking. [Diagram Description: Figure 17 shows the fully assembled Walking Robot with legs, ready to move in sunlight.]

3. Drummer Robot

For the Drummer robot, an empty soda can or similar sized soda bottle can be used as the drum.

Recycled Parts Required:

• Soda Can or Plastic Bottle
• Gear Box
• Solar Module
• Various plastic parts

Assembly & Play:

Step a: Body, Feet, and Legs

Start by assembling the eyes and attaching them to the main body. Following this, add the feet and legs to the main body. [Diagram Description: Shows attaching eyes, feet, and legs to the robot's main body.]

Step b: Gearbox and Solar Module Connection

In this step, take the shoulder of the robot and attach it to the Gearbox (figure 3). Now attach the Solar module and connect its wires to the Gearbox Module (figures 4-5). The two major assemblies can now be connected as shown in figure 6. Connect the GREEN WIRE to the (-) terminal (CONNECT) and the WHITE WIRE to the (+) terminal (CONNECT). [Diagram Description: Figures 3-6 illustrate attaching the shoulder to the Gearbox, connecting the Solar Module, and joining the main assemblies, including wire connections.]

Step c: Arms, Beat Plugs, and Drum

The final step of assembly is to attach the arms, put in the beat plugs, and put on the rubber band (figures 7-9). Place an empty soda bottle or soda can and keep it in place with the stopper. The robot is now fully assembled and will start playing the drum when placed in a sunny area (figure 10). [Diagram Description: Figures 7-10 show attaching arms, beat plugs, rubber band, securing the drum (bottle/can), and the final assembled Drummer Robot.]

Step d: Customizing Beat and Tempo

You can customize the beat and strength of your robot's tune by making minor adjustments. To get a strong or weak beat, adjust the angle of the beat arm. For a customized tempo, the beat plugs can be removed and placed in a custom order. [Diagram Description: Illustrates adjusting the beat arm angle for strong/weak beats and shows beat plugs that can be rearranged for tempo.]

Step e: Disassembly

For disassembly, be careful not to break the plastic parts when you detach them as shown below. [Diagram Description: Shows the sequence of detaching parts for disassembly.]

4. Bottle Yacht

For the Bottle Yacht, you will require a round empty plastic bottle with a volume of 500ml – 600ml.

Recycled Parts Required:

• Plastic Bottle (500-600 ml)
• Gear Box
• Solar Module
• Various plastic parts

Assembly & Play:

Step a: Module and Eye Attachment

Start by attaching the Solar Module to the Gearbox and connecting the wires. Add the eyes to the assembly too. Connect the WHITE WIRE to the (+) terminal (CONNECT) and the GREEN WIRE to the (-) terminal (CONNECT). [Diagram Description: Shows the Solar Module attached to the Gearbox with wires connected, and eyes being added.]

Step b: Bottle Clamp and Fitment

Next, clip on the parts that form the clamp to hold the bottle in place (figure 2). Then fit the plastic bottle and rubber band to keep it in place (figure 3). Further attach the arms that hold the bottle in place as shown in figures 4 and 5. [Diagram Description: Figures 2-5 show assembling clamps, fitting the bottle with a rubber band, and attaching supporting arms.]

Step c: Drive Wheel and Propeller Units

Assemble the drive wheel (1) and propeller units (2) and place them into position (figure 6). Once in place, the drive belt can be put in place (figure 7). [Diagram Description: Figures 6-7 show assembling drive wheel and propeller units and installing the drive belt.]

Step d: Adding Weight and Final Operation

The final step is to put some coins in the bottom of the Yacht in the holder provided. This acts as a weight to keep the Yacht in the water. This completes the Yacht. The propellers will now rotate and the Yacht will sail. [Diagram Description: Shows inserting coins into a holder at the bottom of the yacht for ballast and the completed yacht ready to sail.]

Fill up with coins completely!! Loose space is not allowed, or it may have coins spread out.

5. Flying Bird

For the Flying Bird, you will need an empty plastic bottle of any size.

Recycled Parts Required:

• Plastic Bottle (any size)
• Gear Box
• Solar Module
• Various plastic parts

Assembly & Play:

Step a: Arm Assembly

The first step is to assemble the arm the bird is attached to. Clip the pieces into place as shown in figure 1. [Diagram Description: Figure 1 shows the assembly of the arm structure for the bird.]

Step b: Counter Balance Unit

Assemble the counter balance unit which will house the coins to even weight distribution (Figure 2). [Diagram Description: Figure 2 shows the assembly of a counter-balance unit for coins.]

Step c: Drive Shaft and Gearbox Attachment

Assemble the drive shaft unit and attach it to the Gearbox unit. (Fig 3-4). [Diagram Description: Figures 3-4 show assembling the drive shaft and attaching it to the Gearbox.]

Step d: Wings and Wheel Attachment

Next, take the Gearbox unit and attach the parts that will form the wings (fig 5-6). At the bottom of the Gearbox, an arm is placed. Attach to this arm the wheel that contains the eye (fig 7). [Diagram Description: Figures 5-7 show attaching wing parts to the Gearbox, and then attaching an arm with an eye-containing wheel to the bottom.]

Step e: Wing Preparation and Tail

Now prepare the wings by removing them from the packaging and cutting them free from each other (fig 8). Use the adhesive pads and attach the wings to the main assembly. Also add the parts at the back to form the tail (fig 9). [Diagram Description: Figures 8-9 show preparing wings, attaching them with adhesive pads, and adding tail parts.]

Step f: Module Integration and Balancing

Take assembly 1 (the arm made in the beginning) and attach the Solar module to this arm (fig 10). Attach the arm to the Gearbox unit and connect the wires from the Solar Module to the Gearbox Module (Fig 11). Now connect the counter weight module by sliding it in (fig 12). Adjust Part 2 to balance the lever. [Diagram Description: Figures 10-12 show attaching the Solar Module to the arm, connecting it to the Gearbox, sliding in the counter-weight module, and adjusting for balance.]

Step g: Final Assembly and Operation

The final step for the flying bird is to attach it to the bottle. Before you start, half fill the bottle with water and place cap A15 onto it (fig 13). Now place the coins in the counter balance module and then put the entire assembly onto the bottle (fig 14). Adjust the counter balance module so the bird is level (fig 15). The bird will now fly around when placed in a sunny area (fig 16). [Diagram Description: Figures 13-16 show filling the bottle with water, capping it, placing coins in the counter-balance, attaching the assembly to the bottle, adjusting for level, and the final bird flying.]

Add Water

Insert Coins

6. Street Roller

For the Street Roller, you will require two cans of equal size and some stiff paper or thick cardboard.

Recycled Parts Required:

• Two Soda Cans (330-355 ml, same size)
• Stiff paper or thick cardboard
• Solar Module
• Gear Box
• Various plastic parts

Assembly & Play:

Step a: Module Connection and Initial Assembly

Start the street roller by connecting the Solar Module's wires to the Gearbox. Now clip the Solar Module to the Gearbox using the arm (fig 1). Attach the eyes and gear wheel to the Gearbox Module (fig 2). This will be called Assembly One. Connect the WHITE WIRE to the (+) terminal (CONNECT) and the GREEN WIRE to the (-) terminal (CONNECT). [Diagram Description: Figures 1-2 show connecting Solar Module wires to Gearbox, clipping them together, and attaching eyes and a gear wheel.]

Step b: Bracket and Can Holder Assembly

Attach the following pieces to make the bracket that will hold the cans (fig 3). This is called Assembly Two. Next, assemble the parts in fig 4 which get attached to the bracket as shown in fig 5. This would be called Assembly Three. [Diagram Description: Figures 3-5 show assembling a bracket and then attaching other parts to it to hold the cans.]

Step c: Wheel Preparation

Now we will prepare the wheels of the rollers.

a. Measure the size of your cans. Note the size: for a smaller 5.3cm can, install it at the 'S' mark; for a bigger 5.8cm can, install it at the 'L' hole later. [Diagram Description: Shows a ruler measuring a can's diameter and indicates 'S' and 'L' marks.]

b. Using a cardboard box, trace two circles using the top of the can as a template and cut them out. Trace a similar circle on paper and cut it out as well. [Diagram Description: Figures 7-10 show tracing circles on cardboard and paper using a can as a template.]

c. Find the center of the wheel by folding the paper. Punch a hole in the cardboard circles using the paper wheel and the A1 piece. Then attach adhesive tape to A1 and stick it onto the wheels. There should be 2 completed wheels. [Diagram Description: Shows folding paper to find the center, punching holes, and attaching parts with tape to create wheels.]

d. Put sponges on the top of the can and then attach the wheel to it. [Diagram Description: Shows placing sponges on the can top and attaching the prepared wheel.]

Measure the size of the top of the can using the diagram below. [Diagram Description: A diagram showing how to measure the can's top diameter.]

Using any sheet of paper, trace around the top of the can to create a circle and cut it out. Locate a central point from this paper. Push Part 1A through the circle's central point. Attach adhesive tape to Part A1 and stick it onto the wheels. [Diagram Description: Detailed steps for creating paper templates, finding centers, and attaching parts to form wheels.]

Step d: Bottom Wheels and Can Attachment

As before, make 2 cardboard wheels for the bottom side of the can. (Fig 14-18). When fixing the wheel to the can, use the adhesive tape on the outer rim of the wheel and stick it to the wheel. [Diagram Description: Figures 14-18 show making bottom wheels and attaching them to the can with tape.]

NOTICE: If you are using a small size can (05.3 cm), make sure to install into the 'S' hole at step e. If you are using a large size can (05.8 cm), make sure to install into the 'L' hole at step e. [Diagram Description: Highlights the 'S' and 'L' holes for different can sizes.]

Trace around the bottom of the can to create two circles in the colored gift box. Using any sheet of paper, trace around the bottom of the can to create a circle and cut it out. Locate a central point from this paper. Push B10 through the circle's center point. Attach adhesive tape to Part B and stick it onto the wheels. [Diagram Description: Detailed steps for creating bottom wheels using templates and attaching parts.]

Step e: Roller Assembly

Now we put the roller together by putting the top of the cans into Assembly Number 3. Remember to put it in hole 'S' or 'L' depending on the can size (fig 21). Do the same with the bottom of the can and Assembly 2 (fig 22). There should be no space between the cans and the assembly. [Diagram Description: Figures 21-22 show inserting the can tops into Assembly 3 and the can bottoms into Assembly 2, noting 'S'/'L' holes.]

Step f: Final Assembly and Operation

The final step is to put on the rubber band and place the gearbox unit onto the wheel assembly. Your Street Roller is now ready for use. [Diagram Description: Shows attaching the rubber band and the Gearbox unit to the wheel assembly.]

Maintenance and Care

• This product contains small plastic pieces that can be swallowed by small children. Adult supervision is recommended when children are assembling this product.
• Store all items of the product in a safe place as it can be disassembled and made into different toys at a later stage.
• Retain these instructions for future use.
• Clean the product with a damp cloth and mild soap.

Frequently Asked Questions (FAQ)

Limited Warranty

Merlin Products are covered by a limited one-year warranty policy. If the product suffers from a manufacturing defect, the customer will receive a replacement if claimed within 15 days of the purchase date. Otherwise, the product will be inspected for possible repair options. The product will either be repaired and returned free of charge, or replaced. All repair services past the one-year warranty period will be charged for any repairs that need to be made.

If the client is located outside the UAE, or is otherwise unable to personally deliver the defective product to our service center or retail outlets, they may send it via post at their own cost. The repaired/replaced product will then be returned to the client via courier mail at Merlin's cost, as long as the warranty period is still active.

Important: This limited warranty DOES NOT COVER normal wear and tear, accidents, damage during transit, misuse, abuse, or neglect. Attempting to disassemble the unit will render the warranty null and void.

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