Merlin 6-in-1 DIY Educational Solar Robot Kit

Thank you for purchasing this Merlin Product. Please read this 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.

This product contains small plastic items that can easily be swallowed by children. Adult supervision is recommended when children assemble this product.

General Assembly Instructions

For the assembly of all the different toys in this product, two main items 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. Also, remember to cut off any burrs to make a smoother edge.

1. Gearbox Assembly

The gearbox drives the different toys. There are two different types of gearboxes, A and B. Ensure you have the correct gearbox for the toy you want to construct.

Gearbox A:

Step 1: Start by fitting the main gear axle (P3) into plastic part (D20).
Step 2: Fit the motor (P5) into its slot. Be careful not to insert the motor skewed, as this can damage the plastic parts.
Step 3: Close the gearbox by fitting the cover (D21). Carefully route the wires through the space provided.
Step 4: The finished gearbox should look like the one shown in the diagram.

Gearbox B:

Step 1: Start by fitting the main gear axle (P2) into plastic part (D20).
Step 2: Fit the motor (P5) into its slot. Be careful not to insert the motor skewed, as this can damage the plastic parts.
Step 3: Close the gearbox by fitting the cover (D21). Carefully route the wires through the space provided.
Step 4: The finished gearbox should look like the one shown in the diagram.

2. Solar Module Assembly

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

Step 1: Place the adhesive pads (P4) on plastic module (D22).
Step 2: Place the solar cell (P1) onto the adhesive pads on (D22). Be careful not to bend the terminals. Remove the protective film that covers the solar cell.
Step 3: Place the protective cover onto the module.
Step 4: The completed solar module should look like the one shown in the diagram.

3. Connecting 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 1: Remove the ends off the wires from the solar module. The wires are already partially stripped but left in place 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.
Step 2: Bend over the spring terminal on the solar module and insert the wires (remember to observe the correct colors) through them so they protrude out the other side. Release the spring terminal gently. The wires from the gearbox should be securely in place to form a good connection. If they are loose, repeat the process until they are firmly in place. Ensure that the wires don't touch, as this will cause a short circuit and the motor will not turn.
Step 3: Connect the wires from the gearbox to the solar module. Ensure the polarity is connected correctly as shown in the diagram.

Different Toy Assembly Instructions

1. Solar Windmill

Step 1: Collect all parts for the Solar Windmill. Assemble the base by attaching the feet (A1) to the base (C24).
Step 2: Place the main mast (C27) and holding bracket (D32) in place.
Step 3: Take Gearbox B and attach the solar module using bracket (B4). Then attach the windmill blades.
Step 4: Place the gearbox and windmill assembly on the tower. Connect the wires from the gearbox to the solar module (as shown in general connection step 3).

Finished Product: Solar Windmill.

2. Solar Robot

Step 1: Collect all parts for the Solar Robot. Start with the body: connect (D28) and (D29) to the body (B16). Connect the mounting bracket for the solar module (B4).
Step 2: Assemble the head using (D30) and (D31). Mount the head on the body.
Step 3: Using Gearbox A, connect the wheels (B14) and support brackets (B12 and B15).
Step 4: Attach the body to the wheel assembly and then place the solar module on top.
Step 5: Connect the wires from the gearbox to the solar module.

Finished Product: Solar Robot.

3. Solar Wheeler

Step 1: Collect all parts for the Solar Wheeler. Take Gearbox A and connect the wheels (B14). Add the support brackets (B13) and the front wheel (B12).
Step 2: Place the mounting bracket (B4) on the wheeler, followed by the solar module.
Step 3: Connect the wires from the gearbox to the solar module.
Step 4: Attach the body to the wheel assembly and place the solar module on top.
Step 5: Connect the wires from the gearbox to the solar module.

Finished Product: Solar Wheeler.

4. Solar Airboat

Step 1: Collect all parts for the Solar Airboat. Assemble the floating platform by connecting (A1) pieces together and adding the mounting point (C19).
Step 2: Take Gearbox B and attach the propeller (A3). Connect the mounting bracket (B4) and (B2) to the assembly. Clip the Solar Module to complete the Solar Airboat.
Step 3: Connect the wires from the gearbox to the solar module.

Finished Product: Solar Airboat.

5. Solar Helicopter

Step 1: Collect all parts for the Solar Helicopter. Take the base (C24) and connect the feet (A1) to it. Insert the mast (C26) and turning arm (C25). Add counter balance holder (A5) and fitting (A6).
Step 2: Take Gearbox B and clip the housings (A7 and A8) to it. Add the propeller (A3) to this assembly. Clip this assembly to the turning arm. Attach mounting bracket (B4) and clip the solar module onto it.
Step 3: Connect the wires from the gearbox to the solar module. Carefully feed the wires under the turning arm so they stay out of sight.
Step 4: Place a coin (not included) in the counter balance holder. Adjust the solar module for best balance.

Finished Product: Solar Helicopter.

6. Solar Plane

Step 1: Collect all parts for the Solar Plane. Assemble the base by attaching the feet (A1) to base (C24). Place the main mast (C27) and turning arm (C25) in place. Attach the counter balance (A5) and mounting point (A9) to the arm.
Step 2: Take Gearbox B and clip brackets (A10, A11 and B2) to it. Push the propeller (A3) onto the gearbox. Attach the plane to the turning arm. Clip mounting bracket (B4) to the other side of the turning arm and clip the solar module to it.
Step 3: Connect the wires from the gearbox to the solar module. Carefully feed the wires under the turning arm so they stay out of sight.
Step 4: Place a coin (not included) in the counter balance holder. Adjust the solar module for best balance.

Finished Product: Solar Plane.

How to Play

Place the assembled toy in a well-lit area with strong sunlight. The solar module will provide power, and the toy should start moving. For the Solar Helicopter and Solar Plane, you can adjust the solar module for better balance and insert a coin into the counter balance holder.

Maintenance

Store all product items in a safe place as they can be disassembled and used to build different toys later.
Retain these instructions for future use.
Clean the product with a damp cloth and a mild soap.
Warning: The motor in the gearbox can become warm. Be careful not to get scalded. If it gets too hot, remove the toy from direct sunlight and let it cool down.

FAQ (Frequently Asked Questions)

Q: The gearbox module does not turn.
A: Make sure there is enough sunlight for the Solar Module to provide power. Then, ensure the wires are properly connected between the Solar Module and Gearbox Module.
Q: The gearbox does not make the toy work. What is wrong?
A: Check to see that the correct gearbox module (A or B) was used for the toy in question.

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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For enquiries and information, call our toll-free number 800-MERLIN (available Saturday-Thursday, 9 am - 6 pm).

Contact our support staff for troubleshooting and any other enquiries relating to your Merlin product by sending an email at support@merlin-digital.com, and your issue will be resolved within 48 hours.

Service Center Map

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