Merlin 6-IN-1 DIY Educational Solar Toy Kit Instruction Manual

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Tools you may need:

Diagonal Cutter

Scissors

Pencil

Instructions:
For the assembly of all the different toys in this product two items
need to be assembled first. The Gearbox and the Solar Module.

Hint: Use a small side cutter to remove the individual pieces from
the main plastic assembly. Also remember to cut off the burr to
make a smoother edge.

1). Gearbox:
The gearbox drives the different toys.

a) Start by fitting the motor in its slot as per figure
1 and 2. Be careful to not put the motor in skew it can
damage the plastic parts.

6-in-1 DIY Educational Solar Toy Kit

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 easy be swallowed
by children. Adult supervision is recommended when having
children assemble this product.

Aditional recycled items required for assembly
of different toys:

Colored Box

Gear ( Orange )

Gear with Shaft ( Purple )

Motor with Connectors

Adhesive Tape

Eyes

Rubber Band

Rubber Belt

Wing

Black

Push

Red

Sponge

Solar Panel

Round Shaft

Gear with Shaft ( Green )

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b) Now place the black and red terminals in their
positions and route the wires.

c) Slide the gears into their places as show in figure
4, 5. Lock them in place by putting on the lid like
shown in fig 6.

d) Add the two side covers to complete the gearbox.
The final product should look like figure 8.

2) Solar Module:

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

a) Place the adhesive pads (P8) on plastic module
(A16) and then place the solar cell (P6) onto it. Be
careful to feed the wires through the gap provided.
Remove the protective film that covers the solar cell.

b) The final step in the assembling the solar module is
removing the ends off of 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.

3) Merging of the Solar and Gearbox Modules:

Now that the Gearbox and Solar Modules are completed
we can put them together and start making some of the
toys.

a) It is very important to orientate the gearbox module
before starting this process. In the lower right corner of
the gearbox is a directional arrow pointing to the right.
Have this arrow on your righthand side when performing
this.

b) Observe the (+) and (-) symbols of the gearbox
module. Line up the green wire to the (-) terminal and
the white wire to the (+) terminal of the gearbox module.

c) Bend over the spring terminal on the gearbox module
and insert the wires (remember to observe the 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 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.

Black

Red

Top View

Solar Module Assembly

White

Green

Side View

Completed

Side View

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d) The completed Solar and Gearbox Modules should look like
the picture below. If everything is properly assembled the main
gear will turn when it is taken into the sunlight.

Different Toy Assembly Instructions:

1. CD Racer.
This Toy uses some old unused CD or DVD discs to build.

a) Start by assembling the parts as shown in figure
1 – 3.

b) Connect the Solar module to the Gearbox making careful
note of the polarity of the wires and orientation of the Gearbox.
After this assembly add the brackets that hold the CD wheels in
place.

c) Assemble the wheel bushes and add on the CD to form the

Solar Module

Green

White

CONNECT

GREEN WIRE

Completed

Wires should not Touch each Other.

GREEN

GREEN

CD Racer: Assembly and Play

Recycled Parts Required

PUSH PUSH

WHITE WIRE

Gear Box

Green

Green

GREEN WIRE

CONNECT

CONNECT

WHITE WIRE

White

White

Solar

Module

Part

Part

WHITE

CONNECT

Gear Box

How To The Gear Box

Notice: Find and make sure correct direction of “ “ on gearbox rst,
it would help you to install the parts correctly

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wheel assembly.

d) Now we can put all the module together and
form your racer. The modules all clip together
easily. When its completed the CD racer should
look like the one in Figure 14. Let’s go racing.

e) This unit can be disassembled. If this is done
please follow these instructions to carefully
remove the CD’s from the bushing.

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

a) Start by assembling the body for the robot. This will house
the can and the arms will be attached to it. Attach the modules
Gearbox to these parts.

b) Assemble the bushes and attach them to the main body.

Part

Running

Disassemble:

Walking Robot:

Assembly & Play:

Soda Can 330-355 ml

Gear Box

Recycle Parts required

CD & Plastic Parts

Part

Part

Part

Part

Part