LUNYEE 4040 Nova CNC Router Assembly Guide: Step-by-Step Instructions

LUNYEE 4040 Nova CNC RouterProper assembly is a key factor in setting up the LUNYEE 4040 Nova CNC Router. Accurate alignment, secure fastening, and proper cable routing ensure smooth machine operation and reliable performance.

This guide explains the entire assembly process, from preparing the installation area to assembling the gantry, Z-axis, drag chain, spindle, wiring, and control box.

1. Installation Preparation

Before assembly, prepare a suitable workspace and ensure that you have all the necessary tools.

1.1 Installation Environment

1.1.1 Workspace

The assembled machine measures approximately70.5 × 68 × 53.4 cm. To ensure adequate heat dissipation, leave at least 100 mm of space around the machine, especially around the control box and spindle.

Do not place the machine directly against a wall or block the vents.

1.1.2 Worktable

Place the machine on a level, stable worktable with a load capacity of at least50 kg.

We recommend using a metal worktable or sturdy wooden table to provide a stable base and reduce vibrations during engraving.

1.1.3 Power Supply

Use a properly grounded wall outlet. Ensure that the power supply voltage matches the machine's power selector setting(110 V or 220 V).

1.1.4 Tools

Prepare the following tools before starting:

l Spirit level

l Marker

l Hex key

l Gloves (if needed to prevent scratches)

2. Gantry Assembly

First, attach the side plates andX-axis gantry assembly.

 

2.1 Step 1: Positioning the Side Plates

Remove the two side plates and place them on the assembly worktable.

Ensure that the plates are not bent and that their surfaces are clean and free of oil.

Take the positioning template and place it inside the side plates.

Align the template with the4 sets of pre-installed slide block nuts inside the side plates. Each set contains 2 nuts, for a total of 8 nuts.

Gently push the template into position so that each slide block nut aligns with its corresponding positioning hole. Ensure there is no visible misalignment.

Keep the template in place during the next assembly steps.

Note: The positioning template is for alignment assistance only and does not need to be tightened.

 

2.2 Step 2: Mounting the X-Axis Gantry

Without moving the aligned template and side plates, place the X-axis assembly shim plates under the slide block nuts on both sides.

Place the X-axis gantry frame on top of the two side plates. Align the two mounting holes on each side with the corresponding holes on the positioning template.

Insert 4 M5 × 20 socket button head screws through the mounting holes at the top of the X-axis gantry frame and thread them into the slide block nuts.

First, tighten the screws lightly to ensure smooth engagement and prevent seizing.

First, install one screw on each side to position the gantry. Check that the remaining holes on both sides are correctly aligned with the template.

Once the alignment is confirmed, install the remaining2 screws.

Tighten the 4 screws evenly with moderate force. Avoid overtightening, as this may deform the side plates or gantry frame.

Once the gantry is secured, remove the positioning template.

Important:Tighten the 4 screws in a crisscross pattern, alternating diagonally. This distributes the load evenly and reduces the risk of gantry tilt.

 

 

2.3 Step 3: Mounting the Foot Pads

Use 4 M5 × 16 socket button head screws to secure the four foot pads to the bottom of the 8080 aluminum profile.

Attach one foot pad to each corner of the machine.

 

3. Mounting the Z-Axis Assembly

The next step is to attach theZ-axis assembly to the X-axis carriage.

3.1 Step 1: Mounting the Upper Mounting Row

Place the Z-axis assembly against the X-axis carriage.

Align the row of mounting holes at the top of the X-axis carriage with the row of nuts inside the top of the Z-axis profile.

Insert 6 M5 × 25 socket button head screws.

Do not fully tighten the screws at this stage.

3.2 Step 2: Aligning the Lower Mounting Row

Slide the Z-axis assembly downward.

Position/shim plate notch onto the top plate of the Z-axis assembly, and press the bottom edge of the positioning plate against the X-axis carriage.

This aligns the row of lower mounting holes with the row of nuts inside the bottom of the Z-axis profile.

Next,insert 6 M5 × 25 socket button head screws.

Do not fully tighten the screws yet.

3.3 Step 3: Adjusting and Securing the Z-Axis

Slide the Z-axis assembly upward and adjust it to a position approximately 100 mm from the X-axis carriage.

Slowly tighten the screws in the upper and lower mounting rows one by one.

Important:

Before fully tightening the screws,leave them finger-tight so that the Z-axis remains secured while you adjust it.

Only tighten the screws as much as necessary to secure them. Overtightening may damage the screw threads.

Do not move the Z-axis too close to the X-axis carriage. The required clearance ensures the proper travel range of the Z-axis.

 

4. Mounting the Drag Chain

The drag chain assembly consists of a mounting plate and the drag chain itself.

4.1 Mounting the Drag Chain Mounting Plate

Use 2 M3 × 6 socket pan head screws to secure the two cable clip bases to the drag chain mounting plate.

Locate the pre-drilled holes and the mounting position marked "Drag Chain" on the side of the Z-axis assembly.

Align the mounting plate with the corresponding holes.

Insert 2 M4 × 16 socket button head screws through the mounting plate and thread them into the Z-axis assembly.

First, tighten the screws lightly, thenfully tighten them with an M4 hex key.

Important: Ensure the front of the mounting plate faces outward. The side with the lettering and hole markings must face outward. Incorrect orientation may affect the installation of the drag chain.

 

4.2 Mounting the Drag Chain

The drag chain uses4 M3 T-nuts from the 20 series.

4.2.1 Left End: X-Axis Gantry Side

Prepare 2 M3 × 8 pan head socket screws.

Insert them into the mounting holes on the left end of the drag chain and thread them from underneathinto 2 M3 T-nuts from the 20 series.

Do not tighten the screws yet.The T-nuts must remain movable.

Slide the T-nuts into the slots of the X-axis gantry profile and ensure they are fully seated and will not fall out.

Adjust the drag chain to a natural, loose state. Do not twist or overstretch it.

Once properly positioned,tighten the 2 M3 × 8 screws with an M3 hex key.

After tightening, the left end of the drag chain must remain secured.

4.2.2 Right End: Z-Axis Mounting Plate Side

Use the remaining2 M3 × 8 pan head socket screws.

Insert them into the mounting holes on the right end of the drag chain and align them with the pre-drilled holes in the mounting plate.

These screws thread directly into the mounting plate. T-nuts are not required on this side.

Adjust both ends so that the drag chain does not twist and can extend and retract smoothly with the Z-axis movement.

Once you have confirmed there is no interference, tighten the screws.

Important: After installing the drag chain,manually move the Z-axis up and down. Ensure that the chain does not snag or become overly tight. If there is resistance, readjust both ends before continuing.

 

5. Mounting the Spindle Mount and Trimmer Spindle

The 4040 Nova uses a 65 mm spindle mount designed for use with a trimmer spindle.

Insert the trimmer spindleinto the slot of the 65 mm spindle mount.

Adjust the position of the spindle so that the mounting holes align. Refer to the trimmer spindle manual for the recommended mounting position.

Hold the assembled spindle mount and trimmer spindleand align them with the spindle mounting position at the bottom of the Z-axis assembly.

Align the four lower mounting holes.

Insert 4 M6 × 75 socket screws into the 65 mm spindle mount from the outside of the Z-axis assembly.

Because the screws are relatively long, insert them carefully and slowly to prevent seizing the threads.

Use an M6 hex key to tighten the 4 screws evenly.

After tightening, lightly check the spindle assembly to ensure it is securely fastened and does not move.

If any movement is detected, check the alignment and retighten the screws.

Important: Position the spindle power connector so that the cables can be routed easily. The connector should generally face away from the work area to reduce the risk of cable interference.

 

6. Connecting and Securing the Cables

Proper cable routing is important to keep the cables away from moving parts and ensure sufficient travel for each axis.

6.1 Routing Cables Through the Drag Chain

First, connect the drag chain cable harness to the trimmer spindle power cable.

The connector has a key for orientation. Align the latch correctly and push the connector in until it clicks into place.

Slowly feed the excess cable into the drag chain from the X-axis side.

Ensure the cable does not become tangled, andleave enough slack to allow the Z-axis to extend and retract properly.

After routing the cables through the drag chain, secure the harness.

6.2 Securing the Side Cable Harness

Use 5 M3 × 6 socket pan head screws to secure the five cable clip bases at the designated mounting positions.

Thread the X-axis limit switch cable and the drag chain cable harness through the clips and secure them.

Next,use 4 M3 × 6 socket pan head screws to secure the four cable clip bases at the corresponding positions.

Thread the Y-axis motor cable and Y-axis limit switch cable through the clips and secure them.

6.3 Connecting the Motor and Limit Switch Cables

Check the harnesses for the X Motor, Y Motor, and Z Motor, and connect each to its corresponding motor.

 

Next,check the harnesses for X LIMIT, Y LIMIT, and Z LIMIT, and connect them to the corresponding limit switch ports.

 

The limit switches arelocated at the ends of the X, Y, and Z axes and are marked "LIMIT".

Route the motor and limit switch cablesalong the Z-axis and secure them in the cable slots with cable ties.

Ensure that the cables do not sag or come into contact with moving parts.

Route the excess cable from the adapter boardalong the back of the Z-axis and secure it with cable ties.

Leave enough slack so that the cable is not under tension and reaches the corresponding connection on the control box.

Ensure that all connectors are fully inserted.

Do not overtighten the cable tie. Excessive pressure may damage the cable insulation.

Important: Connect the drag chain power cable to the power output port of the control box. Do not connect it to the power input port.

 

7. Connecting the Power Cable Harness

Before wiring inside the control box, make sure the control box power is turned off.

Remove the screws on the outside of the control box cover and open the cover.

 

Locate the row of internal terminals labeled “Motor,” “Limit,” etc., and the corresponding other connection points.

Connect the external cable harness to the corresponding terminals according to the cable labels and wiring diagram.

Carefully inspect the area around the terminals to ensure that cables do not cross or come into contact with each other, creating a short-circuit risk.

Organize the cables so that they do not block the control box vents or switches.

Important:

Always turn off the control box power before wiring.

Make sure each connector is properly aligned and fully inserted into the corresponding terminal.

 

 

8. Reinstalling the Control Box Cover

After wiring is complete, reinstall the control box cover.

Secure the cover using M4 × 6 socket head screws.

Tighten the6 screws on the side panels and 6 screws on the top panel.

Once all12 screws are securely tightened, the control box assembly is complete.

 

9. 4040 Nova Assembly Video

For a complete visual guide to assembling the LUNYEE 4040 Nova CNC router, please watch the following assembly tutorial video.

This video demonstrates the assembly process step by step, including gantry installation,Z-axis assembly, drag chain installation, spindle installation, cable wiring, and control box wiring.

https://www.youtube.com/watch?v=qeyWyV0hbLg

For best results, watch the video along with the written instructions in this guide. Before proceeding to the next step, make sure each component is properly aligned and securely fastened.

10. Assembly Completion Check

Before proceeding with machine setup and operation, please check the following:

l The worktable is level and stable.

l The gantry andZ-axis assembly are securely fastened.

l All four foot pads are properly installed.

l The drag chain moves smoothly without snagging or excessive tension.

l The spindle is securely installed.

l The Z-axis can move through the required range without interference.

l The motor and limit switch connectors are fully inserted.

l Cables are secured and kept away from moving parts.

l The drag chain power cable is connected to the correct power output port.

l The control box wiring is organized and does not block the vents.

l There is at least100 mm of clearance around the machine for heat dissipation.

l The power selector is set to the available110 V or 220 V power supply.

LUNYEE 4040 NovaAssembly of the is complete, and you are ready to proceed to the next steps of machine setup and operation.