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

Proper assembly is an important part of setting up the LUNYEE 4040 Nova CNC Router. Correct alignment, secure fastening, and proper cable routing help ensure smooth machine movement and reliable operation.

This guide covers the complete 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 make sure the required tools are available.

1.1 Installation Environment

1.1.1 Workspace

The assembled machine measures approximately 70.5 × 68 × 53.4 cm. Leave at least 100 mm of clearance around the machine to allow adequate heat dissipation, especially around the control box and spindle.

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

1.1.2 Work Surface

Place the machine on a level and stable workbench with a load capacity of at least 50 kg.

A metal workbench or solid wood table is recommended to provide a stable base and help reduce vibration during engraving.

1.1.3 Power Supply

Use a properly grounded wall outlet. Make sure the power supply voltage matches the machine's power selector setting, either 110 V or 220 V.

1.1.4 Tools

Prepare the following tools before starting:

Spirit level

Marker

Hex keys

Gloves, if needed to prevent scratches

2. Assemble the Gantry

Start by installing the side plates and X-axis gantry assembly.

 

2.1 Step 1: Position the Side Plates

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

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

Take the alignment template and position it on the inner side of the side plates.

Align the template with the four slide-block nut sets pre-installed inside the side plates. Each set contains two nuts, for a total of eight nuts.

Gently push the template into position so that each slide-block nut is aligned with its corresponding locating hole. Make sure there is no visible offset.

Keep the template in place during the next assembly step.

Note: The alignment template is used only to assist with positioning and does not need to be fastened.

 

2.2 Step 2: Install the X-Axis Gantry

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

Position the X-axis gantry frame onto the two side plates. Align the two mounting holes on each side with the corresponding holes on the alignment template.

From the top of the X-axis gantry frame, insert four M5 × 20 hex socket button head screws through the mounting holes and into the slide-block nuts.

Tighten the screws lightly at first to ensure smooth engagement and prevent binding.

Install one screw on each side first to locate the gantry. Check that the remaining holes on both sides remain properly aligned with the template.

After confirming the alignment, install the remaining two screws.

Tighten all four screws evenly with moderate force. Avoid excessive tightening, which could deform the side plates or gantry frame.

Remove the alignment template after the gantry has been secured.

Important: Tighten the four screws using a cross-tightening pattern, alternating diagonally. This helps distribute the load evenly and reduces the risk of gantry tilting.

 

 

2.3 Step 3: Install the Foot Pads

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

Install one foot pad at each corner of the machine.

 

 

3. Install the Z-Axis Assembly

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

3.1 Step 1: Attach the Upper Mounting Row

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

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

Insert six M5 × 25 hex socket button head screws.

Do not fully tighten the screws at this stage.

3.2 Step 2: Align the Lower Mounting Row

Slide the Z-axis assembly downward.

Use the notch on the positioning/shim plate to hook onto the top plate of the Z-axis assembly, with the bottom of the positioning plate flush against the X-axis carriage.

This positions the lower row of mounting holes in alignment with the lower row of nuts inside the Z-axis profile.

Insert another six M5 × 25 hex socket button head screws.

Do not fully tighten the screws yet.

3.3 Step 3: Adjust and Secure the Z-Axis

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

Gradually tighten the upper and lower rows of screws in sequence.

Important:

Before fully tightening the screws, keep them partially tightened so they remain secure while the Z-axis is being adjusted.

Tighten the screws only until they are secure. Do not overtighten them, as this may damage the threads.

Do not slide the Z-axis too close to the X-axis carriage. The required clearance helps maintain proper Z-axis travel.

 

4. Install the Drag Chain

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

4.1 Install the Drag Chain Mounting Plate

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

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

Align the mounting plate with the corresponding holes.

Insert two M4 × 16 hex socket button head screws through the mounting plate and into the Z-axis assembly.

Tighten the screws lightly first, then fully tighten them using an M4 hex key.

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

 

4.2 Install the Drag Chain

The drag chain uses four 20-series M3 T-nuts.

4.2.1 Left End: X-Axis Gantry Side

Take two M3 × 8 flat head hex socket screws.

Insert them through the mounting holes at the left end of the drag chain and thread them into two 20-series M3 T-nuts from underneath.

Do not tighten the screws yet. The T-nuts must remain able to slide.

Slide the T-nuts into the slot of the X-axis gantry profile and make sure they are fully seated and cannot fall out.

Adjust the drag chain to a natural, relaxed position. Do not twist or overstretch it.

Once the position is correct, tighten the two M3 × 8 screws using an M3 hex key.

The left end of the drag chain should remain fixed after tightening.

4.2.2 Right End: Z-Axis Mounting Plate Side

Use the remaining two M3 × 8 flat head hex socket screws.

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

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

Adjust both ends of the drag chain so that it is not twisted and can extend and retract smoothly as the Z-axis moves.

After confirming that there is no interference, tighten the screws.

Important: Manually move the Z-axis up and down after installing the drag chain. Check that the chain does not bind or become excessively tight. If resistance occurs, readjust both ends before continuing.

 

5. Install the Spindle Mount and Trimmer Spindle

The 4040 Nova uses a 65 mm spindle mount with the trimmer spindle.

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

Adjust the spindle position so that the mounting holes are aligned. Refer to the trimmer spindle instructions for the recommended mounting position.

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

Align the four pre-drilled mounting holes.

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

Because the screws are relatively long, insert them carefully and slowly to avoid thread binding.

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

After tightening, gently check the spindle assembly to make sure it is secure and does not move.

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

Important: Position the spindle power connector in a direction that allows easier cable routing. The connector should generally face toward the rear, away from the working area, to reduce the risk of cable interference.

 

6. Connect and Secure the Cables

Proper cable routing is important for keeping the cables away from moving components and allowing sufficient movement of the axes.

6.1 Route the Cables Through the Drag Chain

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

The connector is keyed. Align the latch correctly and push the connector together until it clicks into place.

From the X-axis side, gently feed the excess cable into the drag chain.

Make sure the cable is not tangled and leave enough slack for the Z-axis to extend and retract normally.

Secure the harness after routing it through the drag chain.

6.2 Secure the Side Cable Harnesses

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

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

Use four additional M3 × 6 hex socket flat head screws to secure the four cable clip bases at the corresponding positions.

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

6.3 Connect the Motor and Limit Switch Cables

Locate the X Motor, Y Motor, and Z Motor harnesses and connect each one to the corresponding motor.

 

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

 

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

Route the motor and limit switch cables along the Z-axis and secure them in the cable slot using zip ties.

Keep the cables from hanging loosely or coming into contact with moving components.

Route the excess cable from the adapter board along the rear of the Z-axis and secure it with zip ties.

Leave enough cable length to reach the corresponding control box connection without putting tension on the cable.

Check that all connectors are fully seated.

Do not overtighten the zip ties, as excessive pressure can damage the cable insulation.

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

 

7. Connect the Power Cable Harness

Before connecting the internal control box wiring, make sure the control box is powered off.

Remove the outer screws from the control box cover and open the cover.

 

Locate the internal terminal row labeled "Motor," "Limit," and other corresponding connection points.

Connect the external cable harnesses to their matching terminals according to the cable labels and wiring diagram.

Check the terminal area carefully to make sure cables are not crossing or contacting each other in a way that could create a short-circuit risk.

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

Important:

The control box must be powered off before wiring.

Make sure each connector is correctly aligned and fully inserted into its corresponding terminal.

 

 

8. Reinstall the Control Box Cover

After completing the wiring, reinstall the control box cover.

Use M4 × 6 hex socket screws to secure the cover.

Tighten the six screws on the side panels and the six screws on the top panel.

Once all 12 screws are secure, the control box assembly is complete.

 

9. 4040 Nova Assembly Video

For a complete visual guide to assembling the LUNYEE 4040 Nova CNC Router, watch the assembly tutorial video below.

The video provides a step-by-step demonstration of the assembly process, including gantry installation, Z-axis assembly, drag chain installation, spindle mounting, cable routing, and control box wiring.

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

For the best results, follow the video together with the written instructions in this guide. Make sure each component is correctly aligned and securely fastened before moving on to the next step.

10. Final Assembly Check

Before moving on to machine setup and operation, check the following:

•  The workbench is level and stable.
•  The gantry and Z-axis assembly are securely fastened.
•  All four foot pads are properly installed.
•  The drag chain moves smoothly without binding or excessive tension.
•  The spindle is securely mounted.
•  The Z-axis can move through its required range without interference.
•  Motor and limit switch connectors are fully seated.
•  Cables are secured and kept away from moving parts.
•  The drag-chain power cable is connected to the correct power output port.
•  The control box wiring is organized and does not block ventilation openings.
•  The machine has at least 100 mm of clearance for ventilation.
•  The power selector is set to match the available 110 V or 220 V supply.

The LUNYEE 4040 Nova is now assembled and ready for the next steps of machine setup and operation.