Thank you for your suggestions! I was thinking no one would write back! -Yes, changed to.004' guides -Yes, new pinch rollers, contacts flipped to new surface, belts flipped from coarse to fine side -Yes, correct.WIR and.TEC files activated -No, not a new alignment eyelet (but the newer of the two we have) -No, not in contact with eyelet- visually move wire to center-ish of 1/4' hole -No, haven't checked upper head for wire fragments (but I DID just pull the whole thing apart to clean it this morning) About to perform complete tear down of upper and lower heads to check for wire fragments. If you took the upper head apart and didn't see any fragments that's good. Check your unspooling pulley, the aluminum one @ the green belt, for an excessive groove. If.01' wire has grooved this too deeply for it to grip.004' wire that may be the problem, but usually causes wire breaks.
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Did you adjust the your pinch rollers for the.004' wire? Not sure if the 240 CC heads are more like the Robofil or the CUT heads, but adjusting the pinch rollers for.004' wire is critical on both. On the Robofil style heads it is a real pita. Too little and the wire moves to the front and slips, too much and it does the same to the back. Which controller does your machine have? Did you run the wire-setup routine after changing everything and activating the proper.WIR and.TEC files?
Also, if this is akin to the Robofil machines be sure to turn 'contact wetting' on when if/when you do this.