Simple diameter measurements not matching reality

[[Ni...]]

Check the evaluation in the characteristic tab. Maybe your machine is using max or min inscribe and the rest are using LSQ or vice versa.
Also check the evaluation on the features tab.

When you qualify your master probe and ref sphere, and then you qualify your stylus, use the long complete qualification. Not the re-qualification.

Also do the same measurement with no programs loaded. Just a new program on all machines. Perhaps the base alignment on the machine is making it look skewed.
Doing the measurement on all CMMs with a new program would give it the default machine alignment. Pretty much make sure everything is exactly the same on all machines.

[[Th...]]

Now for the thrilling conclusion. The answer to "what was wrong with the machine" is "yes".

The tech started the repair service on the 29th, and wrapped up today. Squareness was adjusted, X and Y drive motors were replaced, and the TKEL board in the backpack controller was replaced. Firmware was rolled back from 31.23 to 31.20 to correct some kind of config error. More replacement XT sensors were tested as well prior to the other items, although the initial replacement from late October was functional.