Hi Fubini,
Thank you for the reply. Very helpful. After looking over the posts you suggested I was able to set DEACTIVATE_ABS_ACCUR=TRUE and now see that my robot matches the simulation as expected. A few follow up questions:
1) Is absolute accuracy something that is typically purchased from Kuka? The previous two kuka quantec robots I purchased do not have the same issue as mentioned above. Why would one robot come with this enabled while the other two did not? I did purchase this robot used but as a referb directly from Kuka.
2) Is there any way to read the calibration data from the robot so that I can use more accurate DH parameters in my simulation? Assuming this is indeed more accurate.
3) Is there any documentation on how this calibration would have been done by Kuka?
Anyway, my application does not require absolute accuracy so just deactivating it for now works. The Kuka HMI does give a constant warning with that feature disabled but not a big deal. Again, much appreciated!