Here are some comments I found related to your issue.
"We had this problem at our office as wel. It's probably caused by 2 computers using different hatch pattern files, or by mixing up imperial and metric hatch patterns files.
We fixed it by copying acadlt.pat and acadltiso.pat from 1 pc to all other computers in the office, to make sure we all used the same pattern file. This will also prevent the 'reading hatch pattern error' ( ?) from occuring.
It still comes up when opening old files and files from third parties do. "
MEASUREMENT and MEASUREINIT are set to 1 = metric but the current dimension style is architectural inches
Problem
You have two drawings using the same hatch pattern name, to make the appearance match, one drawing has to have the hatch pattern scale approximately 25 bigger than the other.
Solution
AutoCAD has two hatch pattern files. acad.pat (imperial) and acadiso.pat (metric) The pattern that is used is determined by the setting of MEASUREMENT variable when the pattern is first inserted.
MEASUREMENT 1 uses acadiso.pat (metric)
MEASUREMENT 0 uses acad.pat (imperial)
It would be good practice to set all your template files to the same setting
Below are extracts from the pat files. note the ratio between the files is 3.175/0.125=25.4, (1 inch is 25.4mm)
Acadiso.pat
*ANSI31, ANSI Iron, Brick, Stone, Masonry
45, 0, 0, 0, 3.175
Acad.pat
*ANSI31, ANSI Iron, Brick, Stone, Masonry
45, 0, 0, 0, 0.125
To update a pattern (option 1)
Set the MEASUREMENT variable to the chosen setting, select the hatch, right click pick properties pick scale, change value to anything and change it back again, this forces it to update and refer to the correct pat file.
MEASUREINIT Controls whether a drawing you start from scratch uses imperial or metric default settings.