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Let me explain how I think things work. Just before the machine tries to determine the board thickness by touching the sliding plate, it bobs at the brass roller. This bob is not really a...

Now that I think about it, the truck should not bottom out during normal touching routines. Does the truck move smoothly up and down? If on initially moving up to find 0, it encountered resistance,...

Does the bit touch the bit plate? Is the bit plate swinging out as it should?

That would explain it. The bit needs to be installed longer. Are you using the Rock Chuck?

Could it be that the bob at the brass roller is touching the sled instead of passing beside the sled on the left?

(You may have to post sled pictures or explain exactly every move the machine...

My guess is that the bit touches by the brass roller and so expects to be able to touch at the sliding plate. How close to be sliding plate does the bit come?

(If the bit does not touch at the...

I my experience, if if cannot touch the sliding plate, it asks for the board thickness.

When it asks for board or project thickness it is because it did touch the sliding plate and the thickness...

Did the machine ask for the board thickness before it continued?

I believe that after the machine gives the board too thick message and you press continue, it will cut to the maximum depth possible. Be ready for the bit to cut into the sled. Tabs may be cut.