Bilbo, how far is the lock bar traveling/engaging on your "usual" opening? Could you post a pic? It *may* have to do with the O-rings.
Going from old O-rings to new changed the lockup of my 'Zaan, pretty significantly. I keep procrastinating ordering the Polyurethane replacements from CRK, and have been using #60 Buna's. I tried new Buna's from two suppliers out of curiosity, and the thickness or o.d. must be slightly different between manufacturers, because lockup varied subtly between those as well.
I also get a deeper lockup with a hard opening or with tough/heavy slicing. I've attributed it (in part) to the Buna being a bit softer than PU, but that's just conjecture (until I order PU replacements). Mine hasn't locked up so early as to make me worry, though. If I had it with me tonight, I'd shoot some pics.
Hope you get it worked out. The 'Zaan is phenomenal.