I had a problem with the overlocker just not doing anything right. I took it for service and then the thread in the bottom looper keep breaking free. That seemed to pretty well cure itself and in it's place the right hand needle kept breaking. It seems to be coming down in front of the upper looper rather than behind which then drives it into the presser foot. Then last night the left hand needle started to break or bend. I am careful to ensure they are seated properly but having replaced a dozen needles yesterday I am at my wits end.
I had a similar problem with my machine. What I've started doing with mine is setting the stitch length at 3 and the differential feed ratio at 1.0 then I set all 4 thread tensions at 3. I thread the machine from right to left, and then when everything seems to be working okay I take scrap material to test the tension and then set them to suit the material I'm using. Right now I'm working with a twill so my settings are 4-4-5-5. This seems to have stopped the thread slipping off the bottom looper and I haven't had any more needles break. I hope this is helpful.
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The same thing happens to me sometimes. I take a deep breath and keep rethreading and replacing the needle until it works. I usually only have to replace a needle once and rethread it a million times, happens to me if the fabric is really thick, like denim. I've never taken it in, so I don't know what the real solution is, sorry.
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