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Troubleshooting spray gun issues: Top 5 problems and fixes

Symptoms:

• Patchy coverage
• Heavy spots or streaks
• Distorted fan shape

Causes:

• Clogged or damaged nozzle
• Worn needle or fluid tip
• Incorrect air pressure or fluid settings

Fix:
Disassemble the spray gun and inspect the nozzle and needle. Clean out any blockages with the appropriate tool or cleaning kit. Replace worn parts if needed. Adjust the air pressure and fluid flow until the spray pattern is even.

Symptoms:

• Paint comes out in spits or bursts
• Inconsistent spray flow
• Excess overspray or mist

Causes:

• Loose fluid nozzle or air cap
• Air entering the fluid system (e.g. cracked pickup tube or poor seal)
• Low or fluctuating paint supply

Fix:
Tighten all connections and inspect seals. Ensure the paint cup is adequately filled and check for any damage to the fluid tube. Regular maintenance and replacing worn seals will help prevent air leaks and ensure a steady spray.

Symptoms:

• Trigger engages but no paint is released
• Only air comes out

Causes:

• Clogged fluid tip or needle
• Dried paint inside the gun
• Blocked air vent or damaged air valve

Fix:
Clean the spray gun thoroughly using the appropriate solvent. Inspect the air valve and fluid tip for signs of dried paint or obstruction. Regular cleaning after every use is essential to avoid this issue in future. We stock a range of high-quality cleaning solvents to help you keep your equipment in top condition – ideal for removing dried paint and preventing future blockages.

Symptoms:

• Paint mist spreads beyond the target area
• Uneven coating or loss of material
• Sticky surroundings

Causes:

• Too high air pressure
• Incorrect tip size for the material
• Holding the gun too far from the surface

Fix:
Lower the air pressure to the manufacturer’s recommended setting. Use the correct fluid tip for the type of paint you’re applying. Maintain the proper spray distance – usually between 6-8 inches – for consistent coverage.

Symptoms:

• Trigger sticks or won’t return
• Paint flow won’t stop after releasing the trigger

Causes:

• Damaged or bent needle
• Worn packing or spring
• Build-up of paint residue inside the gun body

Fix:
Disassemble the trigger mechanism and inspect the needle. Clean and lubricate the internal components and replace any damaged springs or packings. If the needle is bent, replace it to avoid further internal wear and inconsistent spray performance.

Proper maintenance is the easiest way to prevent common spray gun problems. Here’s how to reduce downtime and keep your equipment in good shape:

• Clean your spray gun thoroughly after each use
• Store parts in a clean, dry environment
• Use filters to prevent debris from entering the fluid path
• Follow the manufacturer’s maintenance schedule

If problems persist, it may be time to invest in replacement parts or professional servicing.

While many spray gun issues can be resolved with basic maintenance and part replacement, some faults require expert attention – especially if problems keep returning despite regular upkeep.

You may benefit from professional servicing if:

• The spray gun still underperforms after troubleshooting
• There’s internal damage that’s hard to diagnose without specialist tools
• You’ve replaced parts but problems persist
• You’re unsure whether it’s more cost-effective to repair or replace the equipment
• You’re working to tight deadlines and need minimal downtime – we can offer a replacement sprayer during servicing (subject to hire fees)

Professional servicing can help extend the life of your equipment, improve spray quality, and minimise costly downtime. It also provides peace of mind that your gear is in safe, working order – especially in high-demand or safety-critical environments.

Our expert technicians can help with persistent spray gun problems and provide honest advice on servicing or replacements. Get in touch if you’d like support.

We supply a wide range of spray equipment, spares, and accessories – and we’re always happy to help.