How to Troubleshoot and Prevent Spray Gun Malfunctions

Using a spray gun is one of the most efficient ways to apply paint, but even the best equipment can encounter problems. Understanding the causes behind common spray gun issues and knowing how to fix them will help you avoid wasted paint and poor finishes. Here are frequent faults seen with spray guns and their practical solutions.

1. Spray Gun Not Spraying or Weak Spray

If your spray gun suddenly stops spraying or the spray becomes weak, first check the air supply and make sure it’s connected and set to the proper pressure. Inspect the fluid needle, nozzle, and air cap for blockages or clogs. Often, thorough cleaning will restore normal function. If using thick paint, ensure it’s thinned according to manufacturer guidelines.

2. Orange Peel Effect

A rough, dimpled finish—known as “orange peel”—can occur if the paint is too thick or the spray gun’s air pressure is too low. To resolve this, adjust the pressure settings, use the correct nozzle size, and strain or thin the paint as needed. Spraying in thin, even coats also helps achieve a smooth result.

3. Excessive Overspray

Overspray wastes paint and creates a mess. This is usually caused by holding the spray gun too far from the surface or using excessive air pressure. Keep the gun at the recommended distance (typically 6–8 inches), adjust air pressure to the proper level, and use the correct fan width to minimize overspray.

4. Drips and Runs

Paint drips and runs are often the result of moving the spray gun too slowly or applying too much paint in one pass. For a consistent finish, maintain a steady motion, overlap each stroke by about 50%, and keep the gun perpendicular to the work surface.

5. Paint Bubbling or Foaming

Bubbling can occur when air is trapped in the paint line or cup. Always ensure a proper seal and check for cracks or leaks in hoses and connections. If you notice foaming, stop and bleed the air from the system, then resume painting.

Conclusion
Proactive maintenance is the best way to keep your spray gun performing well. Clean all parts thoroughly after each job, use recommended lubricants, and regularly inspect for wear and tear. With these tips, most spray gun issues can be quickly identified and resolved, allowing you to achieve high-quality, professional results every time.

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