High Volume Low Pressure HVLP sprayers have become an essential tool for professionals and DIYers who want smooth, controlled and efficient paint applications. Whether you’re refinishing furniture, painting cabinets, or working on automotive projects, a well-tuned HVLP spray system can deliver stunning, professional results. However, like any mechanical tool, HVLP spray guns can develop issues that affect paint quality, consistency and overall performance. The good news? Most of these problems are easy to fix once you understand their causes.
1. Poor Spray Pattern
A faulty spray pattern is one of the most common frustrations when using HVLP Sprayers. You may notice the spray pattern looks uneven, blotchy or inconsistent.
Common Causes
- Clogged air cap holes
- Dirty or blocked fluid nozzle
- Incorrect air pressure settings
- Thick or improperly thinned paint
- Loose connections or parts
How to Fix It
- Clean the air cap thoroughly. Remove dried paint using a needle, soft brush or solvent.
- Check the fluid nozzle for clogs. Soak it in paint thinner and blow out any remaining debris.
- Adjust your pressure settings. HVLP systems require lower pressure but still need enough airflow to atomise paint properly.
- Thin your paint as required. Always follow the manufacturer's thinning guidelines.
- Tighten all connections. Ensure the cap, nozzle and collar ring are secure.
2. Sputtering or Spitting
Sputtering occurs when the spray gun releases bursts of paint instead of a smooth flow. This leads to drips, runs and uneven coverage.
Common Causes
- Low material flow in the paint cup
- A loose nozzle
- Air leakage through the paint cup lid
- A clogged vent hole
- Worn needle packing
How to Fix It
- Refill the paint cup if the material is too low.
- Tighten the fluid nozzle with the appropriate tool.
- Check the cup lid seal to ensure air isn’t escaping.
- Clean vent holes to allow proper airflow.
- Replace worn packing if the gun is older or frequently used.
3. Orange Peel Finish
An orange peel texture looks like the skin of an orange—bumpy and rough rather than smooth and glossy.
Common Causes
- High paint viscosity
- Low air pressure
- Fast-drying paint
- Incorrect technique (too far back or moving too fast)
- Wrong size nozzle
How to Fix It
- Thin the paint appropriately.
- Increase air pressure slightly to improve atomisation.
- Use slower-drying reducers if needed.
- Move the gun closer (6–8 inches from the surface).
- Use the correct nozzle size, typically 1.3–1.5 mm for most paints.
4. Paint Runs or Sags
Runs and sags appear when too much paint is applied in one area.
Common Causes
- Too slow gun movement
- Too close to the surface
- Excessive material flow
- Incorrect gun angle
How to Fix It Quickly
- Increase your distance to the work surface.
- Speed up your passes to avoid heavy build-up.
- Reduce fluid flow using the material knob.
- Hold the gun perpendicular to the surface.
- If a run forms, let it dry and then sand lightly to level it before recoating.
5. Dry Spray
Dry spray looks dusty or grainy because the paint is drying before it lands on the surface.
Common Causes
- Too much distance between gun and surface
- Not enough material flow
- Fast-drying paint
- Low air pressure
How to Fix It
- Spray closer—target 6–8 inches.
- Increase material flow slightly.
- Add retarder or use a slower reducer.
- Adjust air pressure upward for better atomisation.
6. Excessive Overspray
Overspray occurs when paint misses the target area and settles elsewhere.
Common Causes
- Too high air pressure
- Wrong needle/nozzle combination
- Poor spray technique
- Spraying in windy conditions
- Thin paint mixture
How to Fix It
- Reduce air pressure to HVLP-friendly levels.
- Use recommended nozzle sizes for your coating.
- Apply slow, even passes.
- Avoid spraying outdoors in wind.
- Thicken paint slightly if over-thinned.
7. Gun Not Spraying at All
Sometimes the spray gun refuses to spray—no paint flow, no atomisation.
Common Causes
- Blocked fluid passage
- Dried paint inside the gun body
- Air compressor not delivering enough CFM
- Trigger mechanism issues
- Air cap completely clogged
- Paint too thick to flow
How to Fix It
- Disassemble and clean the gun.
- Check your compressor output, especially CFM.
- Ensure the trigger moves freely and the needle retracts.
- Thin the paint if needed.
- Check air filters and hoses for blockages or leaks.
8. Leaking Paint Cup
A leaking cup creates a mess and prevents proper atomisation.
Common Causes
- Worn or damaged seals
- A cracked or warped paint cup
- Loose threads on the lid
- Clogged vent preventing pressure equalisation
How to Fix It
- Replace seals (they are inexpensive).
- Tighten the paint cup threads gently but firmly.
- Inspect for cracks and replace the cup if needed.
- Unclog the cup vent.
9. Inconsistent Spray Pressure
Inconsistent pressure results in fluctuating spray patterns, uneven coverage and frustration.
Common Causes
- Air hose leaks
- Failing compressor
- Moisture in air lines
- Dirty air filters
- Loose fittings
How to Fix It
- Inspect and tape leaking connections.
- Drain moisture traps regularly.
- Replace air filters on the compressor or spray gun.
- Tighten fittings and couplers.
10. Paint Bubbling in the Cup
Seeing bubbles inside the paint cup usually indicates an air leak.
Common Causes
- Loose fluid nozzle
- Damaged nozzle seal
- Air entering the fluid path
- Misaligned nozzle assembly
How to Fix It
- Tighten the nozzle carefully.
- Check and replace the nozzle seal.
- Make sure the gun is assembled correctly.
- Ensure no cracks exist in the fluid passage.
11. Excess Paint Consumption
When your gun starts consuming too much paint, something’s wrong.
Common Causes
- High pressure settings
- Incorrect technique
- Too much fluid flow
- Worn parts causing poor atomisation
How to Fix It
- Lower air pressure to HVLP-friendly levels.
- Use overlapping passes (50% overlap recommended).
- Reduce material flow using the adjustment knob.
- Replace worn needles or nozzles.
12. Needle Not Returning Properly
If the needle doesn’t retract smoothly after releasing the trigger, it can cause constant dripping or continuous spray.
Common Causes
- Needle packing too tight
- Dried paint restricting needle movement
- Bent needle
- Worn spring
How to Fix It
- Loosen the packing nut slightly.
- Remove and clean the needle.
- Replace bent needles.
- Install a new spring if needed.
Maintenance Tips to Keep HVLP Sprayers Working Smoothly
- Clean After Every Use — Flush with solvent, clean the air cap and brush off residue.
- Lubricate Moving Parts — A few drops of gun lube on trigger joints and springs keeps them smooth.
- Check O-Rings and Seals — Replace worn seals early to avoid leaks and pressure problems.
- Store Properly — Keep your spray gun in a dry environment and protect it from dust.
- Use Recommended Materials — Always choose the right nozzle size and viscosity for your coating.
When to Replace Parts
- Needles
- Nozzles
- Air caps
- Seals and O-rings
- Springs
- Paint cups
If your HVLP Sprayers continue to show issues even after cleaning and adjustments, replacing these parts often restores performance instantly.
Final Thoughts
Using HVLP Sprayers can dramatically improve your painting results—offering a fine finish, reduced overspray and excellent control. But when issues arise, they can lead to wasted material, frustration and poor results. Thankfully, with the solutions in this guide, you can diagnose and fix most spray gun problems quickly. Whether it's a clogged nozzle, poor spray pattern, sputtering or pressure inconsistencies, a bit of basic troubleshooting will get your HVLP system running like new. Regular cleaning, proper maintenance and understanding how your spray gun functions are the keys to ensuring long-lasting performance and professional-quality finishes every time.
