Wagner flexio 590 has flaw leak

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1. how is it great and thumbs down afterwards? makes no sense!
2. Had the same issue. It wasn't tightened properly against the red washer. The tip has to be tightened separately from the adjuster. If not, it will do exactly as you described.
3. unless there's a broken part, the nozzle might not be seated back far enough.  I've not had an issue with either of those two sprayers leaking.  I found that it helps to pull the trigger back when re-assembling so the pin does cause resistance to the nozzle when you're trying to screw the outer ring on.  The outer ring is what holds the nozzle in place.
4. This is probably a stupid question, but did you put the red seal in properly? I have one and I have not had this happen to me yet. I did get some big globs and spitting towards the end of my job. I think I'm gonna try thinning the paint a little. Also clean it when it starts spitting a bit. Sorry for your bad experience 
5. I just used this sprayer for the first time today. I went through the first bit of paint and after I refilled the reservoir it started spraying globs of paint instead of the nice fine mist it sprayed at first. When I released the trigger it started doing the same as in the video. After cooling down from the frustration I cleaned everything and made sure everything was set up right. No more globs. It seems I'm going to have to do some minor cleaning every other filling now that I have an idea about how to set it up. As for the leak like in the video, I found that if you turn the air off with the sprayer tilted up and then loosen the reservoir a half turn and pull the trigger it will release the pressure and not do this. I've painted half of my house with this today and will hit the other half tomorrow. If anything changes I'll post a new comment.