27/01/2026

Sagola 4600 HEX Setup Guide: Pro Workflow, Settings & Buying Guide

Practical Guide

Setting up Sagola 4600 HEX correctly: Reference values, Workflow & Buying Guide

If you want to work cleanly, evenly, and material-efficiently with basecoat or clearcoat, the gun setting determines the result. In this guide, you will get field-tested reference values (pressure, distance, air cap), a 7-step professional workflow, typical fault patterns including fixes – and matching shop links for the 4600 DFT variants.

Refinish / Automotive Basecoat & Clearcoat Manual Reference Values

Product image: Sagola 4600 (DFT/HEX)

Why HEX (and why settings matter so much)

HEX technology is designed for particularly controlled pre-atomization: the goal is a calm, flat spray pattern and uniform droplet distribution – especially when you have to work with higher material flow or want to lay "critical" metallic tones cleanly. Still, the decisive factor remains: pressure, air cap, viscosity, and distance must match, otherwise mottling, dry application, or unnecessary overspray will occur.

Product Overview: Variants, Applications, Advantages (Table)

Variant / Air Cap	Typical Application	Recommended Nozzle Sizes	Key Advantage
DVR BASE	Water- & solvent-based basecoats	1.20 / 1.20 XL / 1.30	Uniform metallic orientation, controlled application
DVR HVLP	Basecoats + special coatings (HVLP setup)	1.20 / 1.20 XL / 1.30	Reduced overspray, high air volume approach
DVR CLEAR	HS/UHS Clearcoats + single-stage paints	1.20 / 1.20 XL / 1.30	Fine atomization for gloss & flow
DVR CLEAR PRO	Express-drying clearcoats (High Gloss)	1.20 / 1.20 XL / 1.30	Fast & high gloss – when timing counts

Note: Nozzle sizes & air caps depend on the material and the desired flow rate. Use these specifications as a guide and always check with the paint manufacturer.

KPI 1

> 65% Transfer

High efficiency with a clean spray pattern – Goal: less mist, more paint on the part.

KPI 2

468 g (without cup)

Less fatigue during spot repair & full resprays – especially during long clearcoat sessions.

KPI 3

1.4–2.2 bar (Reference)

Recommended working pressure range as a starting point – fine-tuning based on results (flow/coverage/overspray).

Pro Tip (quickly visible in the spray pattern): Start with the product regulator fully open (without removing it) and work the material flow up from "too slow" – until the desired amount is reached. This minimizes unnecessary wear on the nozzle/needle and gives you a maximum usable fan width.

Recommended Basic Settings (derived from manual – reference values)

Parameter	Reference / Starting Point	Why it's important
Recommended Working Pressure	1.4–2.2 bar (starting range)	Too high = more mist, less efficiency; too low = coarse/"grainy".
HVLP Working Pressure (Inlet)	1.8 bar (HVLP reference)	HVLP should not be "overdriven" – otherwise overspray increases and transfer decreases.
Factory Setting / Performance Start	2.0 bar inlet pressure	Good reference point for most applications – then adjust to the material.
Spray Distance (EPA)	15–20 cm	Stable fan, good efficiency with controlled mist.
Spray Distance (HVLP)	12–15 cm	HVLP works closer to the object to improve transfer.
Max. Inlet Pressure (Safety)	4 bar (do not exceed)	Protects people, material, and result – more pressure doesn't make it "better".

Note on pressure measurement: Hose length & air supply affect the real pressure. As a guide, a noticeable drop can occur over long lines – therefore, set the regulator so that the result is correct at the setup (not just "at the compressor").

Pro Workflow (7 Steps)

Ensure Clean Compressed Air: Filter out oil/silicone/aerosols and solid particles – clean air is the basis for constant atomization.
Prepare Material: Mix according to the paint data sheet, filter it, and adjust viscosity accordingly (base/clear depending on system).
Open Main Regulators: Fully open the fan control and product regulator (without removing them), then "dial down" cleanly from there.
Set Pressure as Reference: Start in the range of 1.4–2.2 bar (HVLP: 1.8 bar) and check with a spray test.
Adjust Fan: Align air cap openings, set fan width via the fan control (wide for surfaces, rounder for edges/spot).
Fine-tune Material Volume: Slowly open the product regulator until the desired amount is reached; for narrow areas, "dose" via the trigger.
Keep Distance & Speed Stable: EPA typ. 15–20 cm, HVLP 12–15 cm. Too slow = too thick; too fast = too dry/thin.

Troubleshooting (4 typical problems + quick actions)

1) Material bubbling in the cup

Check the nozzle/seat and tighten it.
Clean the seat on the nozzle body; replace if damaged.

2) Not atomizing (no spray pattern)

Material present? Air pressure present and sufficient?
Material too thick: thin it; open/adjust product regulator.
Lines/nozzle: clean them.

3) Intermittent spray (spitting/interrupting)

Refill material; always filter (avoid impurities).
Tighten the nozzle; replace in case of cracks or a defective needle seal.

4) Atomization "not correct" (coarse, mottled, uneven)

Clean the air cap; harmonize air pressure/volume/viscosity.
Readjust the fan opening; check product for foreign bodies and filter.

Maintenance: 5 points to keep the gun "like new"

Clean after every job: Clean the gun and cup with a suitable solvent; no hard/metallic objects on precision holes.
Check product filter: Clean or replace the filter depending on contamination – clogged filters cause poor application.
Treat air cap gently: Deformations at the air outlet worsen atomization – soak, blow out, and clean carefully if necessary.
Don't forget lubrication: Lightly grease threads/friction zones after cleaning (use silicone-free lubricants).
Use original parts: Interchangeability and function remain stable; replace seals/needle/nozzle in good time if leaks occur.

Video (Practical Insight)

If you prefer to see the 4600 in action "live", watch the video:

▶️ Watch on YouTube: Sagola 4600 in use

FAQ (practice-relevant)

1) What pressure is best to start with?

Start in the recommended range of 1.4–2.2 bar. For HVLP, start with 1.8 bar. Then fine-tune via spray test.

2) Why is the result "dry" or the layer too thin?

Often the air pressure is too high in relation to the material volume. Reduce pressure, increase material volume, or adjust viscosity.

3) Why does the paint sag or run off?

Usually too much material with too little control or incorrect speed. Reduce material volume, check viscosity, and move more steadily/faster.

4) Do I really always have to filter?

Yes – foreign bodies are one of the most common reasons for interruptions, poor spray patterns, and clogged nozzles/filters.

5) How do I know when the seal/needle/nozzle are due for replacement?

Leaks, an unsteady spray despite a clean air cap, "spitting," or the needle not closing indicate wear or contamination.

CTA: Buy matching Sagola 4600 DFT/HEX variants directly

Choose the variant suitable for your application (Base/Clear/Express-Clear/HVLP) or complete your nozzle set for reproducible results.

4600 DFT Basis – 1.20 HEX 4600 DFT Clear Pro – 1.20 HEX 4600 DFT Clear – 1.20 HEX Alternative: 3600 XPT Basis – 1.20 1.20 HEX Needle/Nozzle Set

Conclusion

The Sagola 4600 HEX plays to its strengths when you view it as a system: clean air, filtered material, matching air cap, stable distance – and pressure only as high as necessary. Start with the reference values, optimize via spray test, and consistently follow cleaning + lubrication – then you will reproducibly get a calm spray pattern, clean metallic orientation, and clear brilliance with clearcoat.