H L-O-X® Series Hydraulic Lockout Valves Operating Instructions (RC-HLOX-OI)

Overview

The ROSS Controls H L-O-X® Series Hydraulic Lockout Valves provide a reliable, manually operated hydraulic energy isolation solution for maintenance lockout/tagout (LOTO) applications. The H L-O-X® valve isolates hydraulic energy upstream of machinery during maintenance, allowing technicians to safely service hydraulic equipment without risk of unexpected actuator movement from residual hydraulic pressure.

The H L-O-X® Series uses a manual ball valve design with an X-Bore 90° ball pattern. The red handle rotates clockwise to open (valve in-line with the T1 port, free flow from inlet to outlet) and counter-clockwise to close (valve in-line with T2 port, supply blocked). The handle can be padlocked in the closed position to enforce lockout during maintenance.

Available in three port sizes — 1/2 inch (size 08), 3/4 inch (size 12), and 1-1/4 inch (size 20) — with SAE-ORB port thread and carbon steel body. An analog pressure gauge option and limit switch (OFF position) are available. The H L-O-X® valve operates at media temperatures up to 250°F (121°C) and ambient temperatures up to 160°F (71°C). ROSS Controls, founded in 1921, has over 100 years of fluid power expertise. Contact ROSS at 1-800-GET-ROSS or visit www.rosscontrols.com.

Key Features

Manual Padlockable Handle for LOTO Compliance

The H L-O-X® red handle can be padlocked in the closed position using a standard padlock through the hole (Ø 0.34 in / 8.6 mm) provided for lock-in-90° position. To service downstream equipment, turn the handle counter-clockwise to cut off the oil supply and padlock it to ensure supply is not inadvertently turned on during maintenance. This design supports compliance with OSHA 29 CFR 1910.147 energy isolation requirements.

X-Bore 90° Ball Pattern

The X-Bore 90° ball pattern provides clean, reliable shutoff with low internal leakage. Port P is the pressure inlet; Port T1 is the primary tank/outlet port (in-line with handle when open); Port T2 is the secondary tank/outlet port (in-line with handle when closed, i.e., during lockout). Port A is the actuator connection port.

High-Temperature Media Capability

The H L-O-X® handles hydraulic media temperatures up to 250°F (121°C), significantly higher than most pneumatic lockout valves. This capability is important for hydraulic systems with elevated fluid temperatures due to continuous cycling or high-load applications.

Carbon Steel Body with Nitrile (Buna-N) Seals

The carbon steel body provides excellent pressure containment for high-pressure hydraulic systems. Nitrile rubber (Buna-N) O-ring seals are compatible with mineral oil hydraulic fluids. Ball seal material is Delrin; ball and spindle material is carbon steel.

Technical Specifications

Specifications from H L-O-X® Series operating instructions (RC-HLOX-OI):

Valve Type: Manual ball valve, hydraulic lockout
Ball Pattern: X-Bore 90°
Port Sizes: 1/2 inch (Size 08); 3/4 inch (Size 12); 1-1/4 inch (Size 20)
Port Thread/Type: SAE-ORB (O-Ring Boss)
Body Material: Carbon Steel
Ball Seal Material: Delrin
Ball and Spindle Material: Carbon Steel
O-Ring Material: Nitrile Rubber (Buna-N)
Ambient Temperature: -4° to 160°F (-20° to 71°C)
Media Temperature: -4° to 250°F (-20° to 121°C)
Max Fluid Contamination Level: ISO 4406 Class 20/18/15; NAS 1638 Class 9
Flow Media: Mineral Oil HLP, HL per DIN 51524; Vegetable Oil HETG per VDMA 24568
Limit Switch Option: Available for OFF position monitoring
Pressure Measuring Device Option: Analog gauge (G)
Padlock Provision: Yes — hole for lock in 90° closed position; Ø 0.34 in (8.6 mm)
Mounting: Horizontal, 4-bolt bolt pattern per dimensional drawings

Applications

Hydraulic Energy Isolation for Lockout/Tagout (LOTO)

The H L-O-X® is an energy isolation device for hydraulic systems, as defined by OSHA 29 CFR 1910.147 (Control of Hazardous Energy) requirements. It is used to isolate hydraulic energy from machinery during maintenance, die change, and tooling changeover operations. The padlockable handle ensures that isolated energy cannot be inadvertently restored during maintenance procedures.

Maintenance Isolation on Hydraulic Presses and Machinery

Hydraulic presses, injection molding machines, die casting machines, and other hydraulic equipment that require periodic maintenance or die/mold changes use the H L-O-X® to safely isolate hydraulic energy. The three port sizes (1/2, 3/4, 1-1/4 inch) accommodate the plumbing sizes found on a wide range of industrial hydraulic equipment.

Safety and Compliance Standards

OSHA 29 CFR 1910.147 — Control of Hazardous Energy (lockout/tagout)
EN 1037 — Safety of machinery; prevention of unexpected startup
ISO 4406 — Hydraulic fluid cleanliness classification (max Class 20/18/15)
NAS 1638 — Fluid contamination classification (max Class 9)
DIN 51524 — Compatible with Mineral Oil HLP, HL hydraulic fluids
VDMA 24568 — Compatible with Vegetable Oil HETG hydraulic fluids
NOTE: H L-O-X® valves are defined as energy isolation devices — NOT emergency stop devices

Installation and Setup Guide

Mounting the H L-O-X® Valve

The H L-O-X® mounts via a 4-bolt pattern per the dimensional drawings in the operating instructions. Port dimensions and bolt patterns differ by port size (1/2, 3/4, 1-1/4 inch). Ensure the hydraulic system is depressurized before installing or removing the valve. Install the valve in an accessible location to permit operation and padlocking of the handle.

Valve Operation

VALVE OPEN: Rotate the red handle clockwise (in-line with the T1 port). Supply oil flows freely from Port P (inlet) to Port A (outlet/actuator), and flow to Port T2 (exhaust/lockout) is blocked. VALVE CLOSED (Lockout): Rotate the red handle counter-clockwise (in-line with the T2 port). Supply oil is cut off. Padlock the handle in this position to prevent inadvertent opening during maintenance.

Limit Switch Option

An optional limit switch for the OFF (closed/lockout) position is available. This switch can provide an electrical signal to the machine control system confirming that the H L-O-X® is in the locked-out position, enabling interlocked access control systems or safety PLC inputs.

Fluid Cleanliness Requirements

The hydraulic system must maintain fluid cleanliness at or better than ISO 4406 Class 20/18/15 (NAS 1638 Class 9). Contaminated hydraulic fluid can cause premature wear of the ball, seals, and other valve components. Use appropriate hydraulic filtration to maintain required cleanliness levels.

Why Choose ROSS Controls

ROSS Controls has over 100 years of fluid power expertise since 1921. The H L-O-X® Series extends ROSS's proven L-O-X® lockout technology to hydraulic applications, providing a reliable, code-compliant energy isolation solution for hydraulic systems. ROSS offers a complete range of pneumatic and hydraulic safety products. Contact ROSS at 1-800-GET-ROSS or visit www.rosscontrols.com.

Download This Document

The official H L-O-X® Series Hydraulic Lockout Valves Operating Instructions (RC-HLOX-OI) are available as a free PDF download.

PDF Download URL: https://ross-admin-global-us-east.s3.amazonaws.com/production/uploads/document_language_file/file/6826/ROSS_Hydraulic_H_L-O-X_Series_Operating_Instructions_RC-HLOX-OI_en.pdf

Frequently Asked Questions

Q: Is the H L-O-X® an emergency stop device?

A: No. Per ROSS specifications and applicable regulations, H L-O-X® valves are defined as energy isolation devices, NOT emergency stop devices. They are designed for lockout/tagout procedures, not for dynamic machine stopping during operation.

Q: What port sizes are available?

A: 1/2 inch (Size 08), 3/4 inch (Size 12), and 1-1/4 inch (Size 20), all with SAE-ORB (O-Ring Boss) port thread.

Q: How do I lock the valve in the closed position?

A: Turn the red handle counter-clockwise to cut off the oil supply, then insert a padlock through the Ø 0.34 inch (8.6 mm) hole to lock the handle in the 90° closed position. This prevents the valve from being inadvertently opened during maintenance.

Q: What is the maximum hydraulic fluid temperature?

A: Media (hydraulic fluid) temperature: -4° to 250°F (-20° to 121°C). Ambient temperature: -4° to 160°F (-20° to 71°C).

Q: What hydraulic fluids are compatible?

A: Mineral Oil HLP and HL per DIN 51524, and Vegetable Oil HETG per VDMA 24568. The fluid must be compatible with Nitrile Rubber (Buna-N) O-ring material.

Q: What is the maximum allowable fluid contamination level?

A: ISO 4406 Class 20/18/15 (equivalent to NAS 1638 Class 9). Maintain appropriate hydraulic filtration to achieve these cleanliness levels.

Q: Is a pressure gauge available?

A: Yes. An analog pressure gauge option (code "G") is available in the product key identification. The gauge monitors supply pressure at the valve.

Q: Is a limit switch available for the locked position?

A: Yes. A limit switch for the OFF (closed/locked) position is an available option, providing an electrical signal to the machine control system confirming that the valve is in the lockout position.

Q: What body material is used?

A: Carbon steel body with Nitrile Rubber (Buna-N) O-ring seals, Delrin ball seals, and carbon steel ball and spindle.