Charging batteries and changing gas cylinders safely

In practice, a diesel truck cannot be used indoors: the limit value for diesel exhaust particles (measured as elemental carbon, EC) was tightened to 5 µg/m³ as of 1 January 2025, and this cannot be met without very powerful ventilation. Gas (LPG) requires ventilation indoors; electric (lead-acid/Li-ion) and hydrogen are suitable indoors.

When a lead-acid battery is charged, hydrogen is given off and oxyhydrogen gas forms, which is explosive. So only charge in a marked, well-ventilated charging zone with sufficient air exchange, and keep naked flames, sparks and smoking away. Always follow the supplier's instructions on ventilation and fire prevention.

Oxyhydrogen gas is odourless and explosive — ventilation is not negotiable with lead-acid batteries.

Lead-acid batteries require regular checking and topping up with distilled water as well as cleaning. Battery acid is corrosive: wear safety goggles and gloves, and handle heavy batteries with correct lifting equipment. Check the battery case, cells and connectors for damage and leakage during the daily inspection.

Li-ion batteries do not give off gases during charging, so the same statutory requirements for a ventilated charging room as with lead-acid do not apply. They can be opportunity-charged during short breaks (e.g. 15–30 min) without damage, which suits multi-shift operation. The charging location must still be approved according to local fire conditions, however, and a BMS protects against overheating.

When changing an LPG cylinder: drive the truck to a safe, ventilated place outdoors or with good ventilation, switch off the engine, and remove ignition sources (no smoking or naked flames). Close the valve on the empty cylinder fully before you disconnect anything.

Disconnect the coupling from the empty cylinder, remove it and fit the new one. The gas cylinder must be clamped/secured so it cannot move or tip over while driving. Check that the seal/O-ring in the coupling is intact before you connect.

Inspect the gas hose every time you change cylinder, and at least once a year. If the hose is worn, brittle or cracked, it must be replaced. Connect the coupling correctly and tighten it as instructed — a loose or damaged hose is a source of leaks.

Open the valve slowly and check all joints for leaks with soapy water or leak detection spray: bubbles = leak. Close the valve immediately if you find one, fix the leak, and try again. Never use a flame to search for a gas leak. If everything is tight, the truck is ready for use.

Bubbles = shut off. Never look for a gas leak with a match.