Full 5 tons of payload: How your diesel transporter maintains its strength after electrification
Your 5-ton diesel transporter is the backbone of your operation, but rising costs and emission regulations require a new solution. Electrification must not come at the expense of payload. Discover how to maintain the full capacity of 5 tons in a diesel transporter after electrification while reducing operating costs by up to 70%.
The topic briefly and concisely
The HEERO D2E conversion allows you to retain the full 5-ton approval and payload capacity of a diesel transporter after electrification.
By continuing to use chassis and expensive special constructions, significant costs are saved compared to purchasing a new electric special vehicle.
The retrofitting reduces operating costs through lower energy consumption and up to 90% fewer maintenance-intensive parts in the drivetrain.
For many companies, especially in logistics, crafts, or the municipal sector, a van with a 5-ton permissible total weight is indispensable. The switch to electromobility is often associated with concerns about payload loss, as batteries cause a significant additional weight. Standard e-vans from the factory quickly reach their limits here. Heero offers a technologically leading solution with the patented D2E conversion, which makes it possible to maintain the full load capacity of your proven Mercedes-Benz Sprinter and prepare it for an emission-free future. This not only protects your investment in expensive special structures but also sustainably optimizes your total cost of ownership (TCO).
The Payload Trap: Why Standard E-Transporters Often Fail
The electrification of a fleet often begins with a sobering realization: the additional weight of the battery significantly reduces the available payload. A standard electric transporter often weighs several hundred kilograms more than its diesel counterpart. For businesses that rely on every kilogram of payload capacity, this means a direct loss of efficiency and profitability. Many overlook that a reduction in payload of just 200 kg can lead to hundreds of additional trips over the course of a year. This challenge becomes particularly critical for vehicles with a permissible total weight of 5 tons, where the balance between range and payload capacity is crucial. The analysis of total cost of ownership shows that a vehicle that no longer fully meets its transport task quickly becomes unprofitable. The technological basis of many series electric vehicles is not designed to meet the high demands of special bodies with a 5-ton approval.
Technological advantage: Achieving the 5-ton goal through D2E conversion
To maintain the full 5 tons in a diesel van after electrification, a more intelligent approach than simply replacing components is required. Heero's patented D2E conversion (Diesel-to-Electric) is a system solution specifically developed for the Mercedes-Benz Sprinter. We remove the entire combustion engine drivetrain with over 1,000 moving parts and replace it with a highly efficient electric drive with only about 100 parts. This not only drastically reduces future maintenance efforts but also creates the necessary space for optimal weight distribution of the battery modules. The result is a vehicle that retains its original payload and the 5-ton rating completely. The efficiency of the electric motor is up to 94%, compared to a maximum of 35% for diesel. This technological superiority ensures the performance of your fleet for years to come.
Protecting special structures: An investment that pays off
Companies often invest six-figure sums in customized builds – from refrigerated containers to workshop facilities and lift platforms. Purchasing a new e-van would mean giving up these valuable and proven builds. Retrofitting is the most economically sensible alternative here. It allows the continued operation of vehicles that are perfectly tailored to their task. A refrigerated vehicle based on a Sprinter can thus retain its expensive insulation and cooling technology while becoming zero-emission. The advantages of retrofitting are:
Investment protection: The value of your specialized build is fully retained.
No compromises: The functionality and ergonomics of the proven vehicle do not change.
Sustainability: By continuing to use the chassis, tons of CO2 and resources are saved that would be incurred in the production of a new vehicle.
Economic efficiency: The costs for retrofitting are significantly lower than those for a comparable new electric special vehicle.
This approach to the circular economy is not only ecological but also economically superior.
Legal framework conditions: More than just the 4.25-ton rule
To promote electromobility, the legislator has created a special regulation: With a class B driver's license, alternatively powered transporters up to 4.25 tons may be driven. This regulation is intended to compensate for the weight disadvantage of the battery. For genuine 5-ton vehicles, however, this regulation is irrelevant and does not solve the basic payload issue. A vehicle licensed for 5 tons requires a C1 driving license anyway. The conversion by Heero ensures that your vehicle retains its original homologation as a 5-tonner and meets all legal requirements. We take care of the complete technical inspection and re-registration. This way, you can be sure that your converted Sprinter is not only powerful but also 100% compliant.
Practical examples: How municipalities and logistics providers benefit
The challenge of finding suitable electric vehicles for specific municipal tasks is significant. Many cities and municipalities are therefore relying on the conversion of their proven fleets. A flatbed truck for horticulture and landscaping retains its full load capacity for bulk materials and tools after conversion. Logistics companies that transport furniture or other heavy goods can continue to use their box-type transporters without having to compromise on payload. These examples show:
Municipal operations: Waste collection vehicles or green space authority transporters remain in use without restrictions.
Crafts: Service vehicles with heavy shelving systems do not lose any payload.
Logistics: Delivery vehicles for urban areas meet the requirements of environmental zones and maintain their efficiency.
Construction industry: Tippers and flatbed trucks continue to transport the maximum amount of materials.
The D2E conversion is a proven solution that makes the transition to electric mobility manageable and economical.
Conclusion: Your advantage with HEERO
The electrification of your 5-ton transporter fleet does not have to mean a compromise in payload. With the Heero D2E conversion, you ensure the full performance of your vehicles and benefit from the advantages of electromobility. You protect your investments in expensive special equipment, reduce your operating costs, and position your company as a pioneer in sustainable business practices. Heero is your innovative partner, offering you a pragmatic and technologically leading solution. Experience the future of commercial vehicle electrification without compromise. Request your personal consultation now or book a free everyday test.
More useful links
Statista provides a statistic about the number of trucks with alternative drives in Germany.
The Federal Motor Transport Authority provides monthly new registrations of vehicles in Germany.
The Federal Office for Logistics and Mobility offers information on the funding program for climate protection and mobility (KSNI).
The Federal Environment Agency informs about climate protection in transport.
The Federal Ministry for Economic Affairs and Climate Action offers a dossier on the topic of electromobility.
The TÜV Association provides press releases, including the TÜV Report 2025 for electric cars.
The Fraunhofer ISI provides information on the topic of energy systems and electromobility.
FAQ
How long does it take to convert a 5-ton Sprinter?
The entire D2E conversion process for a Mercedes-Benz Sprinter usually takes only 10 working days. During this time, the entire drivetrain is replaced, and the vehicle is reconfigured and approved for electric operation.
What range does a 5-ton van converted by Heero have?
The range is individually tailored to your requirements. Depending on the configuration of the battery modules, practical ranges of up to 425 kilometers are possible without compromising payload.
Can any Mercedes-Benz Sprinter be converted?
Our patented D2E solution is available for a wide variety of Mercedes-Benz Sprinter models. Contact us for free advice to check the compatibility of your specific vehicle or fleet.
Are there any government subsidies for the conversion?
Yes, the conversion of commercial vehicles to electric drive is supported in Germany by various programs. We are happy to advise you on the current funding opportunities and assist you with the application process.
What happens to the old diesel engine?
In the spirit of the circular economy, the removed diesel engines and components are professionally reconditioned and supplied to the spare parts market. This extends the life cycle of the parts and avoids waste.
How can I test the Heero solution?
We offer you the opportunity to experience our technology up close. Simply book a 'everyday test free of charge' and see for yourself the performance and practicality of our converted E-vans.
