Cover story

Fendt thought in detail

Whenever the name Fendt is mentioned to farmers and
agricultural contractors, you're likely to hear terms like
'high-tech', 'comfort' or 'those tractors may not be cheap,
but they are quite simply the best'. That is of course due in
part to the continuously variable Vario transmission, to the
powerful engines in conjunction with SCR technology and
the modern operating concept Variotronic. However, the
true cutting-edge quality of products only really becomes
apparent when you take a closer look. You see, it's the
details that make all the difference.
The search for specialist solutions is what motivates
the people who work in R&D at Fendt. The result: Pre-
mium tractors with exceptional detailed solutions.
Even with the latest series, the Fendt 500 Vario! If you
read on, you will learn details that you certainly
won't have heard before. The 'tractor fathers' work
out of Fendt research and development buildings in
Marktoberdorf where they are spread over 5 floors.
Just last year, a second building was added because
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withstand humidity and dust." The 500 Vario has a
convex windscreen. The challenge lay in designing a
roller blind which followed the windscreen's curves,
covered the entire area and didn't simply hang
down. There is no such design on the market, noth-
ing in the bus or HGV sector. This shape required a
telescope to be integrated in the roller blind, which
could adapt to the different widths and contours of
the windscreen. And it also has to be continuously
adjustable in one smooth movement. "To make
the roller blind stay still in every position was a real
development challenge", says Wagner. "To begin
with, it stayed in one position for 14 days, then it was
rolled up. Then we made notches in the rods. This
still didn't solve the problem though. In the end we
reworked a totally new design: looks primitive from
the outside, but entails a lot of engineering work for
us. Our engineer, Gnther Henning, was undeterred
and put the roller blind on the right track!" It should
also completely disappear in the cab roof lining, to
offer a genuinely unobstructed view.
Unique: no more bleed oil container
"They became known as the pee bottles", laughs
Wagner, referring to the old bleed oil containers.
Tractors have traditionally had these plastic contain-
ers to catch dripping oil whenever the customer con-
nects or disconnects something. The containers fill
up with oil and water and require regular emptying.
"With the 500 Vario, the customer won't find any
more catchment containers. The bleed oil is led
away through houses to the cavity already present in
the lift arm. This is an ingenious way of using 'dead'
chassis space. Our studies show that several thou-
sand operating hours are required before the lift arm
is full and needs emptying", says Wagner. The area
where the plastic container used to be is now used
for other purposes and the customer enjoys less
each and every one of the 400 employees in the R&D
department needs to have enough room. Room for
ideas. Breathing space for new ideas.
Project manager Walter Wagner had a key role to
play in developing the 500 Vario range. Together
with his colleague, Christoph Mayer, 500 Vario Pro-
ject coordinator, a development history saw the light
of day, as thick as 'War and Peace'. But this time we
are more interested in these small, yet extraordinary,
details, such as the sun blind.
"The roller blind drove us crazy".
"The roller blind, a novelty in tractors, just about dro-
ve us crazy", says Wagner, describing the develop-
ment process. "With the VisioPlus, we created a pan-
oramic cab, with the opportunity for a standard
shade solution. Our roller blind might look simple,
but it isn't. It needs to be able to contend with ambi-
ent temperatures of -20 C and +40 C. And also to
(from left) Product manager Walter Wagner with
Karl Schner, 500 Vario product fitter and Christoph Mayer,
500 Vario project coordinator.
Looks simple enough, but required a lot of work: The new
roller blind is perfectly adapted to the convex front
windscreen.
WALTER WAGNER
A FENDT DEVELOPMENT PROCEDURE
The development of a new vehicle takes
us about three years. We manufacture
the initial prototypes and this takes us
at least 14 months to complete. Then
we receive the first feedback from test
drivers and make improvements in the
next construction phase. That takes
about a year. Then prototype series II
goes to pre-series another year goes
by. Continuous improvements are made
in all these steps.
We then ensure that our test vehicles
get driven for about 20,000 operating
hours. This also includes testing in hot
countries: Test vehicles are driven in
temperatures of 40 C in the shade in
southern Italy, including up gradients
of over 50%. Test tractors are also driven
in an Alpine winter environment.
FENDT 500 VARIO
- Large vlsloPlus cab
- Lrgonomlcs ln thelr purest form for
the driver's workplace
- 8rllllant operatlng concept from large
Fendt tractors
- New varlo termlnal - operated by
touch and using the control element
with keypad
- Preclse and rellable Pendt varloGulde
tracking
- Pour-cyllnder englne wlth 4.04 lltre
swept volume (cubic cc) and common
rail fuel injection: 165 hp maximum
power at 1800 rpm
- Compllant wlth exhaust emlsslons
level 3b and optimum fuel economy
- System TMS and automatlc maxlmum
output control as standard specifica-
tion items
- 50 km/h transport speed at reduced
engine speed
- SCP technology
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maintenance expense. "The integrated lift construc-
tion is 100% Fendt and is the brainchild of engineer,
Gottlieb Wlfle. This is an attractive and intelligent
vehicle solution," explains Walter Wagner proudly.
The best cables, the most elegant routing
"In order to maintain the compactness of a vehicle
like the 500 Vario, we need to utilise every little
space. For instance, if we need to locate a larger
hydraulic oil tank for customers, pipes need to be
routed efficiently and securely", says Wagner, empha-
sising the quality requirement. Cable and pipe rout-
ing is very carefully planned and assembled in coop-
eration with electronics, hydraulics and the vehicle
concept. "The customer doesn't see these clean
solutions, but they mean the tractor can carry on
operating, trouble-free", says Christoph Mayer, con-
firming the extra investment. "The cable harnesses
are designed in-house and then routed like a hard
pipe. Even the brackets, or the fixing points, are co-
designed here. No cable ties allowed!" Here at Fendt,
'Routing' teams, comprising electricians, hydraulics
specialists, engine or transmission experts work
together to integrate all components into one sys-
tem.
And even the cables used at Fendt are very high
quality. They can withstand changing temperatures,
are UV-resistant and offer excellent mechanical prop-
erties. The cable harnesses are specially designed:
The cables don't chafe against each other because
they are strapped together again in the channels and
are subject to continuous testing. This is precisely
the level of quality Fendt puts into its tractors. The
customer perceives this through the durability and
dependability of the tractor.
"Just some of the components we use are gold con-
tacts and cable locks, which interlock mechanically.
All plug connections and electronic components are
also extremely resistant to spray", continues Mayer.
"Our Bosch hydraulic valves stand out from competi-
tion valves even if they have the same name.
Because, in collaboration with the supplier, ours
come with fixtures for temperature variation a spe-
cial design, an extra feature for Fendt. These extras
naturally cost us more, but we feel this is worth it
because they offer the customer genuine added val-
ue." And not least because they also have an impact
on the resale value of a Fendt, of course.
More room, more visibility and more safety
the VisioPlus cab
The cab is the icing on the cake of the 500 Vario.
What looks easy and light now was actually a lot of
hard work. "An engineer but the first trim panels are
installed within a week", says engineer Mayer,
describing the work process. "And then the real work
begins: Overhauling the space, designing the fea-
tures in the cab that takes up 80% of the time. You
sit in the prototypes and think, 'Yes, this cab is very
well put together indeed'. But you accept nothing
less than the best and gain 10 mm here, 2cm there.
That makes all the difference afterwards!"
In order to achieve the best possible construction, an
expert group of experienced, but also critical, cus-
tomers were invited to inspect the prototypes. Then
the cab was widened by 4 cm. Four centimetres?
"That makes all the difference in the world for a cab!",
says Wagner, endorsing his colleague Mayer. "Lower-
ing the floor by 2 cm gives you a completely new
sense of space. This can't be seen on the PC, you
need to build a model and have someone sit in it and
evaluate it, make more adjustments and evaluate
again. We go to immensely great lengths to squeeze
the last ounce out of a construction. This costs time
and nervous energy but the end result is worth it
because it's the little things, the details, which count!
Now you sit in it and instead of thinking 'it's OK', you
really do get that 'Wow!' experience.
The designers also worked hard on the lining. A
range of details give the driver that comfortable feel-
At Fendt, cable routing teams work on optimised
component matching. This also creates assembly room
for components. Cables and pipes are laid cleanly,
efficiently and are protected.
Precision-fit lining and soft-
touch surface contribute to
the feeling of comfort in the
VisioPlus cab.
Integrated hydraulic
bleed oil container
Perfectly matched
components: gradual pipe
routing on the hydraulic
oil tank
Clean cable harness
routing with integrated
fxing points
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ing: Inside mirror, coat hook and drink holder and
various storage compartments. All with a wonderful
soft-touch surface. "Nothing rattles, all the lining
meets perfectly, without any gaps", explains Wagner.
"This high-quality equipment is important for cus-
tomers, this is what they expect from a Fendt. So we
haven't only put quality under the bonnet, but also
where the customer notices it everyday. The looks
are standard in an HGV, but tuning for a farm vehicle,
e.g. with rubber surfaces for farming requirements.
The cab is not only attractive, but also safe. It is one
of the few on the market to pass the FOPS test. This
involves freezing the cab roof to -20 C and dropping
a 40 kg steel ball from a height of 3 m onto the roof.
The ball mustn't go through the roof. This means
that the driver is always in a safe environment when
doing forest or front loading work.
"Another ingenious idea we have also implemented
on the 700 Vario, are the squinting work lights", says
Wagner, referring to the next highlight. There used
to be a blind spot on the right-hand side through the
exhaust. "We didn't find any satisfactory solution
with the standard headlight arrangement and simply
redesigned everything. We started out with reflec-
tions at the crossover point, which we were able to
remedy after several test hours." Now the driver
enjoys an optimum, undisturbed field of vision, even
at night. The windscreen was also optimised, remov-
ing any reflections even when it rains or snows.
"On the 500 Vario, we also have the 'coming home'
light", explains Mayer. As is standard in cars, the
headlights and cab light stay on for an extra half a
minute to allow the driver to exit the cab easily and
leave the tractor safely. This is particularly helpful in
an agricultural setting where otherwise there is no
other light source. As simple as it is unusual.
Compact and highly manoeuvrable.
Christoph Mayer places great emphasis on manoeu-
vrability. Therefore, under his project coordination,
a lot of work was done on the lock-to-lock wheel
action. "For example, we significantly amended the
frame width at the front of the 500 Vario to optimise
it for the steering angle", says Mayer. "These are
details on the bonnet, enabling us to recover 2 to
3 steering angle. This makes the turning circle 40
60 centimetres smaller. We want a compact four-
cylinder, which is also extremely mobile, enthuses
Christoph Mayer on the outcome in iron and steel
form.

Nothing can come from nothing the claim and
motivation at Fendt
"We have a highly motivated team at Fendt. And
we have genuinely healthy competition amongst
employees," says Walter Wagner, describing the
working atmosphere. Colleagues from all depart-
ments work on every new project right from day one,
so that everyone can follow everyone else's develop-
ment phases. "But everyone has a point to prove",
smiles Wagner. "The hydraulics engineer wants to
shine in front of an electrician and vice versa. This
drives the team on and leads to new ideas. As pro-
ject manager, I'm proud of my team and appreciate
my highly committed colleagues!"
Customer demands, ambition, achieving engineer-
ing work and feeling proud of our tractors are all
sources of motivation, driving us on to find new
detailed solutions to make the next Fendt even bet-
ter. Therefore:
More to follow
The500Variois not merelyasmart, compact tractor.
Thehigh-qualitydetailedsolutions canalsobefoundunder thebonnet.
Steering angle of 52 on the front axle ensures maximum mobility. Here, every last centimetre has been used: The VisioPlus cab
leaves the driver with a generous sensation of space.
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