Lely Welger RP 415

415Lely Welger RP415


Round balers with variable chambers are used under varying circumstances and therefore the demands that are made on these machines also differ widely.



The Lely Welger RP 415 range features perfect specifications for use in silage hay and straw when there is no need to chop the crop. The feed rotor and wide pick-up have been designed for easy processing of wide swaths while the proven CPS ensures optimum bale density. The best indication for the outstanding quality and sustainability of these balers can be found in the name… Lely Welger!


Wide pick-up – Large swaths

The RP 415 model has a 2.25 m wide free running pick-up with five tine bars. Pick-up capacity is huge; the long 5.60 mm tines have large coils and are therefore ideal to retrieve the crop from high stubble. Due to their great flexibility, the tines can easily adjust to uneven ground contours, thus eliminating contamination. Suspension of the pick-up is adjustable and perfect ground contour following is ensured in combination with the height chains and pick-up wheels.


Good crop intake – Optimum results

An even and constant crop flow is of paramount importance to good output and bale shape. Especially with balers with a wide pick-up a good feed system means the difference between a smooth, continued operation and “jerking and jolting” feeding of the crop. Due to the two transport augers, the crop that is collected on the outside of the pick-up is effortlessly conveyed to the 1.25 m wide entrance of the baler. Thus, the outer layers of the bale are even and compact.


Large feed rotor – Maximum throughput

The Welger RP 415 model features a 500 mm diameter feed rotor with large tines. Due to the diameter of the rotor shaft, the opening to the bale chamber is maximal, which ensures a tremendous flow. Power requirements remain low thanks to the low resistance in the feed channel.


CPS – Best bales, highest speed

For round balers, the start of the bale is crucial in terms of bale shape and output. The mechanical part of the CPS ensures flexibility for the belts, making the starting of a bale smooth and easy. Especially in crops such as hay and straw this ensures a huge increase of output.

As soon as the bale has a core formed, the hydraulic CPS mechanism is engaged and due to the well designed geometry of the tensioning device for the belts, a highly consistent bale density is ensured thanks to the increasing pressure exerted by the belts. Thus, correct bale formation is ensured since baling density remains constant even up to the maximum diameter. The hard outer layer eliminates any loss of quality due to weathering and rain being absorbed.


Four endless belts – Endless trust

The four belts of the baler are constructed from five cord plies, alternated with rubber intermediate layers with strongly staggering connections of the layers. Result: a supple yet outstandingly strong belt that hardly stretches and contains no joiners. All in all: endless baling without replacement or repair.


Variable bales – Easy to control

Baling density can be read from a clearly visible pressure gauge. Bale density can be controlled manually by means of a control block on the machine. In addition, the operator always has a clear view of the bale diameter. A light indicates whether or not the tail gate is locked.


Balercontrol E

As soon as the pre-set bale diameter has been reached, the BCE sends a signal to the operator after which tying (net, Combi or twine) is started either automatically or manually. BCE also shows the number of bales per day as well as the total number of bales.


Easy manual adjustment

The settings for bale size, bale density and net length are easily adjusted on the machine. Clear visible indicators show the density and the increasing bale size. A light indicates whether the tailgate is locked or not.


As standard, the Lely Welger RP 415 model comes with:

• 2.25 m free running pick-up.
• 500 mm diameter feed rotor.
• Varionet net tying system.
• Balercontrol E.
• Automatic chain lubrication.
• Pick-up wheels.


ADS – Extra power for heavy crops

To be able to convey additional power to the belts, the RP 415 models can be fitted with the ADS (Additional Drive System) feature. The additional drive make the baler more suited to silage operations.


New pick-up for modern baler

The new free running pick-up of Lely Welger RP balers has been designed as a result of the increased output from these machines. Improved crop throughput to the bale chamber has eliminated the need for the specific movement of a conventional pick-up. With no cam track the pick-up consists of fewer moving parts. It is more reliable, less sensitive to wear quiet and maintenance free.


More tine bars – cleaner pick-up

Due to the additional space created through the absence of a cam track and cam followers, 5 tine bars are now fitted to the pick-up. Along with the 64 mm interspace of the tines this allows a 25% increase in pick-up capacity resulting in an even better and cleaner pick-up of the crop.


New pick-up – new tines

The tines are the most crucial parts of a pick-up and therefore a completely new tine has been developed for this pick-up.

  • The angle of the tine has been adjusted to ensure the cleanest possible pick-up under all conditions.
  • The longer tine is more flexible and featuresi mproved adaptation possibilities.
  • The tine is made of material with a 5.60 mm thickness, which favours tine life. Due to the larger coil, the tine remains flexible.
  • Improved tine fixation prevents tine breakage as the tension within the material is more evenly spread.


Closer to the rotor – improved crop throughput

Due to the more compact construction the new pick-up is closer to the rotor. Consequently the rotor removes the crop from the pick-up easier ensuring improved crop flow, especially with awkward, short material, this is transported to the bale chamber far more efficiently. Improved crop flow means a better bale shape, plus increased output.


Wear-resistant and maintenance-free

Since the new free running pick-up does not have a cam track, the pick-up unit consists of fewer moving parts. It is more reliable, less sensitive to wear, quiet and maintenance-free.


Numerous benefits

  • The new camless free running pick-up by Lely:
  • Boasts high capacity thanks to good crop flow.
  • Power saving due to not having cam followers.
  • Has fewer moving parts because there is no need for a cam track.
  • Is maintenance-free because the components need no lubrication.



Crop press roller

The crop press roller assists the pick-up when handling a smaller crop volume, ensuring efficient flow due to its rotation. The roller is also improving bale shape by evening out large quantities of crop without creating lumps. This roller is a quality and output increasing factor at all times.



• Castor wheels for pick-up.
• ADS – Additional Drive System.
• Vario twine tying system.
• Variotwine and Varionet Combi tying.
• Drive shaft with shear bolt.
• Drive shaft with cam clutch.
• Bale discharge ramp.


Chopping System

Chopping silage improves your results in many ways

Lely Welger offer many options when choosing a chopping system for your baler. Initially this may seem like an additional investment but chopping the crop will help improve the quality of your forage and thereby your results in so many ways that you actually need more reasons not to choose one.


Xtracut – extra output and additional comfort

To ensure optimum performance when chopping, Lely Welger have designed the Xtracut17 and Xtracut25 chopping mechanisms with selectable knife banks. The operator can select from the E-link control box in the cab various knife bank selections when baling different crops, which is ideal for contractors. Both machines have two sets of knife banks that are hydraulically protected. So on the Xtracut17 you have an option of not chopping, or 8 or 9 or 17 knives engaged. On the Profi you have a choice of not chopping, or 12 or 13 or 25 knives engaged.


Chopping length’s that can be easily adjusted

From the tractor cab the operator can – via the E-link control – easily adjust the chopping length required by using both knife banks at the same time, or disengaging one. For the Xtracut25 this means a chopping length of 45 mm when all knives are engaged, or 90 mm when using 12 knives. Otherwise both groups can also be disengaged.


Always sharp knives

Timely changing of knives ensures a proper chopping action, reduced fuel consumption and also eliminates excessive wear of knives. The Xtracut option offers flexibility to the operator using one bank of knives. When necessary the second bank of knives can be engaged in one simple operation from the tractor cab ensuring continuing high output with a new sharp set of knives.


Chopping for higher density bales

Chopped hay, straw and silage crops are much easier to bale due to the reduced length and elasticity of the forage. This ensures heavy dense bales are produced leading to a reduction in handling, transport and twine/net tying costs.


Chopping to improve feed intake

Silage that has been harvested will ferment much better due to the sugars in the crop being readily available. This results in tastier fodder, which has a positive effect on the roughage intake of animals. In addition, short crops are generally digested better.


Chopping saves time through easier distribution at feeding time

Chopping the crop will avoid the build up of material and prevent blockages on the moving parts of diet feeders, forage boxes and straw choppers etc. Shorter material is also easier and faster to distribute.



Hydroflexcontrol – output is determined by throughput

Often the time for harvesting is limited and sometimes operators overstep a balers limits in terms of overload capacity. These limits are determined by the narrowest passage of the machine, which is decisive for its output. With balers, the space underneath the rotor is the critical factor. The Hydroflexcontrol anti blockage system increases this room in case of peak loads while at the same reducing downtime as a result of an inadequate forward speed or sorting out a blockage.


Flexcontrol + Hydroflex = increased baling output with less downtime

The two functions that are hidden in the name Hydroflexcontrol relate to the hydroflex floor which is underneath the rotor. The flex part avoids blockages; the hydro part solves blockages as and when they may occur. All Lely Welger balers with a chopping unit can be fitted with the Hydroflexcontrol system.


Flexible floor deals with peak loads

Flexcontrol is situated under the rotor where the feed passage is at its narrowest. It allows movement of the front part of the feed chamber floor to flex up and down via a rubber suspension – hence the word ‘flex’. If a small foreign object or a wet lump of material is picked up from the swath, this flexing action smoothes out the crop flow reducing the risk of blockages in the feed area.


Dealing with blockages from the tractor cab

The second feature is a hydraulic stage, whereby the rear of the feed table floor can be lowered hydraulically from the tractor seat to free the rotor of any blockage. When lowering the feed table floor the fact that all knives are also withdrawn ensures the blockage has passed into the bale chamber without any crop wastage before the operator re-engages the machine.


Saving time and money…

Net/twine tying, wrapping, transport and storage are all costs associated with baling. Less bales means lower costs. The bale chamber of a Lely Welger round baler produces the heaviest bales in today’s market place thus saving you time and money.


Bale rotation and pressure are critical for bale density

Bale rotation and pressure are critical for bale density The bale chamber which is fitted with 18 Powergrip steel rollers is critical for bale density. It is of paramount importance that all rollers keep a firm grip on the bale at all times. The number of bale rotations and the pressure exerted on the bale will directly influence final bale density. Therefore the bale chamber needs to have a perfect round shape and be fitted with rollers all around with the bare minimum of space between rollers to ensure maximum contact between the rollers and the bale. The mechanical tail gate locking system ensures that consistently sized bales with the highest density are produced every time.


Powergrip – maximum grip ensuring maximum bale rotation

The 18 Powergrip steel rollers ensure the highest bale compaction and excellent baling performance and rotation under all operating conditions. In a special manufacturing process the ten longitudinal ribs on each roller are pressed into the thick walled 3.2 mm tube. With each roller being seamless, the material structure gives the rollers an unequalled strength and a lifetime that is truly unrivalled in the market place. This unique Powergrip design is a patented feature of Lely Welger round balers and enables the balers to work with all types of materials in virtually every condition.

Mechanical tail gate locking system

All Lely Welger round balers feature a mechanical tail gate locking system. Two heavy-duty hooks secure the tail gate once it is fully closed and ensure that it remains completely closed throughout the baling process. These hooks are linked up with high-grade rubber blocks which increase the pressure that the bale chamber exerts on the bale. Bale density is determined through accurate measuring of the position on the tail gate hooks. This mechanical system can withstand the highest of pressure and it is not liable to the loss of pressure as in hydraulic systems. The result is evenly-sized, high density stable bales with little or no crop loss. Opening the tailgate goes fast and is very easy as only a single-acting hydraulic connection is required for opening the tail gate.


Effective Tying

Effective tying saves costs and time

Making a perfect bale is one thing – preserving the bale for a longer period of time is a different matter…a variety of methods for storing, preserving and feeding bales necessitates a flexible tying system. Correct use of tying material limits costs, reduces the time required for tying the bales which in turn increases output per hour.


Varionet – for perfect bale coverage every time

We don’t just accept high-density bales, they should also look good. The Lely Varionet net wrapping system works perfectly with all standard net widths. Thanks to exhaustive testing, the well-proven tensioning system and a special net spreading device, the net wrap is consistently applied across the bale. Wide net wrap will even reach over the edges of the bale. This means that not only do the bales look great; they are also completely protected against bad weather conditions and crop losses. This process also eliminates any unnecessary air pockets,


Varionet wrapping with Easy Load System (ELS)

The well-proven net wrapping system has ELS which allows easier loading of the net roll from ground level from the left-hand side of the machine. After loading the new net roll is simply tipped backwards with the storage container, lifted into the operating position via the spindle and then locked into position. A spare nett roll can then be located in the frame ready for use. It couldn’t be any easier and will save you time and effort, thereby improving feed quality.


Variotwin – secure, fast, economically viable

The unique feature of this twine tying system is the variable speed control. This device allows for a sufficient number of twine rotations at the bale edges, enabling the bale to be tied quickly and ensuring that the ends do not fall apart. In this way even the lightest of crops can be tied quickly and securely in a cost effective manner.


Combination wrapping – double tying, double protection

All Lely Welger balers are designed to allow simultaneous twine and net-tying. This can result in up to 30% savings in wrapping material costs while in addition minimising crop losses



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