JCB | METALS RECYCLING

JCB | METALS RECYCLING
Committed to providing specialist machines, attachments and support for your industry

CONTENTS
A JCB FOR EVERY TASK
PAGES 1 – 2
END-OF-LIFE VEHICLES
PAGES 3 – 4
AUTOMOTIVE RECYCLING
PAGES 5 – 6
DEFRAGMENTATION
MILLS & SHREDDERS
PAGES 7 – 8
FERROUS & NON-FERROUS
METALS RECYCLING
PAGES 9 – 10
FRIDGE RECYCLING
PAGES 11 – 12
BATTERY RECYCLING
PAGES 13 – 14
CONSTRUCTION METALS RECOVERY
PAGES 15 – 16
MILLS & FOUNDRIES
PAGES 17 – 18
A JCB for Every Task
With the manufacturing sector using more recycled
metals than ever before, the business potential in
metals recycling has never been greater.
Whatever you specialise in – from cars, batteries and
fridges to recovered steel from demolition and melting
down frag into ingots, JCB supply the right machines to
help your business run efficiently.
Wheeled loading shovels to tip into high-sided
containers, JCB Robot skid steer loaders to transport
scrap iron, telescopic Teletruk forklifts to keep
hazardous loads safely away from the operator,
compact Loadalls to handle loose ingots, and big
wheeled re-handlers to load shredders and balers;
these are just a few of our specific solutions built for
metals recovery operations.
At JCB we also tailor our machines to suit your specific
applications. This includes underbelly protection,
heavy-duty filtration, turbo-2 pre-cleaners, extra guard
protection for the operator, solid or filled tyres for
puncture protection, and much more. Our specialists
will advise and help you achieve the ideal specification
for your metals operation.

3
End-of-Life Vehicles
The challenge of End-of-Life Vehicle (ELV) legislation
has transformed the industry. Now that ELV directives
require safe de-pollution before car bodies can be
recycled, a more specialist machine is needed: the
JCB Teletruk 35D.
Developed in consultation with the metals recycling
industry, the 3.5-tonne capacity Teletruk is perfect for
handling End-of-Life cars.
With a telescopic boom instead of a conventional
vertical mast, visibility from the Teletruk cab is superb.
The forks carriage rotates up-down through 111°,
far more than any ordinary forklift, so difficult loads
can be tilted right back and held securely. A 360° left-
right rotator attachment – together with the Teletruk’s
forward reach – ensures safe and accurate placing of
the car on the de-pollution rig. Plus there’s a choice
of 2- or 4-wheeled-drive models to suit your site
conditions precisely.
However, the Teletruk is not the only JCB machine
for the ELV industry. The JCB 416 is a compact,
high-torque wheeled loader for heavy-duty work in
confined spaces and for work on uneven ground.
And the 930 RTFL is a conventional forklift ideally
suited to rough terrain conditions, providing a higher
operating position for improved visibility across vehicle
storage yards.

FAST FACTS
● 3.5-tonne lift and 2430mm
forwards reach allow the
Teletruk to accurately place
cars on ELV rigs
● 111° carriage tilt forwardsback
safely transports
unstable loads
● Excellent all-round vision
enhances health and safety
● High capacity and compact
size are perfect for hightraffic
environments
● JCB 416 and 930 RTFL gives
strong performance in
confined, rough-terrain sites
4

5
Automotive Recycling
15 million cars are scrapped in Europe each year
(2.3 million in the UK alone). But many of these are
relatively new cars, making the recycling of parts a
strongly growing business potential.
Automotive recyclers need a machine that can stack
safely onto a rack and then lift the car chassis down
when needed. Just as in the ELV sector, this is where
the JCB Teletruk 35D comes into its own. The tele-
scopic boom offers 2430mm forwards reach and
superb visibility, so the operator stays safe while handling
awkward loads in busy environments. The 111 ° carriage
rotation allows back-tilt of the load for safe site travel.
Plus, this compact and manoeuvrable machine is
designed to keep you fully operational when busy
areas get congested and incoming deliveries start
queuing to be offloaded.
It’s the confined space in most yards that presents the
biggest challenge. That’s why automotive recyclers are
also turning to JCB compact Loadalls, Robot skid-steer
loaders and masted RTFLs.
Compact Loadalls – the JCB 520-40, 524-50 and
527-55 – offer capacities of 2 to 2.7-tonnes and lift
heights from 4 to 5.6 metres, all in a package less
than 2 metres high and 2 metres wide. The machines
feature hydrostatic drive, providing excellent pushing
power particularly at low speeds, as well as the ability
to operate using only the accelerator. This ensures
smooth acceleration and deceleration and precise
control in tight spaces.
Meanwhile, both the JCB RTFL fitted with extended
forks, and the skid-steer Robot fitted with an industrial
grapple are ideal for shifting cars around the roughest
terrain. Together with the Teletruk 35D, you won’t
find a better choice of equipment (with a choice of
thousands of attachments) to give the efficient and
reliable performance you need and expect.

FAST FACTS
● 3.5-tonne lift and 2430mm
reach allow the Teletruk
to safely stack and grab
car bodies
● 111° carriage up-down
rotation keeps unstable
loads secure during
site travel
● Telescopic boom provides
superb forward vision for
accuracy and safe handling
● Compact Loadalls provide
excellent pushing power
and control in confined
spaces
● Skid-steer Robots and the
RTFL perform even on the
roughest terrain
6

7
Defragmentation Mills & Shredders
About a third of all recycled metals comes from car
bodies, and 80% of a new car’s body is from recycled
metal. These surprising statistics show how important
the industry has become. And with new legislation
continually setting ever-more challenging targets,
serious players in the industry simply can’t afford to
get left behind.
Defragmentation mills and shredder operations are
all about bulk throughput; getting the maximum
amount of recyclables away to the customer each
day. So the quicker you can get raw product in and
frag out, the better.
With proven reliability, specialist features and extra
guards, the new JCB JS200W is our biggest materials
handler yet. A choice of fixed raised cab or hydraulically
raised cab ensures an unimpaired view into containers
and hoppers. There’s a wide range of boom and
dipper options, including mono, tab or materials
handling rig, and for scrap metals a 5-tine cactus grab.
Add all this to a state-of-the-art cab with filtered
heating and ventilation, and you’ve found the perfect
partner for shredder or baler operations.
For loading frag onto trucks or freight trains, you can’t
get better or quicker than the robust and reliable JCB
wheeled loading shovel. Featuring extra protection
guarding, the JCB 456 has optional best-in-class super-
high-lift arms for plenty of clearance when loading.
The arms also have 4-ram geometry for excellent
visibility. Superb traction and power, along with heavy-
duty, puncture-resistant tyres, keep this machine
performing on challenging terrain, while features like
servo controls, low noise levels and the sophisticated
Electronic Monitoring System make for easy operation
throughout every shift.

FAST FACTS
● JS200W features a raised
cab for an unimpaired view
into shredders or balers
● 5-tine cactus grab effectively
handles whole or flattened
car bodies
● 456 wheeled loading shovel
features optional superhigh-lift
arms for loading
● 4-ram geometry loader
end gives excellent visibility
● Machine guards ensure
operator safety and stateof-the-art
cab enhances
comfort
8

9
Ferrous & Non-Ferrous Metals Recycling
Whether you’re a ferrous or non-ferrous specialist, or
you refine non-ferrous metals, the sheer variety of
product for recovery, cleaning, processing and upgrading
(from structured steelwork and white goods casings,
to brass, copper and zinc) means you require versatile
and reliable handling machines.
JCB offer the biggest machine you’re likely to need on
site: the JS200W. With a huge choice of grabs, buckets
and specialist equipment (such as a selector grab with
full rotation or a 5-tine cactus grab) it can load virtually
anything into anything. And it boasts a superb cab
environment with excellent visibility for the most
productive performance all shift.
You’ll also need a couple of compact machines to deal
with shifting metals safely and speedily around the site,
such as the JCB 160 Robot and the Teletruk 35D.
The JCB Robot’s unique single-arm design offers
excellent visibility even in the tightest areas. Fitted with
a grab and solid tyres, the Robot is reliable, fast and
efficient for metals handling in tough conditions.
Developed specifically for metals recycling, the Teletruk
35D is without doubt the most versatile small forklift
you can choose. Compatible with all standard forklift
attachments, what really sets this machine apart in the
metals recycling environment is the Health and Safety
considerations: the cab structure features Roll Over
Protection (ROPS) and Falling Objects Protection
(FOPS) as standard; a front load guard protects the
driver at all times; the telescopic boom keeps dangerous
loads away from the operator; and back-tilt of the 111 °
carriage carries unstable loads securely around the
yard and factory.

FAST FACTS
● JS200W offers a wide
choice of grabs, buckets
and attachments
● Fixed or hydraulically raised
cab allows a clear view into
containers, hoppers or
shredders
● 160 Robot features a unique
single arm for superb
visibility of dangerous loads
● Teletruk 35D is compatible
with standard forklift
attachments for maximum
versatility
● Teletruk offers unique
manual or hydraulic quickchange
of attachments
10

11
Fridge Recycling
Gone are the days, thankfully, when old fridges were
exported to developing countries or buried in landfill –
about 2.5million every year for the UK alone. An
increasing number of European operators have identified
a business niche through obtaining necessary EU
authorisation for fridge recycling. And, due to legislation,
it’s all happened extremely quickly, with the first
licensed fridge recycling plant opening in the UK as
recently as 2002.
A number of highly specialised processes are required
for compliance with the WEEE Directive, such as
degassing and the removal of foam insulation containing
CFCs, before the metal shell of the fridge can be
recycled. If you’re in the business, you’ll know this
means it’s essential that fridges are handled carefully
throughout these processes to prevent gases leaking
before they can be extracted and properly contained
or neutralised.
The Teletruk 35D and compact Loadall are ideal
solutions providing manoeuvrable and productive
performance combined with precision control
and accuracy.
The Teletruk 35D is JCB’s new flagship counterbalanced
forklift, designed specifically for metals recycling.
The telescopic arm is unique on a counterbalanced
industrial truck and gives the big advantage of loading
lorries and rail wagons from one side only. It also
provides reach of up to 2-tonne loads to 2 metres
forwards, so you can accurately place loads.
Another unique feature for a counterbalanced forklift is
a 4-wheel drive option, which brings the benefits of
industrial forklift compactness to rough-site surfaces.
The standard forklift attachment for handling fridges is
of course the flat-face recycling grab, but on the Teletruk
there’s the additional benefit of the forwards-back
111° carriage tilt.

FAST FACTS
● Teletruk 35D lifts 3.5-tonnes
maximum plus there are
4x4 models.
● 111° carriage rotation keeps
loads secure during site
travel with no risk of damage
● Telescopic boom offers
superb visibility and
accurate placing
● Compact Loadalls can be
operated using only the
accelerator for smooth
control
● All compact Loadalls and
Teletruks feature fullyenclosed
hydrostatic drive
for damage-free operation
12

13
Battery Recycling
Battery recycling and lead cell recovery is now a well
established industry in its own right. Whichever type
of battery your business handles, you’re going to need
reliable and versatile machines that keep your operation
running day after day.
The JCB 436 and 456 wheeled loading shovels are
solid workhorses that give dependable performance.
The 456 features best-in-class super-high-lift arms as
an option, ideal for tipping battery loads into containers.
You can also choose heavy-duty, puncture-resistant
tyres to help minimise downtime on challenging
ground conditions. On both machines, servo controls,
low noise levels and an advanced Electronic Monitoring
System make operation easy and comfortable over
long periods of time. Plus, reversing fans and wide-
core radiators help maintain trouble-free working.
The Teletruk 35D is unique in that unlike any other
counterbalanced forklift it offers forwards reach from
a telescopic boom. The ability to lift 2-tonne loads to
2-metre forwards reach gives you increased options,
like loading stillages of battery casings into road trailers
or containers. The forwards reach can reduce the need
for loading space by up to 50% as well as eliminating
the need for heavy goods vehicles to turn trailers for
loading from both sides.
But the Teletruk range is also built with safety in mind.
A fully-enclosed cab can be specified for eliminating any
risk of acid-splash to the forklift operator. The telescopic
boom keeps hazardous loads as far away from the
operator as possible, optional full air conditioning
protects against noxious fumes and 111° carriage tilt
forwards-back adds benefit to the versatility of a
standard 360 degree load rotator. The JCB Teletruk
is the perfect choice for working with hazardous acids
and materials.

FAST FACTS
● Wheeled loading shovels
feature servo controls,
low noise levels and an
Electronic Monitoring
System
● JCB 456 offers optional
super-high-lift arms for
tipping into containers
● Teletruk 35D allows loading
of lorries from one side only,
saving space in the yard
● Enhanced safety features
keep the operator safe
and secure
● Telescopic boom keeps
hazardous loads away from
the operator environment
14

15
Construction Metals Recovery
Steel used in construction is usually of a very high grade
so during demolition work it makes good business sense
to recover it from the concrete frame, particularly when
you consider that a typical 4-storey office development
can contain as much as 166-tonnes of steel.
Few work environments are as demanding as demolition,
but there’s a JCB machine designed to more than
stand the pace . . . the JS260XD tracked excavator.
The dipper on the JS260XD is specially reinforced so
it can handle the most arduous of loads and the rear
plate is also strengthened, protecting it when material is
gripped between a grab attachment and the underside
of the dipper. A 10mm plate protects the whole
underside of the mainframe and the reinforced turret
belly guard is flush fitted to prevent reinforced steel
bars penetrating the machine belly.
Protective measures continue with flush fitted covers
that safeguard the track from re-bar and all other debris,
an engine air pre-cleaner that removes the heavier
dust particles before they get to the air filter, and a fine
mesh grille to keep the radiator clear. All hoses and
pipe work are run inside the undercarriage framework
to avoid damage.
When it comes to maximum performance on site,
you’ll find this machine gives optimum productivity
from whatever attachment you choose to fit. An
optional merged pump facility in the hydraulic system
allows high flows to be delivered to the dipper-end via
the optional combined pipe work for fast operation of
larger hydraulic attachments. Plus, the combined pipe
work provides two-way flow for JCB attachments
such as cutters and crushers.
Specifically designed and built for the industry’s needs,
the JS260XD fitted with JCB industrial shears really is
the perfect machine for cutting away that valuable
metal from concrete constructions.
Speed valve reduces
opening and closing times
Piston rod guards fully protect
cylinders from damage
Two different interchangeable
jaws. Universal and steel
Interchangeable cutting and
crushing teeth
Simple fastening system allows
for easy on-site replacement
Heavy duty swing gear offers
unlimited 360° hydraulic rotation
Interchangeable jaws to provide
maximum versatility
Interchangeable teeth are
made from wear resistant
material for maximum life
and low running costs

FAST FACTS
● Heavy-duty reinforcements
protect the JS260XD for
increased performance and
a longer life
● Engine air pre-cleaner and
mesh radiator grille help
minimise maintenance
● Optional merged pump
delivers high flows to the
dipper end for faster
operation of large
attachments
● Combined pipe work
provides two-way flow
for industrial shears
● Superior cab keeps the
operator safe and
comfortable and improves
productivity
16

17
Mills & Foundries
Health and Safety; it’s got to be the top priority issue
for a mill or a foundry where you’re dealing with
hazardous and unstable molten metal. But the first
job in the process is to get raw product delivered
through the door. And for that you must consider the
very compact JCB Teletruk 35D.
Unlike any other counterbalanced forklift, the TLT35D
offers a tremendous benefit; forwards reach to load and
unload lorries all from one side. It’s perfect alongside
freight containers, trucks or hoppers as loading space
can be reduced by up to 50%.
Another major difference between Teletruks and
conventional masted forklifts is the degree to which the
forks can be rotated forwards-back. Masted industrial
forklifts only offer 6-8° of forwards-tilt for work with
pallets in storage racking. But the Teletruk 35D carriage
rotates 111° allowing excellent back-tilt so there can be
no danger of difficult loads becoming dislodged from
the forks during yard travel.
The most important benefits come from the Teletruk’s
telescopic boom. With excellent visibility and a reach
of 2430mm, this ensures that hazardous loads are
kept well away from the operator. Plus, full cab air-
conditioning is an option no operator should be
without if by-product fumes are present.
Another very versatile machine for mills and foundries
is the JCB Robot skid steer loader. This unique machine
is the only skid steer to offer a maximum-safety, cab
door side-entry design. With a single loader tower for
optimum visibility, the Robot is a compact and highly
manoeuvrable machine which allows direction changes
to be made within the machine length. There is also a
choice of extra-safety kits; heavy-duty bars, front-
screen guards, level II FOPS guards and shatter-proof
screens. It’s a versatile, productive and safe partner
machine for the Teletruk 35D.

FAST FACTS
● Teletruk 35D can load and
unload from one side
● Teletruk 111° carriage tilt
keeps loads stable during
travel
● Telescopic boom keeps
hazardous materials away
from the operator
● JCB Robot features maximum
safety, side-entry design
● Special kits enhance Robot
safety even further

THE BEST BACK-UP IN THE BUSINESS
Always on hand to help
You demand more from your machines than ever before:
more efficiency, more reliability, more performance. That’s why
superb product support has never been so vital.
Together with our extensive dealer
network, at JCB we’re as innovative
and forward-thinking when it comes
to customer care as we are in
machine development. Our product
support and after-sales service have
one aim: to give you peace of mind.
The care and quality we offer is exceptional. All servicing
is carried out by the best, factory-trained JCB engineers.
Using the internet to pass vital information between on-site
service personnel and our product support engineers,
these professionals always have specialist information at their
fingertips, so they can get you up and running again, faster.
Protect your machine and your cashflow
Everyone has individual needs and preferences. So we offer
a range of service options all designed to help you cope with
the unexpected and minimise costly downtime. Whether it’s
additional breakdown cover, an all-inclusive scheduled service
programme, or servicing, we’ve got the best service option
for you.
Finance packages, tailored to your needs
With ever-growing pressures on cashflows, the finance options
available through JCB can provide a vital lifeline. Backed by JCB
Finance, who can provide tax-efficient and cost-effective finance
solutions, designed and tailored specifically to your needs.
Trust the genuine article
JCB parts are renowned worldwide for performance, reliability
and safety. With replacement parts, we supply only the genuine
article, helping to safeguard the impressive residual values that
you can expect in years to come.
As well as large stocks of parts engineered specifically for your
machine, your JCB dealer also holds an extensive range of
JCB premium lubricants, JCB filters and JCB Powermaster
batteries, all manufactured to the same exacting standards.
Your requirements can usually be supplied immediately by our
dealers, but where this is not possible they can be ordered
through the direct computer link between your dealer and
JCB Service and processed through our impressive automated
World Parts Centre warehouse. Despatch is normally the
same day either to you or the dealer.
Whether we’re providing you with support, parts or
finance, we aim for 100% satisfaction. It’s all part of
our promise to put you, the customer, first.
JCB Sales Limited, Rocester, Staffordshire ST14 5JP. Tel: 01889 590312. Fax: 01889 590588. Web: http://www.jcb.com
©2006 JCB Sales. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or
otherwise, without prior permission from JCB Service. JCB reserves the right to change specifications without notice. Illustrations & specifications shown may include optional equipment and accessories.
The JCB logo is a registered trademark of J C Bamford Excavators Ltd. Printed in England. 9999/5225 1/06 Issue 1