Description

JLG TOUCAN 1010 2010 Parts Catalog

If you’ve ever ordered the wrong part for a JLG TOUCAN 1010 2010 Parts Catalog machine, you know the pain. You pull a seal, wait a week, and it doesn’t match the bore. Or you get a control board that’s for a later serial number. That’s wasted time and money. I’ve seen it happen to guys who think a third-party reprint is close enough. It’s not. This 216-page OEM document from JLG cuts that guesswork out completely. Every figure is drawn from the factory drawings, not scanned and re-labeled.

Electrical System Breakdown – Factory Wiring Diagrams

Section 2 covers the Electrical Install with two main figures: Power Circuit and Control Circuit. You get the exact pinouts for the Mate-N-Lok connectors — no more guessing which wire goes where after a harness swap. The manual breaks down the LCB (lower control box) and UCB (upper control box) by serial number, with separate pages for S/N prior and since specific thresholds. For example, Figure 2-2-3 is for S/N prior to A300012503+504; Figure 2-2-4 covers S/N since A300012505+503. If you’re chasing a control circuit fault, that level of detail saves hours. I’ve used these diagrams to track down a bad ground in the joystick components (Figure 2-2-6-2) on a Toucan that had intermittent lift.

Masts, Counterweight, and Frame Assembly Sections

Sections 4 through 6 walk through the mast assemblies (European and Australian variants), the counterweight and frame connection, and the full frame install. Notice how Section 4-3-1 isolates the gear box assembly for Mast 1 – that’s where you find the part numbers for the reduction gear and motor interface. Section 5 gives you the exploded view of the counterweight and mast-to-frame bolts. Section 6 dives into the frame install with sub-figures for release valve, reservoir, brake manifold, function valve, diff-lock, and power unit – each with serial number breaks. If you’re rebuilding the hydraulic distribution on a Toucan 1010, you need Figure 6-1-2-3 for the drive motor distribution manifold. Without the OEM callouts, you’ll be measuring ports with calipers and hoping.

Why This OEM Parts Catalog Beats Aftermarket Reprints

I’ve seen aftermarket “parts catalogs” that reuse generic illustrations from a different model year. They skip the serial number splits and fudge the part numbers. This document is a direct scan of JLG’s own release (publication 31210057, January 01, 2010). Every page has the original French/English layout, and the figures match what you’ll see on the machine. You get the exact factory part numbers for items like the 115/230V 65A Fulmen charger (Appendix C, Figure 10-1-1) and the non-marking wheel install (Appendix B, Figure 9-2). That’s the difference between a smooth job and a call-back.

7 Systems Covered – From Covers to Chargers

The manual breaks the Toucan 1010 into ten sections covering covers, electrical, power bridge, masts, counterweight/frame, frame install, jib and platform, and three appendices. Appendix A gives you cylinders (mast, jib, steering). Appendix B covers tire and wheel options. Appendix C covers battery and charger with seven different charger variants (Fulmen and Oldham, 40A to 80A). You won’t find a more thorough parts breakdown for this platform.

Serial Number Breaks – Critical for Correct Parts Ordering

JLG updated the Toucan 1010 several times during production. This catalog tracks those changes. For example, the drive motor distribution manifold changed at S/N A300012933. The upper control box switched at S/N A300012783. Even the plastic upper control box has its own figure (2-2-6-1). If you order a part without checking your machine’s serial number against these breaks, you’ll likely get the wrong revision. I’ve seen a guy order a lower control box for a prior S/N and it had a different connector layout – wasted three days. This manual has the splits printed right in the figure titles.

Related manuals you should consider: JLG TOUCAN 1010 2006 Service Manual, JLG Toucan 1010 / 1010I Operation and Safety Manual, and JLG 8042, 10042, 10054 2012 Parts Catalog – Factory OEM Skytrak Manual. For a broader view of the construction equipment industry, check the Automotive Industry Overview and Automotive Industry Overview.

Does this catalog cover the 2009 model year Toucan 1010?

It covers S/N 12010+ and later, with revisions through February 2008, July 2009, and January 2010. For earlier machines you need the 2007 original issue.

What’s the difference between the European and Australian mast sections?

Section 4 shows separate assemblies for Europe (Figure 4-1) and Australia (Figure 4-2). The mast structure and gear box are identical, but the platform overload device and jib mounting differ. Appendix A also lists different cylinders for each region. Always confirm your machine’s region and serial number before ordering mast parts.

Are torque specs included in this parts catalog?

No. This is a parts catalog – it shows exploded views, part numbers, and quantities. For torque values you need the service manual. Check the related manuals above.

How do I find the right part for my serial number?

Locate your machine’s serial number (stamped on the frame near the mast). Then cross-reference it with the “S/N prior” or “S/N since” notes in each figure. Most sections have multiple figures for different production runs. Order the part number listed under your serial number range.

This is the factory document you need to keep on the bench. 216 pages of OEM part numbers, real exploded views, and serial number breaks that aftermarket reprints never get right. Stop chasing wrong parts. Access the Factory Manual now.