Description

Lull 644 1994 Parts Catalog – OEM Factory Parts Breakdown

If you are working on a Lull 644 Highlander from 1994 and need to know exactly which part to order, this Lull 644 1994 Parts Catalog is the reference you need. I have seen too many guys order a hydraulic cylinder seal kit based on a visual guess and then fight with a return. A full 724 pages from the factory – not some scanned reprint with blurry drawings. This catalog came off the press in August 1994 under JLG/Lull Industries. That means every part number, every exploded view, every revision marker matches what went onto the assembly line.

Over the years I have used these catalogs to track down obsolete bearings, identify frame weldments, and decode serial number breaks. The difference between a catalog like this and a third-party parts list is the difference between a bolt that fits and one that strips out at 60 ft-lbs. You cannot fix equipment with guesswork.

Drive Train and Hydraulics Sections

Section 1 covers the drive train – axle housings, differentials, planetary gears, drive shafts. If you are pulling a rear axle on a 644, you want the illustrated breakdown on that page. Section 4 and 5 split the hydraulics into upper and lower. Upper covers control valves, lines to the boom. Lower covers the steering and brake circuits. Each part has a reference number tied to the numerical index at the back. No flipping through 200 pages hoping.

What Does Section 7 Electrical Cover?

Electrical systems on rough terrain forklifts are brutal – corrosion, chafed wires, failed switches. Section 7 gives you the harness layouts, connector part numbers, and individual components like the ignition switch and alternator. If you are chasing an intermittent no-crank, this section tells you which relay socket to order. Do not cut a harness because you misidentified a plug.

Use the Numerical Index to Find Parts Fast

The manual includes a full numerical index that cross-references every part number to the page and figure it appears on. If you have an old part number stamped on a hydraulic tube, look it up in the index and go straight to the exploded view. This is not a parts catalog that makes you hunt. For example, a frame bolt for the platform might appear in Section 2 – the index gets you there in one lookup.

Boom & Transfer: Exploded Views for Replacement

Section 3 covers the boom and transfer case. The 644 Highlander has a unique boom structure with transfer chains and wear pads. The exploded diagrams show every bushing, every pin, every snap ring. When you tear down a boom assembly for a rebuild, you can order every part before you start. No running to the dealer mid-job because you missed a seal.

724 Pages of Factory Part Numbers

That 724 page count is not filler. Each section begins with a master illustration, then breaks down into sub-assemblies. Section 8 lists every decal and accessory, including safety decals that must be replaced after paint work. Section 9 covers fork carriages – different capacities and widths. If you are converting a carriage, the part numbers are there.

For background on the rough terrain forklift industry, see Automotive Industry Overview. For related manuals, check out Lull L-812 1983 Parts Catalog – OEM Factory Parts Breakdown and Lull LD50, LL40 1985 Parts Catalog – OEM Factory Specs. Also see Lull 944E-42 644E-42 2009 Parts Catalog – OEM Factory Manual.

Automotive Industry Overview can give you context on safety standards, but the real information you need is in this catalog.

Does this catalog include torque specifications?

No. This is a parts catalog – it lists part numbers and exploded views. For torque specs, you need the service and maintenance manual.

How do I identify the correct part number for a component that was redesigned?

Lull made running changes on the 644 Highlander. This catalog covers machines built as of August 1994. If your machine’s serial number is higher than the break point included in the general information, some parts may have superseded numbers. Use the numerical index and check for any service bulletins from Lull. The catalog includes revision dates for each section, so read the note in the header of each illustration. This will save you from ordering a part that does not fit.

Can I use this catalog for a 644E or later model?

Only if the 644E shares the same part. The boom and drivetrain changed across model years. This catalog is specific to the 1994 644 Highlander. For a 644E-42, for example, you need the 2009 catalog.

How are the exploded views printed?

Each exploded view is a line drawing with callouts and part numbers. The drawings are clear and scaled proportionally. You can read the numbers without a magnifier.

If you are pulling a transmission or chasing a hydraulic leak, stop guessing and start with the right part numbers. Access the Factory Manual now.