Cat DP160N Specifications
The Caterpillar DP160N is a high-capacity
diesel-powered pneumatic-tire forklift engineered for the heaviest industrial
lifting demands. Positioned within Cat’s large internal combustion lift truck
series, the DP160N offers exceptional load stability, powerful engine output,
and robust structural integrity required for steel mills, mining operations,
port terminals, heavy manufacturing, large timber processing, and multi-shift
distribution yards. Its nominal lifting capacity of 16,000 kg (35,300 lb) places
it firmly in the ultra-heavy-duty category.
Designed for continuous operation, the DP160N emphasizes long-term durability,
smooth load handling, and high thermal stability under constant full-load
operation. The integration of the Perkins 1204E industrial diesel engine
provides a combination of high torque, low-speed pulling power, efficient fuel
economy, and Tier 4i/Tier 4 Final emissions compliance depending on
configuration.
The forklift’s reinforced chassis, large
pneumatic tires, heavy powershift transmission, and precision hydraulic
system contribute to reliable performance in demanding terrain and
severe-duty conditions. Operators benefit from a large ergonomic cabin,
excellent visibility, reduced vibration, and responsive control
interfaces. Maintenance technicians value the machine’s wide-swing
engine doors, modular component arrangement, and extended service
intervals.
The Caterpillar DP160N is equipped with the Perkins
1204E industrial diesel engine, a high-output, electronically controlled
4-cylinder turbocharged engine designed specifically for heavy equipment
applications.
Basic Engine Specifications (Perkins 1204E):
- Engine type: 4-cylinder, 4-stroke, turbocharged and aftercooled diesel
- Displacement: 4.4 liters (268 cubic inches)
- Rated power output: approx. 110-129 kW (148-173 hp) @ 2,200 rpm
- Peak torque: approx. 560-700 Nm (413-516 lb-ft) @ 1,400-1,600 rpm
- Fuel system: high-pressure common-rail electronic injection
- Air system: turbocharged with charge-air cooler
- Emissions level: Tier 4 Interim or Tier 4 Final depending on market
- Idle speed: approx. 750 ± 50 rpm
- Governed maximum: approx. 2,300-2,400 rpm
The 1204E is engineered for low-speed torque, stable combustion, low fuel
consumption, and high reliability under long-duration high-load cycles typical
for forklifts in material-handling operations.
Lubrication System:
- Type: full-pressure wet-sump lubrication
- Oil pump: gear-driven, high-volume
- Oil filter: full-flow spin-on type
- Oil capacity: approx. 10-12 liters (10.5-12.7 qt)
- Oil pressure at 2,000 rpm: approx. 350-450 kPa (50-65 psi)
- Recommended oil: SAE 15W-40 (API CJ-4 or CK-4)
- Crankcase ventilation: closed breather system
Cooling System:
- Cooling system: liquid-cooled, forced-circulation
- Coolant capacity: approx. 18-20 liters (19-21 qt)
- Water pump: belt-driven centrifugal pump
- Thermostat: begins opening at approx. 82°C (180°F), full open near 95°C
(203°F)
- Radiator: heavy-duty multi-row industrial core with side-pull design
- Cooling fan: large mechanical fan or viscous-clutch type depending on
configuration
- Coolant mixture: 50/50 ethylene glycol and distilled water
The cooling system is designed for hot-climate continuous duty, ensuring stable
engine temperature under heavy load and slow-speed operation common in
large-capacity forklift cycles.
The DP160N uses a high-capacity industrial powershift
transmission engineered for heavy-duty torque transfer and smooth directional
changes.
Transmission:
- Transmission type: multi-speed powershift (typically 3-speed forward,
3-speed reverse)
- Forward travel speed (unladen): approx. 25-30 km/h (15-19 mph)
- Reverse speed (unladen): approx. 23-28 km/h (14-17 mph)
- Transmission fluid capacity: approx. 22-28 liters (23-30 qt)
- Recommended fluid: CAT TDTO SAE 10W or equivalent heavy-duty
transmission oil
- Cooling method: oil-to-air or oil-to-water transmission cooler
- Directional control: electronic fingertip or column shifter with
clutch modulation
Drive Axle:
- Axle type: planetary reduction front drive axle
- Differential: bevel-gear differential with heavy-duty housing
- Final drive: planetary hub reductions for high torque multiplication
- Drive axle lubrication capacity: approx. 18-22 liters (19-23 qt)
- Lubricant: SAE 80W-90 or 85W-140 gear oil
- Axle rating: designed for high shock loads and extreme lifting
stresses
Braking System:
- Service brakes: hydraulic wet-disc brakes integrated into the drive
axle
- Parking brake: spring-applied, hydraulically released parking brake
- Cooling: oil-immersed discs for long life and minimal fade
- Brake pedal modulation: smooth, predictable control under heavy load
Wet-disc brakes provide superior durability and low maintenance in
severe material-handling applications.
- System voltage: 24 V
- Alternator output: approx. 80-120 A
- Batteries: dual heavy-duty industrial batteries, approx. 120-180 Ah total
capacity
- Starter motor: approx. 5-7 kW heavy-duty starter
- Engine management: ECU for injection timing, fuel metering, boost control, and
emissions
- Safety circuits: neutral start, operator presence, travel-inhibit, hydraulic
lockout
The 24-volt system ensures reliable cold starting and stable electrical supply
for large hydraulic solenoids and safety systems.
Drive
Configuration:
- Drive wheels: front
- Steering wheels: rear
- Drive type: 2WD with massive front drive axle and long wheelbase
Tire Specifications (Pneumatic):
- Front tires: approx. 12.00-20 or equivalent heavy-duty pneumatic
- Rear tires: approx. 12.00-20 matching set
- Optional solid pneumatics for high-debris or high-puncture areas
- Optional non-marking tires for indoor facilities
Chassis Construction:
- Reinforced heavy-plate steel frame
- Oversized counterweight for residual stability
- Protected hydraulic and electrical pathways
- Anti-slip steps and reinforced overhead guard
This chassis is designed to withstand high shock loads, uneven terrain, and the
structural demands of 16-ton lifting cycles.
Steering System:
- Steering type: fully hydrostatic power steering
- Steering pump flow: approx. 15-20 L/min (4-5.3 gpm)
- Steering cylinder: heavy-duty double-acting cylinder
- Steering axle: center-pivot oscillating rear axle for uneven ground
compensation
- Turning radius: approx. 4.2-4.6 m (165-181 in)
Hydrostatic steering ensures low-effort steering and precise control, even with
heavy loads raised.
- Pump type: large-capacity gear pump or load-sensing
pump depending on configuration
- Pump flow: approx. 120-160 L/min (32-42 gpm)
- Maximum system pressure: approx. 18-20 MPa (2,600-2,900 psi)
- Main control valve: multi-section valve with adjustable relief valves
- Hydraulic oil reservoir: approx. 100-130 liters (105-137 qt)
- Recommended hydraulic fluid: ISO VG 46 or CAT HYDO Advanced
- Lift cylinders: large-bore dual-acting lift cylinders
- Tilt cylinders: dual-acting tilt cylinders with cushioning valves
Optional hydraulic circuits:
- Side-shift
- Fork-positioner
- Rotators
- Specialized clamps (coil, paper-roll, lumber)
The hydraulic system provides strong, smooth lifting performance at full load
and excellent fine-control for precision placement.
| Service Refill Capacities |
- Engine oil: 10-12 L (10.5-12.7 qt)
- Cooling system: 18-20 L (19-21 qt)
- Transmission fluid: 22-28 L (23-30 qt)
- Drive axle oil: 18-22 L (19-23 qt)
- Hydraulic tank: 100-130 L (105-137 qt)
- Steering system: integrated into hydraulic reservoir.
Mast Types:
- Duplex (2-stage)
- Triplex (3-stage full free-lift)
- Quad mast optional for very high lift requirements
Typical Lift Heights:
- Duplex: approx. 3.0-4.5 m (118-177 in)
- Triplex: approx. 4.5-7.0 m (177-276 in)
- Quad: approx. 7.0-10.0 m (276-394 in)
Free-Lift: 1.0-1.4 m (39-55 in) depending on mast
Carriage Width: 2.0-2.3 m (79-91 in) depending on mast
Fork Specifications:
- Standard fork length: 1,524 mm (60 in)
- Optional lengths: 1,829-2,438 mm (72-96 in)
- Fork width: 150-200 mm (6-8 in)
- Thickness: 60-80 mm (2.4-3.1 in)
- Fork class: ITA Class V
Rated lifting capacity: 16,000 kg (35,300 lb) at a
600-mm (24-in) load center
Factors affecting de-rating:
- Extended lift heights
- Long forks
- Attachments such as clamps or rotators
- Off-center loads
- Larger load centers up to 900-1,200 mm (35-47 in)
Residual capacity remains strong due to the DP160N’s long wheelbase and heavy
counterweight mass.
- Lift speed (unladen): approx. 0.45-0.55 m/s (90-110
ft/min)
- Lift speed (laden): approx. 0.25-0.40 m/s (50-79 ft/min)
- Lowering speed: controlled through load-sensing valve
- Drawbar pull: approx. 50,000-70,000 N (11,200-15,700 lbf)
- Gradeability (unladen): approx. 25-30%
- Gradeability (laden): approx. 15-20%
The forklift maintains strong acceleration and pushing power thanks to the high
torque of the Perkins 1204E.
- Overall length to fork face: approx. 5.5-6.0 m
(217-236 in)
- Overall width: approx. 2.3-2.5 m (91-98 in)
- Overhead guard height: approx. 2.8-3.0 m (110-118 in)
- Wheelbase: approx. 3.0-3.3 m (118-130 in)
- Ground clearance (lowest point): 200-260 mm (7.9-10.2 in)
- Ground clearance (mast underside): 180-240 mm (7.1-9.4 in)
- Turning radius: approx. 4.2-4.6 m (165-181 in)
- Aisle width (pallet 1000x1200): approx. 7.5-8.3 m (295-327 in)
- Maximum fork height: 3.0-10.0 m depending on mast
- Free-lift height: 1.0-1.4 m
- Fork lengths: 60-96 in common
- Operating weight: approx. 21,000-24,000 kg (46,300-52,900 lb)
- Counterweight mass: approx. 7,000-9,000 kg (15,400-19,800 lb).
250-Hour
Maintenance:
- Replace engine oil and filter
- Lubricate mast channels and steering joints
- Clean radiator and cooler cores
- Inspect air filter element
500-Hour Maintenance:
- Replace transmission filter
- Inspect axle seals and planetary oil
- Check hydraulic suction strainer
- Inspect driveline couplings
1,000-Hour Maintenance:
- Replace transmission oil
- Replace axle oil
- Inspect hydraulic hoses, cylinder seals, and fittings
2,000-Hour Maintenance:
- Replace hydraulic oil and filters
- Replace coolant
- Perform full mast alignment
- Inspect engine mounts and differential backlash
Long-Term Maintenance:
- Valve lash inspection: every 2,000-3,000 hours
- Injector servicing: every 3,000-4,000 hours
- Cooling system de-scaling as required
- Brake disc inspection: every 1,500-2,000 hours.
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