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59-540: The International DuraStar line, known as the 4000 series prior to 2008, is a line of medium-duty trucks produced by Navistar International from 2001 until 2018. Introduced as the successor to the International 4000 series of 1989–2001, the 4000 series was renamed the DuraStar in 2008. Developed as a Class 6-7 product range, the 4000/DuraStar was slotted below the 8000/TranStar regional-haul semitractor, with

118-530: A European driving licence include (among others) B for general motor vehicles, C for large goods vehicles, D for large passenger vehicles (buses), and are limited by the Gross Vehicle Weight Rating and number of passenger seats. The general categories are further divided as follows: For the "trailer" categories, a separate driving test is generally required (e.g., "C", and "CE" require separate tests). The classifications used on

177-716: A diesel-electric truck , with the International DuraStar Hybrid. International Truck and Engine teamed with the Hybrid Truck Users Forum (HTUF), a consortium of utility industry customers, Eaton Corporation , the US Federal Government and the Calstart organization to assist with the cost of bringing the technology to market. It also provided direct customer feedback and support. From 2005 to 2008, International sold

236-468: A 1-ton Dodge Van or a 1 ⁄ 2 -ton GMC Suburban), medium duty trucks (e.g. the 1 1 ⁄ 2 -ton Ford F-550 ) and some military vehicles, like the ubiquitous deuce-and-a-half . Some pickup trucks may be marketed as heavy duty (eg Ram Heavy Duty ), super duty (eg Ford Super Duty ) or simply "HD". This is not to be confused with the truck classification of class 7 and 8 being heavy duty. The Class 8 truck gross vehicle weight rating (GVWR)

295-493: A CDL for any vehicle with three or more axles that has a gross vehicle weight rating of over 6,000 pounds. When light-duty trucks were first produced in the United States, they were rated by their payload capacity in tons : 1 ⁄ 2 (1000 pounds), 3 ⁄ 4 (1500 pounds) and 1-ton (2000 pounds). Ford had introduced the "One-Tonner" in 1938 to their line of trucks. The "Three-quarter-tonner" appeared in

354-433: A CDL for these vehicles under their discretion. A CDL is also required to operate any vehicle that transports at least 16 passengers (including the driver) or hazardous materials requiring placards under federal and state law regardless of the weight of the vehicle. States may extend CDL requirements for additional vehicles, for example, New York requires a CDL to operate a stretched limousine and California requires

413-530: A common chassis; the medium-duty Ford F-Series (which had already entered production in 2000 at General Escobedo) shared its cab with the F-Series Super Duty line (F-250 through F-550). Though smaller F-Series vehicles used Navistar-supplied diesel engines, medium-duty Fords used engines supplied by Cummins and Caterpillar. Serving as the debut line of the NGV (Next-Generation Vehicle) cab structure,

472-550: A coolant temperature sensor blocked vacuum to the EGR valve until the engine reached normal operating temperature . This prevented driveability problems due to unnecessary exhaust induction; NO x forms under elevated temperature conditions generally not present with a cold engine. Moreover, the EGR valve was controlled, in part, by vacuum drawn from the carburetor's venturi, which allowed more precise constraint of EGR flow to only those engine load conditions under which NO x

531-465: A diesel reduces the specific heat ratio of the combustion gases in the power stroke . This reduces the amount of power that can be extracted by the piston, thereby reducing the thermodynamic efficiency. EGR also tends to reduce the completeness of fuel combustion during the power stroke. This is plainly evident by the increase in particulate emissions that corresponds to an increase in EGR. Particulate matter (mainly carbon and also known as soot) that

590-597: A factory-produced crew-cab pickup truck variant of the 4000 series. Named the International RXT (RXT=Recreational Extreme Truck), at 272 inches long, the truck was the longest-length pickup truck ever produced for sale in North America. Unlike the 7000 series-derived CXT, the RXT was rear-wheel drive, marketed towards customers with large RV, boat, and horse trailers; both trucks source a pickup truck bed from

649-578: A medium-duty Navistar vehicle. After 2016, Navistar ended production of the MaxxForce 7, MaxxForce DT, and MaxxForce 9 engines, with the ISB and ISL engines becoming the sole engine offerings of the DuraStar. The International DuraStar shares its cab design with several International product lines, including: the TerraStar Class 5 medium-duty truck, the 7000/WorkStar severe-service trucks (renamed

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708-429: A portion of an engine's exhaust gas back to the engine cylinders . The exhaust gas displaces atmospheric air and reduces O 2 in the combustion chamber. Reducing the amount of oxygen reduces the amount of fuel that can burn in the cylinder thereby reducing peak in-cylinder temperatures. The actual amount of recirculated exhaust gas varies with the engine operating parameters. In the combustion cylinder, NO x

767-494: A reduction in fuel efficiency due to the back pressure created. Diesel particulate filters come with their own set of very specific operational and maintenance requirements. Firstly, as the DPF captures the soot particles (which are made far more numerous due to the use of EGR), the DPF itself progressively becomes loaded with soot. This soot must then be burned off, either actively or passively. At sufficiently high temperatures,

826-530: A separate system of emissions classifications for trucks. The United States Census Bureau also assigned classifications in its Vehicle Inventory and Use Survey (VIUS) (formerly Truck Inventory and Use Survey (TIUS)). United States federal law requires drivers to have a commercial driver's license (CDL) to operate heavy-duty vehicles (Class 7 and 8) in commerce, with the exception of emergency vehicles and vehicles strictly used for recreational and/or agricultural purposes, though it allows states to require

885-459: Is a reduction in engine longevity. For example, because the EGR system routes exhaust gas directly back into the cylinder intake without any form of filtration, this exhaust gas contains carbon particulates . And, because these tiny particles are abrasive, the recirculation of this material back into the cylinder increases engine wear. This is so because these carbon particles will blow by the piston rings (causing piston-cylinder-interface wear in

944-484: Is a vehicle with a GVWR exceeding 33,000 lb (14,969 kg). These include tractor trailer tractors, single-unit dump trucks of a GVWR over 33,000 lb, as well as non-commercial chassis fire trucks; such trucks typically have 3 or more axles. The typical 5-axle tractor-trailer combination , also called a " semi " or "18-wheeler", is a Class 8 vehicle. Standard trailers vary in length from 8 ft (2.4 m) containers to 57 ft (17 m) van trailers, with

1003-420: Is also omitted at idle (low-speed, zero load) because it would cause unstable combustion, resulting in rough idle. Since the EGR system recirculates a portion of exhaust gases, over time the valve can become clogged with carbon deposits, which will prevent it from operating properly. Clogged EGR valves can sometimes be cleaned, but replacement is necessary if the valve is faulty. Because diesel engines depend on

1062-494: Is effectively countered by the DPF, which collects these and in the end will burn those unburnt particles during regeneration, converting them into CO2 and water vapour emissions, that - unlike NOx gases - have no negative health effects. Modern cooled EGR systems help reduce engine wear by using the waste heat recouped from the recirculated gases to help warm the coolant and hence the engine block faster to operating temperature. This also helps lower fuel consumption through reducing

1121-596: Is likely to form. Later, backpressure transducers were added to the EGR valve control to further tailor EGR flow to engine load conditions. Most modern engines now need exhaust gas recirculation to meet NO x emissions standards. However, recent innovations have led to the development of engines that do not require them. The 3.6 Chrysler Pentastar engine is one example that does not require EGR. The exhaust gas contains water vapor and carbon dioxide which both have lower heat capacity ratio than air. Adding exhaust gas therefore reduces pressure and temperature during

1180-438: Is not burned in the power stroke represents wasted energy. Because of stricter regulations on particulate matter (PM), the soot-increasing effect of EGR required the introduction of further emission controls in order to compensate for the resulting PM emission increases. The most common soot-control device is a diesel particulate filter (DPF) installed downstream of the engine in the exhaust system. This captures soot but causes

1239-527: Is produced by high-temperature mixtures of atmospheric nitrogen and oxygen, and this usually occurs at cylinder peak pressure. In a spark-ignition engine, an ancillary benefit of recirculating exhaust gases via an external EGR valve is an increase in efficiency, as charge dilution allows a larger throttle position and reduces associated pumping losses. Mazda's turbocharged SkyActiv gasoline direct injection engine uses recirculated and cooled exhaust gases to reduce combustion chamber temperatures, thereby permitting

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1298-422: The International 3300 is a cowled chassis. The former is sold primarily for commercial applications while the latter is sold nearly exclusively to Navistar subsidiary IC Bus , for both school bus and commercial applications. Production of the DuraStar cowled chassis ended in 2023, outliving its truck counterpart by 5 years. In 2007, Navistar International became the first American truck manufacturer to produce

1357-586: The International Driving Permit are similar to the European model. The licence categories that deal with trucks are B and C: Truck (Lorry) See List of truck types Exhaust gas recirculation In internal combustion engines , exhaust gas recirculation ( EGR ) is a nitrogen oxide ( NO x ) emissions reduction technique used in petrol/gasoline , diesel engines and some hydrogen engines . EGR works by recirculating

1416-570: The gross trailer weight rating (GTWR), and can vary among jurisdictions. In the United States, commercial truck classification is determined based on the vehicle's gross vehicle weight rating (GVWR). The classes are numbered 1 through 8. Trucks are also classified more broadly by the Federal Highway Administration (FHWA), which groups classes 1 and 2 as light duty , 3 through 6 as medium duty , and 7 and 8 as heavy duty . The Environmental Protection Agency (EPA) has

1475-591: The isentropic compression in the cylinder, thereby lowering the adiabatic flame temperature . In a typical automotive spark-ignited (SI) engine, 5% to 15% of the exhaust gas is routed back to the intake as EGR. The maximum quantity is limited by the need of the mixture to sustain a continuous flame front during the combustion event; excessive EGR in poorly set up applications can cause misfires and partial burns. Although EGR does measurably slow combustion, this can largely be compensated for by advancing spark timing. The impact of EGR on engine efficiency largely depends on

1534-470: The 13-class system from the United States' Federal Highway Administration —sometimes with modifications, or in Ontario's case, for limited purposes. British Columbia and Ontario also distinguish between short- and long-combination trucks. In accident reporting, eight jurisdictions subdivide trucks by GVWR into light and heavy classes at approximately 4 500 kg ( 9 921 lb ). Vehicle categories on

1593-534: The 1979 S series. Sharing its chassis with the medium-duty Ford F-Series (introduced in 2000), the International 4300/4400 retained the DT466 and DT530 diesels of their predecessors. For versions equipped with automatic transmissions, electronics for the engine and transmissions were retuned to optimize throttle and shifting response, to increase both performance and fuel economy. To increase forward visibility,

1652-774: The 4100 was introduced, expanding the model line into the Class 5 segment; the model was discontinued a single year of production. The 4200, 4300, and 4400 were produced in both a standard and low-profile frame. The 4400 was also produced in a semitractor; sitting 4 inches higher than the chassis truck, the 4400 tractor was the only version offered with the DT570 engine as an option. (Class 5) (Class 6) Air 4x2 Low Profile (4200LP) (Class 6) Air 4x2 Low Profile (4300LP) (Class 6-7) Air (standard on 4400 tractor) 4x2 Low Profile (4400LP) 6x4 4x2 semitractor Tractor: 128–189 in (3,251–4,801 mm) For 2008, coinciding with

1711-487: The Class 5 International TerraStar (2010–2015) serving as the smallest International conventional-cab product range. The most distinctive features of the DuraStar are the "crescent shape" headlights and a distinctive "black spot" on the left side of the cab. Produced as both a semitractor and a straight/rigid truck, the 4000/DuraStar has been used in a wide variety of applications, including emergency vehicles , towing , flatbed trucks , and cargo box trucks . For bus use,

1770-463: The DPF by burning diesel fuel directly in the oxidation catalyst in order to significantly increase exhaust-gas temperatures through the DPF to the point where PM is incinerated by the residual oxygen in the exhaust. Because diesel fuel and engine oil both contain nonburnable (i.e. metallic and mineral) impurities, the incineration of soot (PM) in the DPF leaves behind a residue known as ash. For this reason, after repeated regeneration events, eventually

1829-547: The DPF must either be physically removed and cleaned in a special external process, or it must be replaced. As noted earlier, the feeding of the low-oxygen exhaust gas into the diesel engine's air intake engenders lower combustion temperatures, thereby reducing emissions of NO x . By replacing some of the fresh air intake with inert gases EGR also allows the engine to reduce the amount of injected fuel without compromising ideal air-fuel mixture ratio, therefore reducing fuel consumption in low engine load situation (for ex. while

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1888-525: The Ford F-350 Super Duty. Derived from the 4200, the RXT was powered by a 230 hp VT365 V8 and an Allison 2200 transmission. In 2008, following lower than expected sales, the XT series was withdrawn. Medium-duty truck Truck classifications are typically based upon the maximum loaded weight of the truck , typically using the gross vehicle weight rating (GVWR) and sometimes also

1947-543: The Ford truck lineup in 1939. Over time, payload capacities for most domestic pickup trucks have increased while the ton titles have stayed the same. The 1948 Ford F-1 had a Gross Vehicle Weight Rating (GVWR) of 4700 pounds. The truck was marketed with a "Nominal Tonnage Rating: Half-Ton." The actual cargo capacity had increased to 1450 pounds. Ford adopted this promotional nomenclature in 1948 to assist buyers, sellers, and users. The now-imprecise ton rating has continued since

2006-723: The International HV), the 8000/TranStar regional-haul semitractor (renamed the International RH), the ProStar aerodynamic long-haul semi-tractor (renamed the International LT), and the LoneStar semitractor. Like the 4000 series before it, the DuraStar served as a popular platform for bus manufacturers, with two configurations sold for bus production. The International 3200 is a cutaway-cab chassis;

2065-680: The TerraStar sat on a lower frame and wore its own hood. For 2015 production, the DuraStar began to phase in Cummins ISB6.7 diesel engines as an option, slotted in between the MaxxForce 7 and MaxxForce DT, with the ISL as an option alongside the MaxxForce 9. Although Cummins ISX engines had been offered in International Class 8 trucks, the expansion marked the introduction of the first selective catalytic reduction diesel engine for

2124-622: The chassis is used in both cowled-chassis and cutaway-cab configurations for school bus and commercial applications. The DuraStar was replaced by the new International MV Series in 2018. In early 2001, Navistar entered into a 50/50 joint venture to produce commercial vehicles with Ford Motor Company, officially named Blue Diamond Truck, LLC. Under the agreement, Navistar assembled medium-duty trucks for both companies in its facility in General Escobedo , Mexico. Though externally different, both Ford and Navistar model lines would share

2183-418: The combustion chamber inhibits the total net production of these and other pollutants when sampled on a time average. Chemical properties of different fuels limit how much EGR may be used. For example methanol is more tolerant to EGR than gasoline. The first EGR systems were crude; some were as simple as an orifice jet between the exhaust and intake tracts which admitted exhaust to the intake tract whenever

2242-488: The combustion temperatures. In modern diesel engines , the EGR gas is usually cooled with a heat exchanger to allow the introduction of a greater mass of recirculated gas. However, uncooled EGR designs do exist; these are often referred to as hot-gas recirculation (HGR). Cooled EGR components are exposed to repeated, rapid changes in temperatures, which can cause coolant leak and catastrophic engine failure. Unlike spark-ignition engines , diesel engines are not limited by

2301-403: The engine to run at higher boost levels before the air-fuel mixture must be enriched to prevent engine knocking . In a gasoline engine, this inert exhaust displaces some amount of combustible charge in the cylinder, effectively reducing the quantity of charge available for combustion without affecting the air-fuel ratio. In a diesel engine, the exhaust gas replaces some of the excess oxygen in

2360-436: The engine was running. Difficult starting, rough idling, reduced performance and lost fuel economy inevitably resulted. By 1973, an EGR valve controlled by manifold vacuum opened or closed to admit exhaust to the intake tract only under certain conditions. Control systems grew more sophisticated as automakers gained experience; Volkswagen's "Coolant Controlled Exhaust Gas Recirculation" system of 1973 exemplified this evolution:

2419-431: The form of an undesirable positive-feedback loop, will worsen as the engine ages. For example, as the piston rings progressively wear out, more crankcase oil will get into the exhaust stream. Simultaneously, more fuel and soot and combustion byproducts will gain access to the engine oil.) The end result of this recirculation of both exhaust gas and crankcase oil vapour is again an increase in soot production, which however

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2478-402: The heat of compression to ignite their fuel, they are fundamentally different from spark-ignited engines. The physical process of diesel-fuel combustion is such that the most complete combustion occurs at the highest temperatures. Unfortunately, the production of nitrogen oxides ( NO x ) increases at high temperatures. The goal of EGR is thus to reduce NO x production by reducing

2537-511: The introduction of the International ProStar and International LoneStar , Navistar revised the branding of its truck model lines. In line with nomenclature previously used by International Harvester, truck lines adopted a "xxxxStar" naming scheme, with the 4000 series adopting the DuraStar model name. This change was completed in its entirety for the 2010 model year. In another revision, to comply with 2007 emissions regulations,

2596-453: The latter is only there to reduce oil vapor emissions, and can be present on engines with or without any EGR system. However, the tripartite mixture resulting from employing both EGR and PCV in an engine (i.e. exhaust gas, fresh air, and oil vapour) can cause the buildup of sticky tar in the intake manifold and valves. This mixture can also cause problems with components such as swirl flaps , where fitted. (These problems, which effectively take

2655-481: The model revision, their usage was highly downplayed, largely relegated to places such as the build plate for the vehicle. Externally, International replaced the numerical series and engine identification with script identifying the model series. In 2010, the International TerraStar model line was introduced, effectively replacing the discontinued 4100 model line. Sharing the cab of the DuraStar,

2714-841: The most common length being the 53 ft (16 m) trailer. Specialized trailers for oversized loads can be considerably longer. Commercial operation of a Class 8 vehicle in the United States requires either a Class-B CDL for non-combination vehicles, or a Class-A CDL for combination vehicles (tractor-trailers). Industries that generally use Class 8 trucks are long-distance freight transportation, construction, and heavy equipment moving. Vehicle classifications vary among provinces in Canada, due to "differences in size and weight regulations, economic activity, physical environment, and other issues". While several provinces use their own classification schemes for traffic monitoring, Manitoba , Ontario , Prince Edward Island and Saskatchewan have adopted

2773-458: The need for a contiguous flamefront. Furthermore, since diesels always operate with excess air, they benefit (in terms of reduced NO x output) from EGR rates as high as 50%. However, a 50% EGR rate is only suitable when the diesel engine is at idle, since this is when there is otherwise a large excess of air. Because modern diesel engines often have a throttle, EGR can reduce the need for throttling, thereby eliminating this type of loss in

2832-464: The new International 4000 series sourced its engines from within the company, carrying over the T444E V8 and DT466E I6 diesel (later VT365, DT466, and MaxxForce engines) from the previous 4000 series (sharing other commercial-grade drivetrain components with Ford and other medium-duty vehicles). In 2015, Ford ended its stake in the joint venture; as part of a redesign, production of medium-duty trucks

2891-422: The nitrogen dioxide component of NO x emissions is the primary oxidizer of the soot caught in the DPF at normal operating temperatures. This process is known as passive regeneration, and it is only partially effective at burning off the captured soot. And, especially at high EGR rates, the effectiveness of passive regeneration is further reduced. This, in turn, necessitates periodic active regeneration of

2950-925: The post World War II era to compare standard sizes, rather than actual capacities. In 1975, a change in U.S. emission laws required any vehicle under 6000 pounds GVWR to burn unleaded fuel. U.S. pickup truck manufacturers responded with a "heavy half" pickup of over 6000 pounds GVWR. The F-150 had a capacity of over 2000 pounds, compared to 1500 pounds for the F-100. This has led to categorizing trucks similarly, even if their payload capacities are different. The Chevrolet Silverado/GMC Sierra 1500, Ford F-150, Nissan Titan, Ram 1500, and Toyota Tundra are called "half-ton" pickups ( 1 ⁄ 2 -ton). The Chevrolet Silverado/GMC Sierra 2500, Ford F-250, and Ram 2500 are called "three-quarter-ton" pickups. The Chevrolet Silverado/GMC Sierra 3500, Ford F-350, and Ram 3500 are known as "one ton" pickups. Similar schemes exist for vans and SUVs (e.g.

3009-492: The powertrain lineup underwent extensive revision, with the 6.0L VT365 V8 replaced by the 6.4L MaxxForce 7 V8. The DT inline-6 engine family underwent revisions as well, with the DT466 becoming the MaxxForce DT and the DT570 becoming the MaxxForce 9, adopting four-valve cylinder heads and exhaust gas recirculation to reduce emissions. While each International model series retained the use of numerical model codes, after

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3068-417: The pre-combustion mixture. Because NO x forms primarily when a mixture of nitrogen and oxygen is subjected to high temperature, the lower combustion chamber temperatures caused by EGR reduces the amount of NO x that the combustion process generates. Gases re-introduced from EGR systems will also contain near equilibrium concentrations of NO x and CO; the small fraction initially within

3127-471: The process) and then end up in the crankcase oil, where they will cause further wear throughout the engine simply because their tiny size passes through typical oil filters. This enables them to be recirculated indefinitely (until the next oil change takes place). Exhaust gas—which consists largely of nitrogen, carbon dioxide , and water vapor—has a higher specific heat than air, so it still serves to lower peak combustion temperatures. However, adding EGR to

3186-424: The same way that it does for spark-ignited engines. In a naturally aspirated (i.e. nonturbocharged) engine, such a reduction in throttling also reduces the problem of engine oil being sucked past the piston rings into the cylinder and causing oil-derived carbon deposits there. (This benefit only applies to nonturbocharged engines.) In diesel engines in particular, EGR systems come with serious drawbacks, one of which

3245-452: The size of the windshield was increased by over 60%, with additional attention paid to improvements in ventilation. At the launch of the 4000 series, the standard 4300 and higher-GVWR 4400 were introduced as replacements for the previous 4900 model series. In 2002, the lower-GVWR 4200 was introduced as the replacement for the 4700 series, marking the introduction of the VT365 engine. In 2006,

3304-401: The specific engine design, and sometimes leads to a compromise between efficiency and NO x emissions. In certain types of situations, a properly operating EGR can theoretically increase the efficiency of gasoline engines via several mechanisms: EGR is typically not employed at high loads because it would reduce peak power output. This is because it reduces the intake charge density. EGR

3363-436: The time after cold starts during which the engine controller has to inject somewhat larger amounts of fuel into the cylinders to counter the effects of fuel vapor condensation on cylinder walls and lowered combustion effectiveness because of the engine block still being below ideal operating temperature. Lowering combustion temperatures also helps reducing the oxidization of engine oil, as the most significant factor affecting that

3422-452: The vehicle is coasting or cruising). Power is not reduced by EGR at any times, as EGR is not employed in high load engine situations. This allows engines to still deliver maximum power when needed, but lower fuel consumption despite large cylinder volume when partial load is sufficient to meet the power needs of the car and the driver. EGR has nothing to do with oil vapor re-routing from a positive crankcase ventilation system (PCV) system, as

3481-539: Was relocated from Mexico to Ohio (replacing the E-Series van), with Navistar continuing production at General Escobedo. Semi-tractor International DuraStar In February 2001, Navistar released its all-new 4000 series, dubbed as "High Performance Trucks". Developed in the Blue Diamond Truck joint venture with Ford, the 4000 series marked the first completely new truck line from International since

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