Blue Star Power Systems · Diesel Product Line (Perkins)
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Blue Star PD80-01
80 kW standby · Diesel · Liquid-cooled
80 kW Tier 3 diesel standby generator built by Blue Star Power Systems. Perkins 1104D-E44TAG2 turbocharged intercooled engine, Stamford UCI224G alternator, DSE DCP7310 controller.
The Blue Star PD80-01 is an 80-kilowatt Tier 3 diesel standby generator powered by the Perkins 1104D-E44TAG2, a 4.4-liter electronically injected turbocharged and charge-air-cooled four-cylinder engine. Adding intercooling to the 4.4-liter Perkins platform unlocks 80 kWe output and improves altitude performance relative to the PD60-01.
Blue Star Power Systems (North Mankato, Minnesota) pairs the 1104D-E44TAG2 with a Stamford UCI224G alternator and DSE DCP7310 controller on a 90×44 in skid — a step up in footprint from the 80×38 in platform used by the PD50-01 and PD60-01. The 90×44 in pad is shared with the PD100-01, making future power upgrades straightforward without structural changes.
The 1104D-E44TAG2 combines electronic injection with turbocharging and charge air cooling to extract 80 kWe from 4.4 liters — the highest output of any non-intercooled competitor on the same displacement. The intercooler reduces combustion temperatures, which also contributes to the EPA Tier 3 certification. Exhaust temperature at 1,218°F is consistent with the intercooled operating cycle and should be accounted for in exhaust piping specifications.
The 1104D-E44TAG2 is one of the most widely serviced 4-cylinder Perkins generator engines. The intercooler adds a maintenance touchpoint — inspect hoses and charge air connections at each annual service. Follow the Perkins 1100D generator series schedule. Parts are globally available through the Perkins dealer network.
Tell us about the application — kW, voltage, application, install timeline — and we'll respond within one business day with budgetary pricing, lead time, and any sizing notes.
Adjust load percent and tank size to estimate runtime. Pre-filled with this model's spec where available.
Estimate runtime on this tank
Estimated runtime
39.2 hours(1.6 days)
Fuel consumption ≈ 5.11 GPH at 75% load. Estimate based on industry-typical 1800 RPM standby curves (≈0.07 GPH/kW at full load). Actual consumption varies by engine, ambient temperature, fuel quality, and tuning.
Service intervals
Manufacturer-recommended intervals for the Blue Star PD80-01 under standby duty. Field intervals may differ based on load profile, ambient conditions, and fuel quality.
Oil & filter
Every 500 hours or 12 months
Coolant change
Every 6000 hours
Air filter
Every 1000 hours
Fuel filter
Every 500 hours
Major overhaul
≈ 20,000 hours
Load bank test
Every 12 months
Common failure modes
What we've seen fail on this platform. Use as a service-planning reference, not a diagnostic — actual failure modes depend heavily on duty cycle and maintenance history.
Component
Symptom
Typical hours
Severity
Fuel quality / tank contamination
Hard starting, filter clogging, injector fouling
4,380+
moderate
Battery
Failed to start, slow crank
8,760+
minor
Coolant hoses
Slow coolant loss, weeping at clamps
8,000+
minor
Frequently Asked Questions
What engine does the PD80-01 use?
The Perkins 1104D-E44TAG2 — a 4.4-liter, four-cylinder electronically injected turbocharged and charge-air-cooled diesel rated for this 80 kWe standby application. The TAG designation indicates turbocharging plus charge air cooling (intercooling), which lowers intake charge temperature and allows the 4.4-liter block to produce 80 kWe. The same engine powers the PD100-01 at a higher output rating. It is EPA Tier 3 certified for stationary emergency use. Rated power is available up to 6,562 ft (2,000 m) at ambient temperatures to 104°F (40°C).
What controller does the PD80-01 use?
The DSE DCP7310 Digital Control Panel, with CAN Bus J1939 engine communication, digital metering, RS-485 interface, 8 programmable contact inputs, 10 contact outputs, and NFPA 110 Level 1 compatibility. It is cULus Listed and CE Approved with IP 65 ingress protection (with supplied gasket).
How does the PD80-01 compare to the PD60-01 and PD100-01?
The PD60-01 uses the non-intercooled 1104D-E44TG1 at 60 kWe on an 80×38 in skid (2,325 lbs, 4.98 gph). The PD80-01 adds charge air cooling (TAG2 designation) for 80 kWe on a larger 90×44 in platform (2,425 lbs, 6.62 gph). The PD100-01 uses the same 1104D-E44TAG2 engine at a higher output (100 kWe) on the same 90×44 in footprint, paired with a larger UCI274C alternator (2,500 lbs, 7.64 gph). The PD80-01 and PD100-01 share the same equipment pad dimensions.
What are the thermal and ventilation requirements for the PD80-01?
The PD80-01 requires 6,502 CFM of radiator cooling airflow and 312 CFM combustion air. Heat radiated to ambient is 100,740 BTU/hr; the coolant circuit rejects 188,220 BTU/hr. Exhaust exits at 1,218°F at 714 CFM — specify flexible exhaust connectors and a critical grade silencer rated for these conditions. For fuel planning: at full load (6.62 gph), a 500-gallon tank provides approximately 75 hours of runtime.
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100 kW standby · Diesel · Liquid-cooled
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