Reinforcing a Worn Hensley Bucket on a Komatsu PC210-10 with Wear Bars

[MikePhua]

The PC210-10’s Role in Mid-Class Excavation
The Komatsu PC210-10 hydraulic excavator is a globally recognized workhorse in the 20-ton class. Designed for general construction, quarrying, and utility work, it combines fuel efficiency with high breakout force and advanced hydraulic control. Komatsu, founded in 1921 in Japan, has sold millions of excavators worldwide, and the PC210 series remains one of its most popular models. The PC210-10 features a Komatsu SAA6D107E-2 engine, delivering around 165 hp, and supports a wide range of buckets and attachments.
One of the most common aftermarket upgrades for this machine is reinforcing the bucket—especially when paired with a Hensley heavy-duty digging bucket. Over time, abrasive materials like granite, concrete, or compacted clay wear down the bucket shell, especially the underside. Adding wear bars is a proven strategy to extend bucket life and reduce downtime.
Terminology Notes

• Wear Bar: A hardened steel strip welded to high-wear areas of a bucket to absorb abrasion.
  
• Bucket Shell: The curved underside of the bucket that contacts material during digging.
  
• Base Edge: The leading edge of the bucket where teeth are mounted.
  
• Hardfacing: A welding technique that deposits abrasion-resistant material onto surfaces.
  
• AR Plate: Abrasion-resistant steel, often used for wear bars and liners.
  

Why Reinforce with Wear Bars
Buckets are subjected to constant friction, impact, and material flow. Once the shell wears thin, structural integrity is compromised, and cracks or punctures can occur. Replacing a bucket costs thousands of dollars, while adding wear bars costs a fraction and can double the service life.
Benefits include:

• Increased resistance to abrasion and gouging
  
• Reduced shell deformation under load
  
• Easier future maintenance (bars can be replaced individually)
  
• Lower long-term operating costs
  
• Improved resale value of the bucket
  

Field Case: Quarry Loader in Alberta
A PC210-10 operating in a limestone quarry showed signs of excessive wear on its Hensley bucket. The shell had thinned to under 5 mm in places. The crew welded six AR400 wear bars across the bottom, spaced evenly and stitched with 7018 rod. After 1,200 hours of use, the bars showed minimal wear, and the bucket remained structurally sound. “It’s like armor plating,” the operator said. “We stopped chewing through steel.”
Recommended Installation Strategy

• Clean bucket underside thoroughly with grinder and degreaser
  
• Use AR400 or AR500 steel bars, ¾" to 1" thick
  
• Preheat bucket shell to ~150°C to prevent cracking
  
• Weld using low-hydrogen rod (e.g., 7018) or flux-core wire
  
• Stitch weld in 6" increments to allow thermal expansion
  
• Space bars 4–6 inches apart for balanced coverage
  
• Cap ends of bars to prevent peeling or snagging
  

Suggested Parameters and Materials

• Wear Bar Thickness: ¾" minimum for general use, 1" for quarry work
  
• Bar Width: 3–4 inches
  
• Welding Rod: E7018 or dual-shield flux-core wire
  
• Preheat Temperature: 120–180°C depending on ambient conditions
  
• Weld Length: 6–8 inches per pass with 2-inch gaps
  
• Material Grade: AR400 or better
  

Preventive Maintenance Tips

• Inspect wear bars every 250 hours for cracking or delamination
  
• Re-weld loose ends before they catch and tear
  
• Grind smooth any sharp edges to prevent hang-ups
  
• Monitor shell thickness with ultrasonic gauge annually
  
• Avoid digging with excessive downforce on flat surfaces
  
• Keep bucket teeth sharp to reduce drag on the shell
  

Operator Anecdotes and Practical Wisdom
A demolition crew in Maine reinforced their bucket with staggered wear bars and added hardfacing beads between them. The combination resisted concrete rubble and rebar abrasion. “It’s not just steel—it’s strategy,” the foreman said.
In Georgia, a contractor used recycled grader blades as wear bars. Though unconventional, the hardened steel lasted over 800 hours in clay. “It’s field ingenuity,” the technician noted. “Not everything needs a catalog.”
Parts Availability and Support

• AR400 and AR500 wear bars available through steel suppliers and bucket manufacturers
  
• Welding consumables stocked by industrial distributors
  
• Templates and jigs for bar placement can be fabricated in-house
  
• Technical manuals include bucket specs and welding guidelines
  
• Hensley buckets supported by Komatsu dealers and aftermarket vendors
  

Conclusion
Adding wear bars to a worn Hensley bucket on a Komatsu PC210-10 is a practical, cost-effective upgrade that pays dividends in durability and uptime. With proper material selection, welding technique, and inspection discipline, operators can extend bucket life dramatically. In the world of excavation, protection isn’t passive—it’s proactive. And a well-armored bucket is a statement of foresight, not just fabrication.