Building a Hydraulic Tree Remover on a Terex 1048 Square Shooter

[MikePhua]

The Terex 1048 and Its Role in Telehandler Innovation
The Terex 1048 Square Shooter is a rough-terrain telehandler designed for lifting, placing, and maneuvering heavy loads in construction and land-clearing environments. Introduced in the late 1990s, the 1048 featured a four-wheel drive chassis, telescopic boom, and a lifting capacity of approximately 10,000 lbs. Its square boom design improved torsional rigidity and load stability, especially when extended.
Terex Corporation, founded in 1933 as a division of General Motors, expanded aggressively into lifting and material handling equipment through acquisitions of brands like Genie and Powerscreen. The Square Shooter series was developed to compete with Lull and JLG in the high-capacity telehandler market. Though production of the 1048 model has since ceased, thousands remain in service across North America, particularly in forestry, demolition, and utility sectors.
Retrofitting a Tree Limb Remover onto a Telehandler
In a custom modification project, an operator sought to convert a Terex 1048 into a hydraulic tree limb and top remover. The concept involved replacing the standard forks with a specialized header equipped with multiple hydraulic cylinders. One function could be powered by the tilt cylinder’s hydraulic circuit, but the second required an independent oil supply.
This raised a common challenge in telehandler customization: how to route additional hydraulic lines down the boom without compromising structural integrity or mobility.
Hydraulic Routing Options and Cable Reel Integration
When factory auxiliary hydraulics are limited or undersized, operators must consider aftermarket solutions. One approach is to install a hydraulic cable reel system—similar to those used on lattice boom cranes. These reels:

• Mount near the boom tip or midsection
  
• Include roller guides to prevent hose abrasion
  
• Allow for continuous extension and retraction without kinking
  

However, cable reels can be expensive, often exceeding $2,000 for heavy-duty configurations. They also require careful alignment and anchoring to avoid interference with boom articulation.
In this case, the operator planned to use electric valve controls to manage multiple cylinder functions. That meant not only hydraulic routing but also electrical wiring—necessitating a wire reel or flexible conduit system to protect signal lines during boom movement.
Evaluating Factory Auxiliary Flow and Cylinder Demands
The Terex 1048 includes auxiliary hydraulic lines for fork leveling, but their diameter and flow rate may not be sufficient for multi-cylinder attachments. Typical flow rates for auxiliary circuits on older telehandlers range from 5 to 10 gallons per minute (GPM), depending on pump size and system pressure.
To determine compatibility:

• Measure cylinder bore and stroke to calculate oil volume per cycle
  
• Estimate cycle time requirements for each function
  
• Compare with available flow from the auxiliary circuit
  
• Consider sequential operation if simultaneous actuation exceeds flow limits
  

For example, a 3-inch bore cylinder with a 24-inch stroke requires roughly 2.9 gallons per full extension. At 5 GPM, that translates to a 35-second cycle time—acceptable for trimming but slow for production clearing.
Electric Valve Control and Multi-Function Management
Electric solenoid valves allow operators to switch between hydraulic functions using toggle switches or joystick buttons. These valves are typically mounted near the attachment and wired back to the cab. Key considerations include:

• Voltage compatibility (12V or 24V)
  
• Weatherproof connectors and harness routing
  
• Fuse protection and relay integration
  
• Control logic for priority or interlock functions
  

In one forestry application, a contractor used a four-function valve block with proportional control to operate a grapple, saw head, tilt cylinder, and limb pusher—all from a single joystick. The system was powered by the telehandler’s auxiliary circuit and managed via a custom switch panel.
Field Anecdote and Patent Development
The operator in this case had patented the tree limb and top remover, indicating a unique design tailored for selective clearing. Unlike traditional shears or mulchers, this tool likely focused on precision removal of upper canopy material—ideal for utility line maintenance or selective thinning.
In Georgia, a land-clearing crew retrofitted a similar system onto a Genie telehandler and used it to remove limbs overhanging power lines. The ability to reach 40 feet vertically and operate hydraulic tools from the cab reduced labor costs and improved safety.
Recommendations for Successful Integration
To ensure reliable operation of a custom hydraulic attachment on a Terex 1048:

• Confirm auxiliary flow and pressure specs with the manufacturer or dealer
  
• Use high-quality hose rated for continuous flexing
  
• Install a hydraulic accumulator if flow is intermittent
  
• Protect electrical wiring with braided sleeving and strain relief
  
• Test each function individually before full deployment
  

If factory hydraulics are insufficient, consider adding a PTO-driven pump or hydraulic power pack mounted on the chassis. These systems can deliver 15–20 GPM and operate independently of the boom’s movement.
Conclusion
Transforming a Terex 1048 Square Shooter into a tree limb remover is a bold and inventive project that blends hydraulic engineering with field practicality. While challenges like hose routing, flow limitations, and electrical integration must be addressed, the result is a versatile machine capable of precision canopy work. In the world of custom attachments, innovation often begins with a single question: “Can I make this do more?” With the right tools and vision, the answer is almost always yes.