Bosch 1521 User Manual

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BM 3609929810 11-0411/15/04

10:40 AM Page 1





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Power Tool Safety Rules

! WARNING Read and understand all instructions. Failure to follow all instructions listed below, may result in electric shock, fire and/or serious personal injury.


Work Area

Keep your work area clean and well lit.

Cluttered benches and dark areas invite accidents.

Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases, or dust. Power tools create sparks which may ignite the dust or fumes.

Keep by-standers,children, and visitors away while operating a power tool.

Distractions can cause you to lose control.

Electrical Safety

Double Insulated tools are equipped with a polarized plug (one blade is wider than the other.) This plug will fit in a polarized outlet only one way. If the plug does not fit fully in the outlet, reverse the plug. If it still does not fit, contact a qualified electrician to install a polarized outlet. Do not change the plug in any way. Double Insulation eliminates the need for the three wire grounded power cord and grounded power supply system. Before plugging in the tool, be certain the outlet voltage supplied is within the voltage marked on the nameplate. Do not use “AC only” rated tools with a DC power supply.

Avoid body contact with grounded surfaces such as pipes, radiators, ranges and refrigerators. There is an increased risk of electric shock if your body is grounded. If operating the power tool in damp locations is unavoidable, a Ground Fault Circuit Interrupter must be used to supply the power to your tool. Electrician’s rubber gloves and footwear will further enhance your personal safety.

Don't expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock.

Do not abuse the cord. Never use the cord to carry the tools or pull the plug from an outlet. Keep cord away from heat,

oil, sharp edges or moving parts. Replace damaged cords immediately. Damaged cords increase the risk of electric shock.

When operating a power tool outside, use an outdoor extension cord marked "W-A"or "W."These cords are rated for outdoor use and reduce the risk of electric shock. Refer to “Recommended sizes of Extension Cords” in the Accessory section of this manual.

Personal Safety

Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use tool while tired or under the influence of drugs, alcohol, or medication. A moment of inattention while operating power tools may result in serious personal injury.

Dress properly. Do not wear loose clothing or jewelry. Contain long hair. Keep your hair, clothing, and gloves away from moving parts. Loose clothes, jewelry, or long hair can be caught in moving parts. Keep handles dry, clean and free from oil and grease.

Avoid accidental starting. Be sure switch is “OFF” before plugging in. Carrying tools with your finger on the switch or plugging in tools that have the switch “ON” invites accidents.

Remove adjusting keys or wrenches before turning the tool “ON”. A wrench or a key that is left attached to a rotating part of the tool may result in personal injury.

Do not overreach. Keep proper footing and balance at all times. Proper footing and balance enables better control of the tool in unexpected situations.

Use safety equipment. Always wear eye protection. Dust mask, non-skid safety shoes, hard hat, or hearing protection must be used for appropriate conditions.


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Tool Use and Care

Use clamps or other practical way to secure and support the workpiece to a stable platform. Holding the work by hand or against your body is unstable and may lead to loss of control.

Do not force tool. Use the correct tool for your application. The correct tool will do the job better and safer at the rate for which it is designed.

Do not use tool if switch does not turn it “ON” or “OFF”. Any tool that cannot be controlled with the switch is dangerous and must be repaired.

Disconnect the plug from the power source before making any adjustments, changing accessories, or storing the tool.

Such preventive safety measures reduce the risk of starting the tool accidentally. Store idle tools out of reach of children and other untrained persons. Tools are dangerous in the hands of untrained users.

Maintain tools with care. Keep cutting tools sharp and clean. Properly maintained tools, with sharp cutting edges are less likely to bind and are easier to control. Any alteration or modification is a misuse and may result in a dangerous condition.

Check for misalignment or binding of moving parts, breakage of parts, and any

other condition that may affect the tools operation. If damaged, have the tool serviced before using. Many accidents are caused by poorly maintained tools. Develop a periodic maintenance schedule for your tool.

Use only accessories that are recommended by the manufacturer for your model. Accessories that may be suitable for one tool, may become hazardous when used on another tool.


Tool service must be performed only by qualified repair personnel. Service or maintenance performed by unqualified personnel could result in a risk of injury. For example: internal wires may be misplaced or pinched, safety guard return springs may be improperly mounted.

When servicing a tool, use only identical replacement parts. Follow instructions in the Maintenance section of this manual.

Use of unauthorized parts or failure to follow Maintenance Instructions may create a risk of electric shock or injury. Certain cleaning agents such as gasoline, carbon tetrachloride, ammonia, etc. may damage plastic parts.

Safety Rules for Shears

Hold tools by insulated gripping surfaces when performing an operation where the cutting tool may contact hidden wiring or it own cord. Contact with a "live" wire will make exposed metal parts of the tool "live" and shock the operator.

Always unplug the tool from the power source before changing accessories or making any adjustments. Accidental start up may occur causing serious personal injury.

Always wear safety goggles or eye protection, leather gloves and safety shoes when using this tool. Shears produce sharp metal strips or edges that if

contacted can lacerate skin easily.

Wear ear protectors when using the tool for extended periods. Prolonged exposure to high intensity noise can cause hearing loss.

Use thick cushioned gloves and limit the exposure time by taking frequent rest periods. Vibration caused by shearing action may be harmful to your hands and arms.

Do not run the tool while carrying it at your side. The cutters could become entangled with clothing and injury may result.



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Secure the material being cut. Never hold small pieces in your hand or across your legs. Do not touch cutters or reach below work or remove cut material during use of the shear. Shears that cut metal will cut skin easily.

Protect the cord from sharp metal edges or strips while shearing metals. Position the cord clear of rotating bit. Sharp metal edges can pierce the jacket of the cord, which can be a shock hazard.

Do not cut material greater than the rated capacity of the shear. Cutting material greater than the capacity of the shear may cause damage to the cutting edges of the shear.

Do not use dull or damaged cutters or accessories not intended for this shear. Replace worn cutters. Sharp cutters minimize stalling.


Some dust created by power sanding, sawing, grinding, drilling, and other construction

activities contains chemicals known to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are:

Lead from lead-basedpaints,

Crystalline silica from bricks and cement and other masonry products, and

Arsenic and chromium from chemicallytreated lumber.

Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these chemicals: work in a well ventilated area, and work with approved safety equipment, such as those dust masks that are specially designed to filter out microscopic particles.

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IMPORTANT: Some of the following symbols may be used on your tool. Please study them and learn their meaning. Proper interpretation of these symbols will allow you to operate the tool better and safer.










Voltage (potential)












Frequency (cycles per second)


































Size of drill bits, grinding wheels, etc.





No load speed

Rotational speed, at no load


Revolutions or reciprocation per minute

Revolutions, strokes, surface speed,











orbits etc. per minute





Off position

Zero speed, zero torque...

1, 2, 3, ...

Selector settings

Speed, torque or position settings.



Higher number means greater speed








Infinitely variable selector with off

Speed is increasing from 0 setting











Action in the direction of arrow



















Alternating current

Type or a characteristic of current










Direct current

Type or a characteristic of current



















Alternating or direct current

Type or a characteristic of current



















Class II construction

Designates Double Insulated




















Construction tools.




















Earthing terminal

Grounding terminal



















Warning symbol

Alerts user to warning messages




























Ni-CadRBRC seal

Designates Ni-Cadbattery recycling























This symbol designates that this tool is listed by Underwriters Laboratories.

This symbol designates that this tool is listed by the Canadian Standards Association.

This symbol designates that this tool is listed to Canadian Standards by Underwriters Laboratories.

This symbol designates that this tool is listed by Underwriters Laboratories, and listed to Canadian Standards by Underwriters Laboratories.

This symbol designates that

this tool complies to NOM Mexican Standards.



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Functional Description and Specifications

Disconnect the plug from the power source before making any assembly, adjustments or changing accessories. Such preventive safety

measures reduce the risk of starting the tool accidentally.

Sheat Metal Shear

FIG. 1










FIG. 2









#2 608 635 406

Model number



Voltage rating

120 V

50 - 60Hz





FIG. 3








#2 608 635 410 EACH

Amperage rating

4.5 A

No load speed

n0 5,600/min


Shear Capacities:





Max. Sheet Thickness

Mild Steel (60,000 PSI)

up to


Ga. (.060")

Most Alum. (36,000 PSI)

up to


GA. (.075")

Stainless (87,000 PSI)

up to


Ga. (.036")


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Always unplug the tool from the power source before changing accessories or making any adjustments.

The blade should not be reground.

1.Push the blade pin far enough to the right or left so you will be able to pull the blade pin out of the shear head (Fig. 2).

2.Pull blade forward out of the shear head.

3.Lightly grease the blade pin and the new blade, and insert the blade into the head of the shear..

4.Align hole in blade with hole in the shear head, and push the blade pin through hole in blade until feel a detent.


The cutting jaws should not be reground.

The cutter jaws and are identical, and can be interchanged to extend the life.

When the cutting performance is unsatisfactory, rotate each cutter 180° or replace.

To rotate,remove allen screws with the wrench provided and rotate the cutter jaws 180° and mount them on opposite sides of the shear head, if both sides of the cutter jaws are blunt they must be replaced (Fig. 3).

The use of any accessory or attachment other than recommended in this instruction manual or the BOSCH Catalog may present a risk of personal injury.

Operating Instructions


Following a few simple tips will reduce wear on the tool and the chance of injury to the user.

With the tool unplugged from the power supply and the ON/OFF Switch in the “OFF” position, become familiar with handling the shear and learning the location of its parts.

Secure or clamp small workpieces to be cut to prevent slippage.

Inspect the blades for excessive wear, rotate or replace if necessary.

Always direct the cord toward the rear, and away from the shear. Keep it away from sharp edges.

Never start the shear with the blades in contact with the material being cut.

Do not exceed recommended capacities for this shear. Premature blade failure will occur when the shear is over-gaged.

To extend blade life and prevent corrosion, occasional light lubrication of the blades is recommended. Any light weight machine oil can be used for this purpose.


The tool is switched “ON” by the switch button located at the side of the motor housing. The switch can be locked in the “ON” position, a convenience for long cutting operations.

TO TURN THE TOOL “ON” without locking it, slide the switch button forward by applying pressure ONLY at the REAR portion of the button. When pressure is released the switch button will snap to “OFF” position.

TO LOCK THE SWITCH “ON”, slide the switch button forward and press “IN” the FRONT portion.

TO UNLOCK THE SWITCH, simply press and release the REAR portion of the button. Switch is spring loaded and will snap back automatically.

Start the tool before applying to work and let the tool come to full speed before contacting the workpiece. Lift the tool from the work before releasing the switch. DO NOT turn the switch “ON” and “OFF” while the tool is under load; this will greatly decrease the switch life.



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Tool Tips

Before cutting, lightly oil the cutting line.

Do not tilt tool to the side.

Hold the tool at a angle 15° to the metal surface (fig. 4.)

FIG. 4


Excessive feed rates reduce the performance considerably and shorten the life of the cutters.

Sharp cutters produce good cutting results and protects the tool.

Do not load the tool so heavily that it stalls.

Cutting curved lines: Do not tilt the tool and work with low feed rate.

See special cutter blades on page 9 for various materials.



Preventive maintenance performed by unauthorized personnel may result in misplacing of

internal wires and components which could cause serious hazard. We recommend that all tool service be performed by a Bosch Factory Service Center or Authorized Bosch Service Station.


Your Bosch tool has been properly lubricated and is ready to use. It is recommended that tools with gears be regreased with a special gear lubricant at every brush change.


The brushes and commutator in your tool have been engineered for many hours of dependable service. To maintain peak efficiency of the motor, we recommend every two to six months the brushes be examined. Only genuine Bosch replacement brushes specially designed for your tool should be used.


After about 300-400hours of operation, or at every second brush change, the bearings

should be replaced at Bosch Factory Service Center or Authorized Bosch Service Station. Bearings which become noisy (due to heavy load or very abrasive material cutting) should be replaced at once to avoid overheating or motor failure.


To avoid accidents always disconnect the tool from the power supply before cleaning or

performing any maintenance. The tool may be cleaned most effectively with compressed dry air. Always wear safety goggles when cleaning tools with compressed air.

Ventilation openings and switch levers must be kept clean and free of foreign matter. Do not attempt to clean by inserting pointed objects through openings.

Certain cleaning agents ! CAUTION and solvents damage

plastic parts. Some of these are: gasoline, carbon tetrachloride, chlorinated cleaning solvents, ammonia and household detergents that contain ammonia.



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If an extension cord is necessary, a cord with adequate size conductors that is capable of

carrying the current necessary for your tool must be used. This will prevent excessive voltage drop, loss of power or overheating. Grounded tools must use 3-wire extension cords that have 3-prong plugs and receptacles.

NOTE: The smaller the gauge number, the heavier the cord.



Cord Size in A.W.G.

Wire Sizes in mm2


















Cord Length in Feet

Cord Length in Meters


































































*Standard cutter blade for 18 to 16 gauge mild steel and striaght cut #2 608 635 406

*Hex key 1/8" (3mm) #1 907 950 003

**Side blade #2 608 635 410

**Cutter blade for 20 to 24 gauge mild steel and striaght cut # 2 608 635 407

**Cutter blade for curve cutting # 2 608 635 408

**Cutter blade for 20 gauge stainless steel #2 608 635 409

(*= standard equipment)

(**= optional accessories)


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Règles de Sécurité Générales



Vous devez lire et comprendre toutes les instructions. Le non-respect, même


partiel, des instructions ci-aprèsentraîne un risque de choc életrique, d'incendie

et/ou de blessures graves.




Aire de travail

Veillez à ce que l'aire de travail soit propre et bien éclairée. Le désordre et le manque de lumière favorisent les accidents.

N'utilisez pas d'outils électriques dans une atmosphère explosive, par exemple enprésence de liquides, de gaz ou de poussières inflammables. Les outils électriques créent des étincelles qui pourraient enflammer les poussières ou les vapeurs.

Tenez à distance les curieux, les enfants et les visiteurs pendant que vous travaillez avec un outil électrique. Ils pourraient vous distraire et vous faire faire une fausse manoeuvre.

Sécurité électrique

Les outils à double isolation sont équipés d'une fiche polarisée (une des lames est pluslarge que l'autre), qui ne peut se brancher que d'une seule façon dans une prise polarisée. Si la fiche n'entre pas parfaitement dans la prise, inversez sa position ; si elle n'entre toujours pasbien, demandez à un électricien qualifié d'installer une prise de courant polarisée. Ne modifiez pas la fiche de l'outil. La double isolation élimine le besoin d'un cordon d'alimentationà trois fils avec mise à la terre ainsi que d'une prise de courant mise à la terre. Avant de brancher l'outil, assurez-vous que la tension de la prise correspond, à celle indiquée sur la plaque signalétique. N'utilisez pas d'outils prévus pour courant alternatif seulement avec une source de courant continu.

Évitez tout contact corporel avec des surfaces mises à la terre (tuyauterie, radiateurs, cuisinières, réfrigérateurs, etc.). Le risque de choc électrique est plus grand si votre corps est encontact avec la terre.Si l'utilisation de l'outil électrique dans un endroit humide est inévitable, un disjoncteur de fuite à la terre doit être utilisé pour alimenter votre outil. Des chaussures et des gants en caoutchouc d'électricien contribueront à accroître davantage votre sécurité personnelle.

N'exposez pas les outils électriques à la pluie ou à l'eau. La présence d'eau dans un outil électrique augmente le risque de choc électrique.

Ne maltraitez pas le cordon. Ne transportez pas l'outil par son cordon et ne débranchez pas la fiche en tirant sur le cordon. N'exposez pas le cordon à la chaleur, à des huiles, à des arêtes vives ou à des pièces en mouvement. Remplacez immédiatement un cordon endommagé. Un cordon endommagé augmente le risque de choc électrique.

Lorsque vous utilisez un outil électrique à l'extérieur, employez un prolongateur pour l'extérieur marqué « W-A» ou « W ».Ces cordons sont faits pour être utilisés à l'extérieur et réduisent le risque de choc électrique. Reportez-vous aux « Dimensions recommandées des cordons de rallonge » dans la section Accessoires de ce manuel.

Sécurité des personnes

Restez alerte, concentrez-voussur votre travail et faites preuve de jugement. N'utilisez pas un outil électrique si vous êtes fatigué ou sous l'influence de drogues, d'alcool ou de médicaments.Un instant d'inattention suffit pour entraîner des blessures graves.

Habillez-vousconvenablement. Ne portez ni vêtements flottants ni bijoux. Confinez les cheveux longs. N'approchez jamais les cheveux, les vêtements ou les gants des pièces en mouvement.

Des vêtements flottants, des bijoux ou des cheveux longs risquent d'être happés par des pièces en mouvement. Gardez les poignées sèches, propres et exemptes d'huile et de graisse.

Méfiez-vousd'un démarrage accidentel. Avant de brancher l'outil,assurez-vousque son interrupteur est sur ARRÈT.Le fait de transporter un outil avec le doigt sur la détente ou de brancher un outil dont l'interrupteur est en position MARCHE peut mener tout droit à un accident.

Enlevez les clés de réglage ou de serrage avant de démarrer l'outil. Une clé laissée dans une pièce tournante de l'outil peut provoquer des blessures.

Ne vous penchez pas trop en avant. Maintenez un bon appui et restez en équilibre entout temps. Une bonne stabilité vous permet de mieux réagir à une situation inattendue.

Utilisez des accessoires de sécurité. Portez toujours des lunettes ou une visière. Selon les conditions, portez aussi un masque antipoussière, des bottes de sécurité antidérapantes, un casque protecteur et/ou un appareil antibruit.

Utilisation et entretien des outils

Immobilisez le matériau sur une surface stable au moyen de brides ou de toute autre façon adéquate. Le fait de tenir la pièce avec la main ou contre votre corps offre une stabilité insuffisante et peut amener un dérapage de l'outil.