The STIHL TSA 500 Cordless Cut-Off Machine is a high-output professional battery disc cutter built for demanding construction, landscaping, groundwork and pipework applications. Its 350 mm cutting wheel, maximum cutting depth of 125 mm and mechanical output of up to 4.2 kW provide the cutting capacity required for concrete, paving, brick, natural stone, reinforced concrete, rebar and steel.
Powered by two batteries from the professional STIHL AP System, the TSA 500 offers cutting performance comparable with the petrol STIHL TS 500i while removing the need for fuel, pull-starting and engine idling. It produces no exhaust emissions at the point of use and generates less vibration than a conventional petrol cut-off saw, helping the operator make accurate, controlled cuts.
Please note: this is a tool-only machine. Batteries and charger are not included. Two STIHL AP 500 S batteries are recommended for maximum performance.
STIHL TSA 500 at a glance
- Best suited to: professional construction, landscaping, hardscaping, groundwork, pipework and emergency-service applications
- Cutting-wheel diameter: 350 mm / 14 inches
- Maximum cutting depth: 125 mm / 4.9 inches
- Mechanical output: up to 4.2 kW
- Rated voltage: 72 V
- Battery system: STIHL AP / ALLPRO System
- Batteries required: two STIHL AP batteries
- Recommended batteries: two STIHL AP 500 S batteries
- Indicative working time: approximately 20–40 minutes with fully charged AP 500 S batteries, depending on the material, cutting wheel and working conditions
- Supplied with: 350 mm composite resin abrasive cutting wheel
- Battery and charger: not included
- STIHL part number: TA010116600
Why Masseys recommends the STIHL TSA 500
Masseys recommends the TSA 500 for professional users who need the cutting capacity of a full-size 350 mm cut-off saw but want to reduce their reliance on petrol machinery.
The combination of a 125 mm cutting depth, powerful 4.2 kW mechanical output and two-battery power supply makes it particularly well suited to demanding site work. Unlike a smaller cordless disc cutter, it has the capacity for substantial concrete, paving and steel-cutting jobs without sacrificing the instant starting, lower maintenance requirements and reduced vibration associated with battery power.
We would choose the TSA 500 for contractors already invested in the STIHL AP professional cordless system, as well as organisations looking to standardise a fleet of professional battery equipment. For maximum output, we recommend running it with two AP 500 S batteries and using a suitable STIHL diamond cutting wheel for longer or more intensive work.
Professional 350 mm cutting performance
The STIHL TSA 500 accepts 350 mm or 14-inch cutting wheels and provides a maximum cutting depth of 125 mm. This gives it the capacity to process a wide range of construction materials, including:
- Concrete and reinforced concrete
- Concrete blocks and bricks
- Paving slabs and kerbstones
- Natural stone
- Steel and structural metal
- Rebar
- Metal and plastic pipework, when used with the correct approved cutting wheel
Always select a cutting wheel approved for both the TSA 500 and the material being cut. The machine is supplied with a 350 mm composite resin abrasive wheel, while a suitable diamond wheel is recommended for prolonged or intensive cutting of mineral materials.
Two-battery 72 V power system
The TSA 500 draws power from two STIHL AP batteries, creating a 72 V operating system capable of delivering up to 4.2 kW of mechanical output.
Two STIHL AP 500 S batteries should be used when maximum cutting performance is required. AP 200 S and AP 300 S batteries may be compatible, but STIHL advises that the machine’s available performance will be reduced.
Users starting a new battery system will also need a compatible STIHL AP battery charger. For professional use, an AL 501 rapid charger or an AL 301-4 multiple charger can help reduce charging delays and manage several batteries more efficiently.
Comparable cutting performance to the petrol TS 500i
STIHL describes the TSA 500 as delivering cutting performance comparable with its petrol TS 500i. It is therefore a serious professional machine rather than a light-duty cordless alternative.
Battery operation provides several practical benefits:
- Instant electronic starting
- No petrol or two-stroke fuel mixture
- No engine idling between cuts
- No exhaust emissions at the point of use
- Lower vibration for more controlled cutting
- Reduced routine engine maintenance
- Lower operating noise between and during cuts
For customers who still prefer a conventional petrol-powered 350 mm machine, compare it with the STIHL TS 420 petrol cut-off saw.
Accurate, controlled cutting
The low-vibration EC motor and rigid construction help the operator follow marked cutting lines accurately. Because there is less engine vibration than with a petrol machine, the TSA 500 can produce a narrower, more controlled cutting kerf.
The ergonomic handle layout and positioning of the motor and batteries are designed to distribute the machine’s weight evenly. This improves control when beginning a cut and helps reduce fatigue during repeated professional use.
Three operating levels and digital controls
The HMI ADVANCE PLUS control interface provides clear machine and battery information directly on the operating handle. The operator can view the battery charge status and select from three operating levels to match the wheel speed and power delivery to the application.
STIHL Constant Power electronics help the TSA 500 maintain a consistently high level of performance as the batteries discharge. Power Boost communication between the machine and compatible batteries also makes the maximum available battery output accessible when the cutting load requires it.
Fast-stop brake with energy recuperation
When the trigger is released, the fast-stop brake brings the cutting wheel to a standstill in less than four seconds. Energy recovered during braking is fed back into the batteries, helping to extend the available working time.
The rapid stopping action also allows the operator to move between cuts more efficiently than with a wheel that continues to rotate for an extended period.
Water connection for dust suppression
An integrated, adjustable water connection supplies water directly to the cutting area. This helps suppress airborne dust, cool the cutting wheel and maintain visibility during wet cutting.
The adjustable magnesium wheel guard includes an integrated water guide and directs cutting residue away from the operator. Its design also provides a clear view of the cutting wheel and cutting line.
Cutting concrete, masonry and other silica-containing materials can create hazardous dust. Appropriate water suppression or approved dust extraction, respiratory protection and site-control measures must always be used.
STIHL magnetic filter
Metal cutting can draw fine ferromagnetic particles into the machine’s cooling airflow. The STIHL magnetic filter captures these particles before they reach the motor, helping protect internal components and maintain long-term performance.
The magnets can be removed and cleaned, making routine maintenance straightforward for contractors regularly cutting steel or reinforced materials.
Low-maintenance EC motor
The brushless EC motor is efficient, smooth-running and almost wear-free. It does not require the fuel-system, spark-plug or engine-filter maintenance associated with a petrol cut-off saw.
Electronic motor management also monitors operating conditions and can temporarily adjust output if the machine or batteries are placed under excessive load.
Suitable for demanding outdoor work
The TSA 500 carries an IPX4 splash-water protection rating and is designed for professional work in typical wet-weather conditions. This does not mean that the machine or batteries should be submerged or cleaned with a pressure washer.
Can the STIHL TSA 500 be used indoors?
Because the TSA 500 produces no petrol exhaust emissions at the point of use, it can be considered for indoor work where a combustion-engine cut-off saw would be unsuitable.
However, battery operation does not remove the hazards created by cutting dust, sparks, noise or the material being processed. Indoor operation must only take place with appropriate ventilation, dust suppression or extraction, personal protective equipment and a suitable workplace risk assessment.
STIHL TSA 500 versus TSA 300
The TSA 500 is the better choice when maximum cordless cutting capacity is the priority:
- TSA 500: 350 mm cutting wheel, 125 mm maximum cutting depth and up to 4.2 kW mechanical output
- TSA 300: smaller 300 mm cutting wheel and 110 mm maximum cutting depth, with a more compact and portable design
Choose the TSA 500 for deeper cuts, larger materials and intensive professional work. Choose the STIHL TSA 300 cordless cut-off saw where lower weight and easier handling are more important than maximum cutting depth.
For shorter cuts and smaller 230 mm wheels, the STIHL TSA 230 cordless cut-off saw may be a more economical and compact option.
What is included?
- STIHL TSA 500 cordless cut-off machine
- 350 mm composite resin abrasive cutting wheel
- Integrated water connection
- STIHL connected functionality
- Instruction manual
Not included:
- STIHL AP batteries
- STIHL battery charger
- Diamond cutting wheel
- Personal protective equipment
Technical specifications
| Model | STIHL TSA 500 |
|---|---|
| Machine type | Professional cordless cut-off machine |
| Battery system | STIHL AP / ALLPRO System |
| Rated voltage | 72 V |
| Maximum voltage | 80 V |
| Mechanical output | Up to 4.2 kW |
| Batteries required | Two STIHL AP batteries |
| Recommended batteries | Two STIHL AP 500 S batteries |
| Cutting-wheel diameter | 350 mm / 14 inches |
| Maximum cutting depth | 125 mm / 4.9 inches |
| Working time | Approximately 20–40 minutes with fully charged AP 500 S batteries, depending on use |
| Motor | Brushless EC motor |
| Operating levels | Three selectable levels |
| Dust suppression | Integrated adjustable water connection |
| Connectivity | STIHL connected integrated |
| Weather protection | IPX4 splash-water protection |
| Part number | TA010116600 |
| Battery and charger included | No – tool only |
Frequently asked questions
How many batteries does the STIHL TSA 500 need?
The TSA 500 operates using two STIHL AP batteries at the same time. Two AP 500 S batteries are recommended for maximum cutting performance.
Are batteries included with the TSA 500?
No. The TSA 500 is supplied as a tool-only machine without batteries or charger.
Can the TSA 500 use AP 300 S batteries?
AP 300 S and AP 200 S batteries may be used, but STIHL advises that the available machine performance will be reduced. Two AP 500 S batteries are required to achieve maximum output.
How deep can the STIHL TSA 500 cut?
The maximum cutting depth is 125 mm when used with an approved 350 mm cutting wheel.
What materials can the TSA 500 cut?
With the correct approved cutting wheel, the TSA 500 can cut concrete, reinforced concrete, bricks, paving, natural stone, steel, rebar and suitable pipe materials.
Does the TSA 500 come with a cutting wheel?
Yes. It is supplied with a 350 mm composite resin abrasive cutting wheel. A suitable diamond wheel is recommended for intensive cutting of concrete, paving and other mineral materials.
How long does the battery last?
STIHL gives an indicative working time of approximately 20–40 minutes with AP 500 S batteries. Actual working time varies according to the material, cutting wheel, cutting depth, operating level, battery condition and operator technique.
Is the TSA 500 as powerful as a petrol cut-off saw?
STIHL states that the TSA 500 provides cutting performance comparable with the petrol TS 500i, with mechanical output of up to 4.2 kW.
Can the TSA 500 be used in the rain?
The machine has an IPX4 splash-water protection rating and is designed for professional work in wet-weather conditions. It must not be submerged or cleaned using a pressure washer.
Can the STIHL TSA 500 be used indoors?
The machine produces no exhaust emissions at the point of use, but cutting can still create hazardous dust, sparks and noise. Suitable dust suppression or extraction, ventilation, PPE and workplace controls remain essential.
Buy the STIHL TSA 500 from Masseys
Masseys is an authorised STIHL dealer based in Swadlincote, Derbyshire. Our team can help you select the correct AP batteries, charger and cutting wheel for the materials and workload you expect to handle.
Visit our Swadlincote showroom for professional advice, or browse our complete range of STIHL cut-off saws and cordless cut-off machines online.
