Question about Bissell 6594 PowerForce Bagless Upright Vacuum

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How to disassemble the brush to empty anything that might be stuck inside of the brush? The motor seems to be overheating, all belts have been checked, all airways are clear and the filter is clean. The vacuum is vibrating and releasing a burning smell, but still sucking up dirt. There is nothing stuck on the outside of the brush, but is there a way to check inside of it to see if that is where a clog is occuring?

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If there's a burning smell and the belts are fine, the problem is going to be hot wires causing the insulation to melt, or the motor going bad. Discontinue use and have it checked at a repair shop.

Posted on Apr 11, 2011

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Posted on Jan 02, 2017

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The brush roller is clogged with debris and unable to rotate. Because of this, the new belt was unable to move and the motor shaft spun in one place until it burned through. The brush roller has to be removed and disassembled to allow the end caps to be cleaned inside.

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The brushes don't appear to be spinning...it looks like the belt falls off, though it's not broken. Also, the motor reves down to what seems to be very slow speed if it's been on for more than a few...


The brush roller may be clogged on the ends, causing the belt to stretch and fall off. If you remove the brush roller and check for free rotation of the ends you may have to disassemble it to remove hair and/or other debris.

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My brush will not turn, and the brush control is stuck on "off"


I have had problems with the belts on my Mach 5 overheating (smell of burning rubber) and also with the motor overheating and shutting down.
I learned the hard way that one of the issues might be that the roller/brush on the bottom of the unit has a metal bearing inside the roller/brush that can become clogged with hair (both human and pet hair) which effects performance of the unit.
It’s fairly easy to fix.
Lay the vacuum on the floor so that you can see the roller/brush. Then remove the phillip head screws that hold the protective plastic plate over the roller/brush. (There are about 6 screws that hold this plastic protective plate in place) Also, you will be removing the (1) screw that also holds the plastic plate over the belts. There are (2) belts that you can remove and when in doubt replace these (2) belts for around $9.00.
Once you have the protective plastic plate off that covers the roller/brush disconnect the belt is around the roller. Take the roller and cut off any hair that is wrapped around the roller. Next, grab the roller by each end and twist the ends caps and (1) of the ends will unscrew. Once you have unscrewed one of the ends remove any hair or dust that is trapped under this cap. (Be careful not to lose the small metal washer that sit on top of the bearing)You will notice under this cap is a metal bearing that can become clogged and jammed with hair. The hair should come out fairly easy and allow the brush to spin fairly easy once you have screwed the end caps back in place test that it spins freely. If it doesn’t spin freely replace the roller/brush with a new one for about $23.00.
When you put the belts back on the thick rubber one (Belt # 40201-271) has probably become stretched and should be replaced for about $3.00. The small diameter belt that goes over the roller/brush probably does not usually need to be replaced and does not usually fit very tight. I have heard that people will take the small roller/brush belt and turn it upside down to get a better fit.
I just did this on my Mach 5 and it runs like a new machine. I did end up replacing the roller/brush head.
Hopefully you will find this useful.

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1 Answer

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