Bissell ION Rechargeable Vacuums Lithium Ion battery pack schematic

Introduction

Schematic and instructions for replacing rechargeable battery pack for Bissell ION vacuums.

What you need

Step 1 Battery

Careful: steps 1-5 are sourced from a guide that's marked as in-progress.

Bissell ION Rechargeable Vacuums Lithium Ion battery pack schematic, Battery: step 1, image 1 of 2

Bissell ION Rechargeable Vacuums Lithium Ion battery pack schematic, Battery: step 1, image 2 of 2

Push the silver button to disconnect the dirt dish from the handheld vacuum.

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Step 2

Remove the four 4 .4cm screws using your P0 screwdriver head and screwdriver.
Remove the Bissell sign to remove the two 4.4cm screws, using your P0 screwdriver head and screwdriver.

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Step 3

Bissell ION Rechargeable Vacuums Lithium Ion battery pack schematic: step 3, image 3 of 3

Using the metal spudger, insert and lift up to remove the frame from the body.
Move along the line and repeat on the other side.

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Step 4

Remove the orange frame
Remove the 3 screws on the right side of the vacuum.

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Step 5

Bissell ION Rechargeable Vacuums Lithium Ion battery pack schematic: step 5, image 3 of 3

With metal spudger remove the metal clip on both sides.
Pull device apart using great force

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Step 6 Battery Pack Schematic

Bissell ION Rechargeable Vacuums Lithium Ion battery pack schematic, Battery Pack Schematic: step 6, image 1 of 1

Three wires lead to a female connector, probably for cell balancing, voltage sensing, etc. They are blue, yellow and white (the black wire in this schematic.)
The batteries are 18650 Li-Ion, LG MG1: 2850 mAh, 10A 3.62v
The inline fuse on the (+) positive lead is F16AH250VP

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Step 7 Assembling the battery pack

Bissell ION Rechargeable Vacuums Lithium Ion battery pack schematic, Assembling the battery pack: step 7, image 1 of 3

Bissell ION Rechargeable Vacuums Lithium Ion battery pack schematic, Assembling the battery pack: step 7, image 2 of 3

Bissell ION Rechargeable Vacuums Lithium Ion battery pack schematic, Assembling the battery pack: step 7, image 3 of 3

Detach old battery pack (photo 1) from circuit board. My power leads were crimped, and easily de-crimped with a needle nose pliers.
Gently pry 3-wire female plug from circuit board.
Disassemble/desolder old pack. Loose assemble the new batteries. I used the old holding bracket (photo 2) and wires.
Solder batteries together according to schematic (photo 3.) Wrap completed pack in shrink wrap or electrical tape.
Connect (+) and (-) leads with crimps, solder, or small wire nuts. I used wire nuts.
Reconnect 3-wire plug to circuit board.
Place battery pack in handle location, and reassemble vacuum.

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Conclusion

There are no replacement battery packs available for the Bissell Bolt-ION series of rechargeable vacuum cleaners. Shame.

But making your own is easy if you have moderate soldering skills.

Get replacement batteries with soldering tabs. Four new ones should be about $25.