ZD620 and ZD420

Desktop Printers with Link-OS®

Service Manual

212529-002
Copyright

© 2017 ZIH Corp. and/or its affiliates. All rights reserved. ZEBRA and the stylized Zebra
head are trademarks of ZIH Corp., registered in many jurisdictions worldwide. All other
trademarks are the property of their respective owners.
COPYRIGHTS AND TRADEMARKS: For complete copyright and trademark information, go to www.zebra.com/copyright
WARRANTY: For complete warranty information, go to www.zebra.com/warranty
END USER LICENSE AGREEMENT: For complete EULA information, go to www.zebra.com/eula

Terms of Use

Proprietary Statement: This manual contains proprietary information of Zebra

Technologies Corporation and its subsidiaries (“Zebra Technologies”). It is intended solely
for the information and use of parties operating and maintaining the equipment described
herein. Such proprietary information may not be used, reproduced, or disclosed to any
other parties for any other purpose without the express, written permission of Zebra
Technologies.
Product Improvements: Continuous improvement of products is a policy of Zebra
Technologies. All specifications and designs are subject to change without notice.
Liability Disclaimer: Zebra Technologies takes steps to ensure that its published
Engineering specifications and manuals are correct; however, errors do occur. Zebra
Technologies reserves the right to correct any such errors and disclaims liability resulting
therefrom.
Limitation of Liability: In no event shall Zebra Technologies or anyone else involved in
the creation, production, or delivery of the accompanying product (including hardware and
software) be liable for any damages whatsoever (including, without limitation,
consequential damages including loss of business profits, business interruption, or loss of
business information) arising out of the use of, the results of use of, or inability to use such
product, even if Zebra Technologies has been advised of the possibility of such damages.
Some jurisdictions do not allow the exclusion or limitation of incidental or consequential
damages, so the above limitation or exclusion may not apply to you.

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Online resources available to support this printer
• ZD620 and ZD420 Desktop Printers User’s Manual
• “How To” videos
• ZD620 or ZD420 Desktop Printer Product page links for printer specifications
• Printer accessory, supplies, parts, and software links
• Various setup and configuration guides
• Programmer’s manuals
• Printer Drivers (Windows, Apple, OPOS, etc.)
• Printer Firmware
• Printer Fonts
• Utilities
• Knowledge base and support contacts
• Printer warranty and repair links

Use these links to get to your Online printer support resources:

• ZD620 Thermal Transfer Printer — www.zebra.com/zd620t-info
• ZD620 Direct Thermal Printer — www.zebra.com/zd620d-info
• ZD420 Thermal Transfer Ribbon Cartridge Printer — www.zebra.com/zd420c-info
• ZD420 Thermal Transfer Printer — www.zebra.com/zd420t-info
• ZD420 Direct Thermal Printer — www.zebra.com/zd420d-info

3
Other Valuable Printer Resources
Zebra has a large suite of free and fee based software, Apps (applications), and other
technical resources for your Zebra Link-OS printer.
These are just some of the extensive software and resource areas available Online:
• Label Design software
• Printer Management tools
• Virtual Devices for legacy languages normally associated with other printer
brands
• Cloud based Enterprise printer management and printing
• XML and PDF format file printing
• Oracle and SAP support
• IoT data tools (Zatar)
• A suite of Link-OS Mobile Apps (applications for phones, tablets, etc.)
• Link-OS software development kit (SDK)
• Additional Operating Systems (OS) and Service platforms

See ZebraLink, Zebra Link-OS, and Zatar from this Online link: www.zebra.com/software

Zebra OneCare Printer Service and Support

For maximum productivity, we can help your business ensure its Zebra printers are Online
and ready for business. See the descriptions of the Zebra OneCare service and support
options available for your printers Online at this link: www.zebra.com/zebraonecare

Environmental Management
Do not dispose of this product in unsorted municipal waste. This product is recyclable, and
should be recycled according to your local standards.
For more information, please see our website at:
Web address: www.zebra.com/environment

4
Document Conventions

The following graphic icons are used throughout the documentation set. These icons and
their associated meanings are described below.
Caution • If the precaution is not heeded, the user could receive minor or moderate injury.

Eye Injury Caution • If the precaution is not taken, the user’s eyes could be damaged. EXAMPLE:
Wear protective eyewear when installing or removing E-rings, C-clips, snap rings, springs, and
mounting buttons. These are under tension and could fly off.

Electrical Shock Caution • If the precaution is not taken, the user could receive an electrical shock.
EXAMPLE: Turn off (O) the printer and disconnect it from the power source before performing the
following procedure.

Hot Surface Caution • If the precaution is not taken, the user could be burned. EXAMPLE: The
printhead may be hot and could cause sever burns. Allow the printhead to cool.

Product Damage Caution • If the precaution is not taken, the product could be damaged.
EXAMPLE: Unplugging the computer without properly shutting it down may corrupt the data on your
hard drive.

ESD Caution • If the precaution is not taken, the product electronics could be damaged by an
electrostatic discharge. EXAMPLE: Observe proper electrostatic safety precautions when handling
static-sensitive components such as circuit boards and printheads.

Important • The text here indicates information that is important for the user to know. EXAMPLE:
Run the setup.exe file for the product BEFORE connecting the product to your printer.

Note • The text here indicates information that is supplemental for the user to know and that is not
required to complete a task. EXAMPLE: Refer to zebra.com for complete information on product
warranties.

5
Contents

Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Terms of Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Online resources available to support this printer . . . . . . . . . . . . . . . . . . . . . . . . . .3
Other Valuable Printer Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Zebra OneCare Printer Service and Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Environmental Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Document Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

• Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
• Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
How Repairs and Maintenance Procedures are Documented . . . . . . . . . . . . . . . . . . .12
Thermal Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Preparing a Static-Safe Work Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Packaging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Environmental and Shock Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Long Term Printer Inactivity or Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Real Time Clock (RTC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

• Cleaning and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Cleaning Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Recommended Cleaning Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Standard Platen (Drive) Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Linerless Platen (Drive) Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Media Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Label Dispenser Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Cutter Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Cleaning the Printhead. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
ZD620 / ZD420 Direct Thermal Printers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

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ZD620 / ZD420 Thermal Transfer Printers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

ZD420 Ribbon Cartridge Printers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Media Path Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Lower Half of ZD620/ZD420 Printers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Upper Half of ZD620/ZD420 Direct Thermal Printers. . . . . . . . . . . . . . . . . . . . . . .23
Upper Half of ZD620/420 Thermal Transfer Printers . . . . . . . . . . . . . . . . . . . . . . .23
Upper Half of ZD420 Thermal Transfer Ribbon Cartridge Printers . . . . . . . . . . . .24
Cleaning the Cutter and Label Dispenser Options . . . . . . . . . . . . . . . . . . . . . . . . .25
Cutter Option Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Label Dispenser Option Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Sensor Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Lower Half of ZD620/ZD420 Printers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Upper Half of ZD620/ZD420 Direct Thermal Printers. . . . . . . . . . . . . . . . . . . . . . .28
Upper Half of ZD620/ZD420 Thermal Transfer Printers. . . . . . . . . . . . . . . . . . . . .28
Upper Half of ZD420 Ribbon Cartridge Printers. . . . . . . . . . . . . . . . . . . . . . . . . . .29
Platen Cleaning and Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Removing the Platen Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Replacing the Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
ZD620 and ZD420 Direct Thermal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Removing the Printhead. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Replacing the Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
ZD620 and ZD420 Thermal Transfer Ribbon Roll . . . . . . . . . . . . . . . . . . . . . . . . .41
Removing the Printhead. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Replacing the Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
ZD420 Thermal Transfer Ribbon Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Printhead Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Updating Printer Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
USB Host . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Using USB Host for Firmware Updates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Flash Drive Preparation and Firmware Update . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Other Printer Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

• Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Resolving Alerts and Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Alert: Printhead Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Possible Cause - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Alert: Media Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Possible Cause - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Possible Cause - 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Possible Cause - 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Possible Cause - 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

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Possible Cause - 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

Alert: Ribbon In (ZD420 Cartridge Printer only) . . . . . . . . . . . . . . . . . . . . . . . . . .56
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Possible Cause - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Alert: Ribbon Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Possible Cause - 2 (ZD420 Cartridge Printer only) . . . . . . . . . . . . . . . . . . . . . . . .57
Possible Cause - 3 (ZD420 Cartridge Printer only) . . . . . . . . . . . . . . . . . . . . . . . .57
Possible Cause - 4 (Standard Roll - Thermal Transfer Printers) . . . . . . . . . . . . . .57
Alert: Ribbon Low (ZD420 Cartridge Printer only) . . . . . . . . . . . . . . . . . . . . . . . .58
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Alert: CUT ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Alert: PRINTHEAD OVER TEMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Possible Cause - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Alert: PRINTHEAD SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Alert: PRINTHEAD UNDER TEMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Possible Cause - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Alert: OUT OF MEMORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Resolving Print Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Issue: General Print Quality Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Possible Cause - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Possible Cause - 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Possible Cause - 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Possible Cause - 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Possible Cause - 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Issue: No Print on the Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Possible Cause - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Issue: Labels Are Distorted in Size or Print Area Start Position Varies . . 64
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Possible Cause - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Possible Cause - 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Possible Cause - 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Communication Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Issue: Label Job Sent, No Data Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Possible Cause . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Issue: Label Job Sent, Skips Labels or Prints Bad Content . . . . . . . . . . . 65

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Possible Cause . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

Issue: Label Job Sent, Data Transfers, But No Print . . . . . . . . . . . . . . . . . 66
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Possible Cause - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Possible Cause - 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Miscellaneous Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Issue: Settings are Lost or Ignored . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Possible Cause - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Possible Cause - 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Possible Cause - 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Issue: Non-continuous labels act as Continuous labels.. . . . . . . . . . . . . . 68
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Possible Cause - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Issue: Printer Locks-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Possible Cause - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Issue: Erroneous Ribbon Cartridge Faults . . . . . . . . . . . . . . . . . . . . . . . . . 68
Possible Cause . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Printer Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Power-On Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
SmartCal Media Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Test Printing with the Configuration Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Configuration Report (CANCEL Self Test) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Printer Network (and Bluetooth) Configuration Report. . . . . . . . . . . . . . . . . . . . . .73
Print Quality Report (FEED self test) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Reset Printer Factory Defaults (PAUSE + FEED Self Test). . . . . . . . . . . . . . . . . .77
Reset Network Factory Defaults (PAUSE + CANCEL Self Test) . . . . . . . . . . . . . .77
Reset Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
Communication Diagnostics Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Sensor Profile. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Advanced Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
Manual Media Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Manual Print Width Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Manual Print Darkness Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Factory Test Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86

• Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
• Replacing Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Repair Procedure Sequence for ZD420 Cartridge Printers . . . . . . . . . . . . . . . . . . . . .89
Repair Procedure Sequence for Thermal Transfer ZD Printers . . . . . . . . . . . . . . . . . .90
Repair Procedure Sequence for Direct Thermal ZD Printers . . . . . . . . . . . . . . . . . . . .91
How to Determine a Repair Sequence for your Part . . . . . . . . . . . . . . . . . . . . . . .92
Repair Path Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92

9
 Contents

Repair Preparation and Post Repair Basic Operational Tests . . . . . . . . . . . . . . . . . . .93

ZD420 Cartridge Printer: Accessing the Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . .94
ZD Thermal Transfer Printers: Accessing Inside the Cover . . . . . . . . . . . . . . . . . . . . .95
Disconnecting the Cover from the Ribbon Carriage. . . . . . . . . . . . . . . . . . . . . . . .95
Re-connecting the Ribbon Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Replacing the Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
ZD620 and ZD420 Direct Thermal Printhead. . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Removing the Printhead. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Replacing the Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
ZD620 and ZD420 Thermal Transfer Ribbon Roll Printhead . . . . . . . . . . . . . . . .103
Removing the Printhead. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Replacing the Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
ZD420 Thermal Transfer Ribbon Cartridge Printhead . . . . . . . . . . . . . . . . . . . . .108
Printhead Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Replacing the Platen (Drive) Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Removing and Replacing Connectivity Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Replacing a Front Bezel Option (Tear-off, Dispense, Cut) . . . . . . . . . . . . . . . . . . . . .116
Removing the Printer Base for Repair Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
Replacing the Printer’s Feet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
Replacing the Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
Thermal Transfer Roll and Cartridge Printers . . . . . . . . . . . . . . . . . . . . . . . . . . .120
Direct Thermal Printer Window Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .121
Replacing the Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Replacing the Head-Up Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
Replacing the Main PCBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Replacing the Movable Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
Replacing the Hinge in Thermal Transfer Printers . . . . . . . . . . . . . . . . . . . . . . . . . . .136
Replacing the Hinge in Direct Thermal Printers . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
Replacing the Cover Assembly on Thermal Transfer (Roll) Printers . . . . . . . . . . . . .142
Replacing the Cover Assembly on Cartridge Printers . . . . . . . . . . . . . . . . . . . . . . . .143
Replacing the Cover Assembly on Direct Thermal Printers . . . . . . . . . . . . . . . . . . . .145
Replacing the Cover - Thermal Transfer Printers. . . . . . . . . . . . . . . . . . . . . . . . . . . .147
Replacing the Cover - Direct Thermal Printers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150
Replacing a 3-Button Control Panel PCBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
Replacing a LCD Control Panel PCBA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
Replacing the Latch Assembly - Thermal Transfer Printers . . . . . . . . . . . . . . . . . . . .153
Replacing the Latch Arm Assembly - Direct Thermal Printers . . . . . . . . . . . . . . . . . .154
Replacing the Upper Array Sensor - Thermal Transfer Printer . . . . . . . . . . . . . . . . .158
Replacing the Upper Array Sensor - Thermal Transfer Printer . . . . . . . . . . . . . . . . .159
Replacing the Ribbon Roll Printer’s Ribbon Trailer Sensor PCBA . . . . . . . . . . . . . . .162
Replacing the Cartridge Printer Ribbon Sensor PCBA . . . . . . . . . . . . . . . . . . . . . . .164
Replacing the Ribbon Carriage in Thermal Transfer (Roll) Printers . . . . . . . . . . . . . .166
Replacing the Ribbon Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169

10
 Contents

Replacing the Upper Media (Gap/Web) Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172

Replacing the Print Mechanism or Upper Inner Frame . . . . . . . . . . . . . . . . . . . . . . .175

• Main PCBA Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

Main Printed Circuit Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180
Main Printed Circuit Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181

• Cable Routing for ZD420c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182

ZD420c - Ribbon Cartridge printers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182

• Cable Routing for ZD420t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

ZD620 and ZD420 Ribbon Roll Printers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189

• Cable Routing for ZD420d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197

ZD420c - Direct Thermal printers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197

• Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Types of Thermal Media. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .202
Determining Thermal Media Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .202
General Media and Print Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203
Label Dispenser (Peeler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204
Standard (Media) Cutter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205
Linerless (Media) Cutter - Direct Thermal only. . . . . . . . . . . . . . . . . . . . . . . . . . .205

• ZPL Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

Managing the ZPL Printer Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206
ZPL Printer Configuration Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .207
Configuration Setting to Command Cross-reference . . . . . . . . . . . . . . . . . . . . . . . . .208
Printer Memory Management and Related Status Reports . . . . . . . . . . . . . . . . . . . .211
ZPL Programming for Memory Management . . . . . . . . . . . . . . . . . . . . . . . . . . . .211

11
Introduction

This manual provides ZD420 and ZD620 printer repair, maintenance, and troubleshooting
procedures for field engineers or technicians.
Follow the part replacement procedures as closely as possible. If you are unsure of any
procedure, please contact your service representative or call the products technical
support group at Zebra Technologies Corporation.
Zebra Technologies stocks all replacement parts for the printer. Be sure your facility stocks
sufficient parts for the printer so that scheduled maintenance can take place in a timely
manner.

How Repairs and Maintenance Procedures are Documented

This manual is designed to provide training and instruction for repair and maintenance of
your Zebra printer.
Each Link-OS 4 inch Desktop printer Spares Kit has one or more repair procedures that
support it. The Replacing Parts section of this service manual includes a repair flow
diagram. See a list of available Spare Parts Kits at:
http://www.zebra.com/parts

12
 Introduction

Thermal Printing

Hot Surface Caution • The printhead becomes hot while printing. To protect from
damaging the printhead and risk of personal injury, avoid touching the printhead. Only use
the cleaning pen to perform printhead maintenance.

Preparing a Static-Safe Work Area

Prepare a static-safe work area before opening the printer for repair. The area must
include a properly grounded conductive cushioned mat to hold the printer and a conductive
wrist strap for the technician. ESD protective devices are available from most electronic
supply stores or by contacting 3M corporation at (800) 328-1368.

ESD Caution • The discharge of electrostatic energy that accumulates on the surface of
the human body or other surfaces can damage or destroy the printhead and other
electronic components used in this device. You must observe static-safe procedures when
working with the printhead or the electronic components under the top cover.

Packaging

Printers are carton shipped and wrapped inside a protective bag. Keep all packing
materials in case you need to reship the printer later or store the printer for any length of
time.

Environmental and Shock Protection

Extreme temperature and humidity fluctuations or mishandling can damage the printer and
power supply.
Allow 30 minutes or more before opening the printer's plastic bag. This time allows the
printer to stabilize temperature especially after storage in a cool, dry location and then
placed in a warmer, more humid location. Warm, humid air condenses on the cool
components of the printer and this condensation may damage the components.
Move the printer carefully. Mechanical damage can certainly result from falls or rough
handling.

Long Term Printer Inactivity or Storage

Over time the printhead may stick to the platen (drive) roller. To prevent this, always store
the printer with a piece of media (a label or paper) between the printhead and platen roller.
Do not ship the printer with a roll of media installed or damage to the printer or media may
result.

13
 Introduction

Real Time Clock (RTC)

The Real Time Clock (RTC) is included with some ZD620 and ZD420 Ribbon Cartridge
printers.
The clock’s battery is rated to provide approximately ten (10) years of service and is not
user replaceable. See a Zebra authorized service technician to replace the battery. See
the warranty for your printer for more details at the Zebra Web site:
www.zebra.com/warranty
Caution • The printer has a three volt lithium battery. You can discern a low or flat battery
if the printer provides a consistently delayed date stamp. Battery replacement must be
performed by a qualified service technician. Only use a Zebra approved replacement
battery.
Important • Recycle batteries according to local your guidelines and regulations. Wrap the
battery when disposing (or storing) to avoid a short circuit.

Caution • DO NOT short circuit the battery. Short circuiting the battery may result in heat
generation, fire or bursting.

Caution • DO NOT heat, disassemble or dispose of battery in fire.

Fuses

There are no replaceable fuses in ZD-Series printers or power supplies.

14
Cleaning and Maintenance

This section provides routine cleaning and maintenance procedures.

Cleaning

Your Zebra printer may require periodic maintenance to keep your printer functional and
printing high quality labels, receipts, tags, etc.

Cleaning Supplies
The following printer cleaning supplies are recommended for use with your printer:
• Printhead Cleaning Pens for simple operator printhead cleaning
• 99% pure Isopropyl Alcohol (Use a labeled dispenser. Never re-moisten clean-
ing materials used to clean the printer).
• Fiber-free Cleaning Swabs for media path, guides, and sensors and Cleaning
Wipes for media path and interior (for example Kimberly-Clark Kimwipes ).
• Can of Compressed Air.
Important • The cutter mechanism does not require maintenance cleaning. DO NOT clean
the blade or mechanism. The blade has a special coating to resist adhesives and wear.

Important • Using too much alcohol can result in contamination of the electronic
components requiring a much longer drying time before the printer will function properly.

Important • Do Not Use an air compressor in place of the can of compressed air. Air
compressors have micro contaminants and particles the get into the air system and
damage your printer.
Eye Injury Caution • Use eye protection to protect your eyes from flying particles and
objects when using compressed air.

Get Zebra Supplies and Accessories for Cleaning Your Printer

Go to the Zebra Web site: www.zebra.com/accessories

15
 Cleaning and Maintenance

Recommended Cleaning Schedule

Printhead
Interval: Clean the printhead after every roll printed.
Procedure: Cleaning the Printhead
Standard Platen (Drive) Roller
Interval: As needed to improve print quality. Platen rollers can slip causing print image
distortion and in worst case scenarios not move the media (labels, receipts, tags, etc.).
Procedure: See Platen Cleaning and Replacement.
Note • Standard platen rollers come in two colors, black (203 dpi) and gray (300 dpi).

Linerless Platen (Drive) Roller

Interval: If there is observed build-up of particles on the platen roller, use this procedure.
The linerless platen normally does not require cleaning. The adhesive side of the media
picks up particles as you print.
If the linerless media is sticking and binding in the printer, the linerless platen normally
needs to be replaced. The silicon non-stick coating has been used up.
Important • Linerless platen rollers come in two colors, reddish-brown (203 dpi) and brown
(300 dpi).

Important • Cleaning the roller with solutions or rubbing the delicate surface of this type of
roller will permanently damage or shorten the usable life of the linerless platen.

Important • The platen roller can accumulate adhesive on the outer edges of the roller.
After using many rolls of media, these ‘rings’ of adhesive can get dislodged when using the
printer. These particle clumps can then get transferred to other areas in the printer, most
importantly, the printhead.
Procedure: To remove adhesive particles, use the adhesive side of a piece of linerless
media to gently press and remove the particles from the plater roller. Use the Platen
Cleaning and Replacement procedure to get better access for particle removal.

16
 Cleaning and Maintenance

Media Path
Interval: Clean as needed.
Method: Clean it thoroughly with fiber-free cleaning swabs and cloths moistened with 99%
isopropyl alcohol. Let alcohol evaporate completely.
Procedure: See Media Path Cleaning.
Interior
Interval: Clean the printer as needed.
Method: Use a soft cloth, brush or compressed air to wipe or blow dust and particles out
of the printer. A 99% isopropyl alcohol and a fiber-free cleaning cloth can be used to
dissolve contaminants like oils and grime.
Exterior
Interval: Clean as needed.
Method: Use a soft cloth, brush or compressed air to wipe or blow dust and particles out
of the printer. The exterior of the printer can be cleaned using plain soap and water
solutions to moisten the cloth. Only use the minimum amount of cleaning to avoid getting
solution in the printer or other areas. Do not clean connectors or interior of the printer. with
this method.
Healthcare Printer Models — The latest models now include Ultra-Violet (UV) and
disinfectant-safe plastics for hospital and other similar environments. The user interface is
sealed so it can be cleaned with the rest of the printer’s exterior. See the ‘Guide To
Disinfecting and Cleaning Zebra® Healthcare Printers’ on the Zebra Web site for the
latest information on tested and approved cleaning materials, and cleaning methods.
Label Dispenser Option
Interval: As needed to improve label dispensing operations.
Procedure: See Label Dispenser Option cleaning.

17
 Cleaning and Maintenance

Cutter Option
Interval: Not an operator serviceable component. Do Not Clean inside the cutter opening
or blade mechanism. You may use the Exterior cleaning to clean the cutter bezel
(housing).
Method: None at this time.
Procedure: None
Cut Warning • There are no operator serviceable parts in the cutter unit. Never remove
the cutter cover (bezel). Never attempt to insert objects or fingers in to the cutter
mechanism.
Important • The blade has a special coating to resist adhesives and wear. Cleaning it may
ruin the blade.

Important • Using un-approved tools, cotton swabs, solvents (including alcohol), etc.; all
may damage or shorten the cutter’s usable life or cause the cutter to bind.

18
 Cleaning and Maintenance

Cleaning the Printhead

Always use a new cleaning pen on the printhead (an old pen carries contaminants from its
previous use that may damage the printhead).
When you load new media, you should clean the printhead for optimal print operations.
Hot Surface Caution • The printhead becomes hot while printing. To protect from
damaging the printhead and risk of personal injury, avoid touching the printhead. Only use
the cleaning pen to perform printhead maintenance.
ESD Caution • The discharge of electrostatic energy that accumulates on the surface of
the human body or other surfaces can damage or destroy the printhead and other
electronic components used in this device. You must observe static-safe procedures when
working with the printhead or the electronic components under the top cover.
ZD620 / ZD420 Direct Thermal Printers
When you load new media, you can also clean the printhead.
1. Rub the cleaning pen across the dark area of the printhead. Clean from the middle to
the outside. This will move adhesive transferred from the edges of media to the
outside of media path.

2. Wait one minute before closing the printer to allow the components to dry.

19
 Cleaning and Maintenance

ZD620 / ZD420 Thermal Transfer Printers

When you load new media or ribbon, you can also clean the printhead.
1. If transfer ribbon is installed, remove it before proceeding.

2. Rub the cleaning pen across the dark area of the printhead. Clean from the middle to
the outside. This will move adhesive transferred from the edges of media to the
outside of media path.

3. Wait one minute before closing the printer or loading ribbon to allow all components to
dry.

20
 Cleaning and Maintenance

ZD420 Ribbon Cartridge Printers

1. Pull the two (2) Release Arms out to release the Ribbon Drive Transport. See
Accessing the Printhead of the Ribbon Cartridge Printer for more details.

2. Lift the Printhead Actuator Arm up to gain access to the printhead. Rub the cleaning
pen across the dark area of the printhead. Clean from the middle to the outside. This
will move adhesive transferred from the outer edges of media to the area outside of
media path.

3. Wait one minute before closing the printer.

4. Release the Printhead Actuator Arm and then push the Ribbon Drive Transport into
the Printhead Actuator Arm. The Release Arms will snap into place relinking the
Ribbon Drive Transport to the top cover and the Printhead Actuator Arm.

21
 Cleaning and Maintenance

Media Path Cleaning

Use a cleaning swab and/or a lint free cloth to remove debris, dust or crust that has built-
up on the holders, guides and media path surfaces. Lightly moisten the swab or cloth with
99% solution medical-grade alcohol. For hard to clean areas, use extra alcohol on a
cleaning swab to soak the debris to break up any adhesive that may have accumulated on
surfaces in the media compartment.
Do not clean the printhead, sensors, or platen as part of this process.
Lower Half of ZD620/ZD420 Printers
The lower half of these printers these printers get cleaned the same.
1. Wipe the inside surfaces of the roll holders and the underside of the media guides
with a cleaning swabs and wipes.

2. Wipe the movable sensor slide channel (but not sensor). Move the sensor to get to all
areas.

3. Wait one minute before closing the printer. Discard used cleaning supplies.

Media Roll Holders

Media Guides

Don’t Clean Sensor

22
 Cleaning and Maintenance

Upper Half of ZD620/ZD420 Direct Thermal Printers

1. Wipe the areas (outlined in orange) to remove adhesive and other contaminants. Do
not clean the sensor array.

Don’t Clean Sensor

Upper Half of ZD620/420 Thermal Transfer Printers

1. Wipe the area (outlined in orange) near the printhead on the front of the ribbon
carriage.

23
 Cleaning and Maintenance

Upper Half of ZD420 Thermal Transfer Ribbon Cartridge Printers

1. Pull the two (2) Release Arms out to release the Ribbon Drive Transport. See ZD420
Cartridge Printer: Accessing the Printhead for more details.

2. Wipe the areas (outlined in orange) below the Printhead Actuator Arm and the Ribbon
Drive Transport.

Don’t Clean Sensor

3. Release the Printhead Actuator Arm and then push the Ribbon Drive Transport into
the Printhead Actuator Arm. The Release Arms will snap into place relinking the
Ribbon Drive Transport to the top cover and the Printhead Actuator Arm.

24
 Cleaning and Maintenance

Cleaning the Cutter and Label Dispenser Options

This is a continuation of cleaning the media path for either option, if installed.
Cutter Option Cleaning
The plastic media path surfaces can be cleaned but not the internal cutter blades or
mechanism.
Important • The cutter blade mechanism does not require maintenance cleaning. DO NOT
clean the blade. This blade has a special coating to resist adhesives and wear.

Cut Warning • There are no operator serviceable parts in the cutter unit. Never remove
the cutter cover (bezel). Never attempt to insert objects or fingers into the cutter
mechanism.
Note • Using un-approved tools, cotton swabs, solvents (including alcohol), etc. all may
damage or shorten the cutter’s usable life or cause the cutter to jam.

1. Wipe the ridges and the plastic surfaces of the media entry (inside) and exit slot
(outside) of the cutter. Clean inside the areas outlined in orange.

2. Repeat as necessary to remove any adhesive or contaminate residue after it dries.

25
 Cleaning and Maintenance

Label Dispenser Option Cleaning

1. Open the door and clean the peel bar, inner surfaces and ridges on the door.

2. Wipe the roller while rotating it. Discard the swab or cloth. Clean again to remove
diluted residue.

3. Clean the sensor window. The window should be clear of streaks and residue.

Inside Wall

Label Taken
Sensor

Peel Bar Pinch Roller Ridges

26
 Cleaning and Maintenance

Sensor Cleaning
Dust can accumulate on the media sensors. Do not use an air compressor to remove dust.
Compressors add moisture, fine grit, and lubricant which can contaminate your printer.
Lower Half of ZD620/ZD420 Printers
1. Clean the Movable Sensor’s window. Gently brush away dust or use a can of
compressed air; if necessary, use a dry swab to brush away dust. If adhesives or
other contaminants remain, use an alcohol moistened swab to break it up.

2. Use a dry swab to remove any residue that may be left from the first cleaning.

3. Repeat steps 1 and 2 as required until all residue and streaks are removed from the
sensor.

Movable Sensor
(Black Mark and
Lower Web/Gap)

27
 Cleaning and Maintenance

Upper Half of ZD620/ZD420 Direct Thermal Printers

1. Spray the Upper Web (Gap) Array Sensor below the printhead with a can of
compressed air. If necessary, use an alcohol moistened swab to break up adhesive or
other non-dust contaminants. Use a dry swab to remove any residue that may be left
from the first cleaning.

Upper Half of ZD620/ZD420 Thermal Transfer Printers

1. Spray the Upper Web (Gap) Array Sensor below the printhead with a can of
compressed air. Complete sensor cleaning (very rare) requires a service technician

Spray Sensor
Up Here

28
 Cleaning and Maintenance

Upper Half of ZD420 Ribbon Cartridge Printers

1. Pull the two (2) Release Arms out to release the Ribbon Drive Transport. See ZD420
Cartridge Printer: Accessing the Printhead for more details.

2. Swing the Printhead Actuator Arm up until it touches the printer’s top cover. Hold the
Printhead Actuator Arm in this position for access to the area below the printhead,
see the next graphic.

3. Spray the Upper Web (Gap) Array Sensor under the Ribbon Drive Transport and the
Ribbon Out Sensor on the underside of the Printhead Actuator Arm with a can of
compressed air. If necessary, use an alcohol moistened swab to break it up. Use a
dry swab to remove any residue that may be left from the first cleaning.

Ribbon Out Sensor

Upper Web (Gap)

Array

29
 Cleaning and Maintenance

Cleaning Ribbon Cartridge Sensor

4. Ribbon Cartridge Sensor Pins - Only clean when the cartridges are failing
detection. Clean the Ribbon Cartridge interface pins with a gentle wiping from right to
left. Up and down motions may damage the pins.

Ribbon Cartridge
Sensor
Contact Pins

30
 Cleaning and Maintenance

Platen Cleaning and Replacement

The platen (drive roller) normally does not require cleaning. Normally, paper and liner dust
can accumulate without affecting print operations.
Clean the platen (and media path) whenever the printer has significantly poorer
performance, print quality or media handling. The platen is the print surface and drive roller
for your media. If sticking or jamming continues even after cleaning, you must replace the
platen.
Important • Contaminants on the platen roller can damage the printhead or cause the
media to slip or stick when printing. Adhesive, dirt, general dust, oils and other
contaminants should be cleaned immediately off the platen.
Important • LINERLESS PLATENS — Do not wash or scrub. Only remove adhesive
particles by using the adhesive side of linerless media. Lightly touch the platen roller with
a linerless label to lift particles off the exposed area of the platen roller and the media path
areas.

31
 Cleaning and Maintenance

Removing the Platen Roller

The platen can be cleaned with a fiber-free swab (such as a Texpad swab) or a lint free,
clean, damp cloth very lightly moistened with medical grade alcohol (90% pure or better).
1. Open the cover (and dispenser door, if the dispenser is installed). Remove media
from platen area.

2. Pull the platen bearing latch release tabs on the right and left sides towards the front
of the printer and rotate them up.

Platen Bearings

Platen Bearings

32
 Cleaning and Maintenance

3. Lift the platen out of the printer’s bottom frame.

Platen Bearings

4. Slide the gear and the two (2) bearings off the shaft of the platen roller.

33
 Cleaning and Maintenance

5. Cleaning Only — Clean the platen with the alcohol moistened swab. Clean from the
center out. Repeat this process until all of the roller surface has been cleaned. If there
has been heavy adhesive build-up or label jam, repeat with a new swab to remove
residual contaminants. Adhesives and oils, for example, may be thinned by the initial
cleaning but not completely removed.

Important • LINERLESS PLATENS — Only use the adhesive side of a piece of linerless
media to gently lift the particles from the plater roller for cleaning.

6. Discard the cleaning swabs after use - do not reuse.

7. Make sure the bearings and drive gear are on the shaft of the platen roller.

8. Align the platen with the gear to the left and lower it into the printer’s bottom frame.

9. Rotate the platen bearing latch release tabs down on the right and left sides towards
the rear of the printer and snap them into place.

10. Allow the printer to dry for one minute before closing the dispenser door, media cover
or loading labels.

34
 Cleaning and Maintenance

Replacing the Printhead

If you need to replace the printhead, read the procedure and review the removal and
installation steps before actually replacing the printhead.
ESD Caution • Prepare your work area by protecting against static discharge. Your work
area must be static-safe and include a properly grounded conductive cushioned mat to
hold the printer and a conductive wrist strap for yourself.
Caution • Unplug the printer from the power supply and allow the printer to cool to prevent
injuries or damage to printer circuitry.
Use one of the following model specific procedures to replace the printhead.
• ZD620 and ZD420 Direct Thermal
• ZD620 and ZD420 Thermal Transfer Ribbon Roll
• ZD420 Thermal Transfer Ribbon Cartridge

35
 Cleaning and Maintenance

ZD620 and ZD420 Direct Thermal

Removing the Printhead
1. Turn the printer OFF. Open the printer.

Printhead

2. Push the printhead release latch away from the printhead. The right side of printhead
releases.

36
 Cleaning and Maintenance

3. Swing the loose right side of the printhead out of the printer. Pull it out and to the right
a little to get the left side of the printhead clear. Pull the printhead out and free of the
top cover to gain access to its attached cables on the backside of the printhead. Note,
the red highlights the left side printhead retainer slot.

4. Gently but firmly pull the two printhead cable bundle connectors off of the printhead.
Pull the ground wire off the printhead.

Connectors

Printhead Ground Wire

Printhead Assembly

37
 Cleaning and Maintenance

Replacing the Printhead

1. Push the right side printhead cable connector into the printhead. The connector is
keyed to only insert one way.

2. Attach the ground wire to the printhead’s ground tab.

3. Push the left side printhead cable connector onto the printhead.

Printhead Ground Wire

Connector with Key

Printhead Ground Tab

Spring Wire Notch

4. Insert the left side of the printhead assembly into the recessed slot (highlighted in red)
on the left side of the printer.

Slot

38
 Cleaning and Maintenance

5. Align the Spring Wire Notch on the backside of the printhead to the Spring Wire. Push
the right side of the printhead into the printer until the latch locks the right side of the
printhead into the printer.

Spring Wire in Notch

39
 Cleaning and Maintenance

6. Verify that the printhead moves up and down freely when pressure is applied and
remains locked when released.

7. Clean the printhead. Use a new pen to wipe body oils (finger prints) and debris of the
printhead. Clean from the center of the printhead to the outside. See Cleaning the
Printhead.

8. Reload media. Plug in the power cord, turn on the printer and print a status report to
ensure proper function. See Test Printing with the Configuration Report.

40
 Cleaning and Maintenance

ZD620 and ZD420 Thermal Transfer Ribbon Roll

Removing the Printhead
1. Turn the printer OFF. Open the printer.

Printhead

2. Push the printhead release latch toward the printhead (shown as green for visibility).
The right side printhead releases down and away from the Printhead Actuator Arm.

41
 Cleaning and Maintenance

3. Swing the loose right side of the printhead out of the printer. Pull it to the right a little to
get the left side of the printhead clear. Pull the printhead down and free of the ribbon
carriage to gain access to its attached cables.

4. Gently but firmly pull the two printhead cable bundle connectors off of the printhead.

Connectors

Printhead Assembly

42
 Cleaning and Maintenance

Replacing the Printhead

1. Push the right side printhead cable connector into the printhead. The connector is
keyed to only insert one way.

2. Push the left side printhead cable connector onto the printhead.

3. Insert the center tab on the printhead assembly into the center slot on the Printhead
Actuator Arm.

43
 Cleaning and Maintenance

4. Insert the left side tab of the printhead assembly into the recessed slot on the left side
of the Printhead Actuator Arm.

Slot

Tab

5. Push the right side of the printhead into the printer until the latch locks the right side of
the printhead into the printer.

44
 Cleaning and Maintenance

6. Verify that the printhead moves up and down freely when pressure is applied and
remains locked when released.

7. Clean the printhead. Use a new pen to wipe body oils (finger prints) and debris of the
printhead. Clean from the center of the printhead to the outside. See Cleaning the
Printhead.

8. Reload media. Plug in the power cord, turn on the printer and print a status report to
ensure proper function. See Test Printing with the Configuration Report.

45
 Cleaning and Maintenance

ZD420 Thermal Transfer Ribbon Cartridge

Printhead Removal
1. Turn the printer OFF. Open the printer.

2. Pull the two (2) Release Arms out to release the Ribbon Drive Transport. See ZD420
Cartridge Printer: Accessing the Printhead for more details.

3. Swing the Printhead Actuator Arm up until it touches the printer’s top cover. Hold the
Printhead Actuator Arm in this position for access to the printhead. Push the printhead
release latch toward the printhead (shown as pink for visibility). The right side
printhead releases down and away from the Printhead Actuator Arm.

4. Swing the loose right side of the printhead out of the printer. Pull it to the right a little to
get the left side of the printhead clear. Pull the printhead down and free of the
Printhead Actuator Arm to gain access to its attached cables.

46
 Cleaning and Maintenance

5. Gently but firmly pull the two printhead cable bundle connectors off of the printhead.

Connectors

Printhead Assembly

47
 Cleaning and Maintenance

Replacing the Printhead

1. Push the right side printhead cable connector into the printhead. The connector is
keyed to only insert one way.

2. Push the left side printhead cable connector onto the printhead.

3. Insert the center tab on the printhead assembly into the center slot on the Printhead
Actuator Arm.

Tab Slot

4. Insert the left side tab of the printhead assembly into the recessed slot on the left side
of the Printhead Actuator Arm.

Tab Slots - both sides

48
 Cleaning and Maintenance

5. Push the right side of the printhead into the printer until the latch locks the right side of
the printhead into the printer.

Slot
Guide

6. Verify that the printhead moves freely into the printer when pressure is applied (see
arrow) and remains locked when pressure is released.

7. Clean the printhead by using a new cleaning pen to wipe body oils (finger prints) and
debris off the printhead. See Cleaning the Printhead.

8. Reload media. Turn on the printer and print a status report to ensure proper function.
See Test Printing with the Configuration Report.

49
 Cleaning and Maintenance

Updating Printer Firmware

The printer’s firmware may need to be updated periodically to get new features,
improvements, and printer upgrades for media handling and communications.
Use Zebra Setup Utilities (ZSU) to load new firmware.
1. Open Zebra Setup Utilities.

2. Select your installed ZD620/ZD420 printer.

3. Click on the ‘Open Printer Tools’ button and a ‘Tools’ window will open.

4. Click on the ‘Action’ tab.

5. Load the printer with media.

6. Click on the text line - ‘Send file’. The lower half of the window will present a filename
and path with a Browse (...) button to select the latest firmware file you have
downloaded from the Zebra Web site.

7. Observe the user interface and wait.

If the firmware version is different than the version installed on the printer, the
firmware will download to the printer. The data indicator will flash green while the
firmware is downloading. The printer will restart with all indicators flashing. When the
firmware update has completed, the STATUS indicator will display solid Green as the
firmware is validated and installed. A printer Configuration Report is automatically
printed and the firmware update has been completed.

50
 Cleaning and Maintenance

USB Host

The USB host port allows you to connect USB devices — such as a keyboard, scanner, or
USB Flash (memory) drive — to the printer.
USB Host Port Uses

• Firmware updates,
• File transfers and management
• A port for low power USB data entry devices (keyboards, scales, scanners, and
other wedge devices).

USB Host Port

Important • The USB Flash drive must be formatted with the FAT file system. Filenames
may be 1 to 16 alphanumeric characters (A, a, B, b, C, c, ..., 0, 1, 2, 3, ...) only. Only use
ASCII characters. Do not use Asian characters, Cyrillic characters, or accented characters
in file names. Some functions may not work properly if there are underscores in a file
name. Use periods instead.

51
 Cleaning and Maintenance

Using USB Host for Firmware Updates

The USB host port allows you to connect an USB Flash drive to the printer to perform
firmware updates.
This is an example of using the powerful printer management, Zebra Mirror functions. See
the printer ZPL programming manual — Mirror and Set-Get-Do (SGD) usb.mirror
commands operation.
Note • See Online resources available to support this printer section for information and
support links for your specific printer model.

Important • Supports USB Flash drives (or “thumb drive” or “memory stick”) up to
1 Terabyte (TB). The printer will not recognize drives larger than 1 TB.

Flash Drive Preparation and Firmware Update

1. On your USB Flash Drive, create the following:
• a folder called Zebra
• in that folder, create three sub-directories:
• appl
• commands
• files

2. In the /appl folder, place a copy of the latest firmware for your printer.
3. Load the printer with media.
4. Insert the USB Flash drive into the USB host port on your printer.
5. Observe the user interface and wait.
If the firmware version on the USB Flash drive is different than the version installed on
the printer, the firmware will download to the printer. The data indicator will flash
green while the firmware is downloading. The printer will restart with all indicators
flashing. When the firmware update has completed, the STATUS indicator will display
solid Green as the firmware is validated and installed. A printer Configuration Report
is automatically printed and the firmware update has been completed.
Remove the USB Flash drive from the printer.

Other Printer Maintenance

There are no user level maintenance procedures beyond those detailed in this section.
See the Troubleshooting for more information on diagnosing printer and print problems.

52
Troubleshooting

This section provides troubleshooting procedures and information.

Resolving Alerts and Errors

Alert: Printhead Open

A print command or a FEED button has been pressed and the printer has detected that the
printhead (cover) is not closed.

HEAD OPEN
CLOSE HEAD

Possible Cause - 1
The cover is open or has not been closed properly.
Resolution
Closed the cover/printhead. Push down on the front top corners of the printer’s cover. You
should normally hear and feel the cover latches snap in place to lock the cover closed for
printing.
Possible Cause - 2
The printer’s Head-Open switch needs service.
Resolution
Replace the Head-Up PCBA.

53
 Troubleshooting

Alert: Media Out

A print command, a FEED button has been pressed, or you are printing; and the printer
can not detect media in the print path.

MEDIA OUT
LOAD MEDIA

Possible Cause - 1
There is no media (roll) in the printer.
Resolution
Load your chosen media in the printer and close the printer. You may need to press the
FEED button once or the PAUSE button the get the printer to resume your print operation.
Possible Cause - 2
Open the printer: If there is a missing label on the roll between two labels at the end of a
roll of labels, then this is the method used by the label roll manufacture to identify the end
of the roll.
Resolution
Replace the empty media roll and continue printing. Do not power the print off or you will
loose your print job.
Possible Cause - 3
Misaligned media sensor.
Resolution
Check the position of the media sensor.
The printer may need to be calibrated for the media after the adjusting the sensor location.
See SmartCal Media Calibration.
Possible Cause - 4
The printer is set for noncontinuous (labels or black mark) media, but continuous media is
loaded.
Resolution
Check the position of the media sensor is in the center default location.
The printer may need to be calibrated for the media after the adjusting the sensor location.
See SmartCal Media Calibration.

54
 Troubleshooting

Possible Cause - 5
The media sensor is dirty.
Resolution
Clean the Upper Web (Gap) Sensor Array and the lower Movable Media sensors. See
Sensor Cleaning.
Reload your media, adjust the Movable Media sensor’s position for your media, and
recalibrate the printer for the media. See SmartCal Media Calibration.
Possible Cause - 6
The media sensing is not working. Possible data corruption of memory or faulty
components.
Resolution
1 — Reload the printer’s firmware. See Updating Printer Firmware.
2 — If this does not fix this issue, replace the Upper Array Sensor.
3 — Replace the Main PCBA.

55
 Troubleshooting

Alert: Ribbon In (ZD420 Cartridge Printer only)

A print command has been sent to the printer and it is in Direct Thermal Mode with Ribbon
installed.
Note • The printer has two different heat settings - one for Direct Thermal and one for
Thermal Transfer. They are designed to have equivalent print density/darkness at the
same setting level.

WARNING
RIBBON IN

Possible Cause - 1
There is a Ribbon Cartridge in the printer while the printer is set to Direct Thermal Mode
(and printing on direct thermal media).
Resolution
Remove the ribbon cartridge from the printer without turning the printer OFF. Close the
printer. You may need to press the FEED button once or the PAUSE button the get the
printer to resume your print operation.
Possible Cause - 2
The printer is incorrectly set to Direct Thermal Mode when you are trying to print using
Transfer Media and Ribbon Cartridge to print.
Resolution
Change the PRINT METHOD to THERMAL TRANS (Thermal Transfer) mode. The print
format/form send for this print job may have Direct Thermal mode set with a ^MTD set
instead of ^MTT. See the ZPL Programmer’s Manual for details on printer programming.
For printer links to manuals, see the Online resources available to support this printer
section of this guide.
To change this setting on the dynamically:
• Use the printer’s LCD user interface (if present) to change the setting.
• Use an Ethernet (LAN or WLAN) printer’s Print Server Web page to access and
set the PRINT METHOD to THERMAL TRANS (Thermal Transfer) mode.

56
 Troubleshooting

Alert: Ribbon Out

1 — The printer is printing and stops while printing.
2 — A print job has been sent to the printer and the printer immediately reports this Alert.

ALERT
RIBBON OUT

Possible Cause - 1
The printer has detected the end of the ribbon. The end of the ribbon has a reflective trailer
on the end of Genuine Zebra Transfer Ribbon that the printer ‘sees’ as End of Ribbon.
Resolution
Remove the ribbon and replace the ribbon rolls or ribbon cartridge in the printer without
turning the printer OFF. Close the printer. You may need to press the FEED button once
or the PAUSE button the get the printer to resume your print operation.
Possible Cause - 2 (ZD420 Cartridge Printer only)
A ribbon cartridge needs to be loaded in the printer. The printer is set for Thermal Transfer
Mode.
Possible Cause - 3 (ZD420 Cartridge Printer only)
The media sensing is not working. Possible dirty ribbon cartridge data chip or cartridge
sensor contacts; data corruption of memory; or faulty cartridge or printer components.
Resolution
1 — Try another working ribbon cartridge, if available.
2 — Clean the Ribbon Cartridge chip with an alcohol moistened swab.
3 — Clean the Ribbon Cartridge Sensor’s contact pins. See Upper Half of ZD420 Thermal
Transfer Ribbon Cartridge Printers for cleaning instructions.
4 — Reload the printer’s firmware. See Updating Printer Firmware.
5 — If this does not fix this issue, replace the Ribbon Transport (to replace the Cartridge
Sensor).
6 — Replace the Main PCBA.
Possible Cause - 4 (Standard Roll - Thermal Transfer Printers)
The media sensing is not working.
Resolution
1 — Reload the printer’s firmware. See Updating Printer Firmware.
2 — If this does not fix this issue, Replace the Ribbon Sensor.
3 — Replace the Main PCBA.

57
 Troubleshooting

Alert: Ribbon Low (ZD420 Cartridge Printer only)

The printer reports this Alert.

ALERT
RIBBON LOW

Possible Cause - 1
The printer has calculated that the ribbon cartridge has only 10% of the ribbon left in the
cartridge. The ribbon low value can be changed by programming.
Resolution
Check for the availability of ribbon cartridges. To change the Ribbon Low warning point,
see the SGD commands. See the ZPL Programmer’s Manual for details on printer
programming. For printer links to manuals, see the Online resources available to support
this printer section of this guide.

Alert: CUT ERROR

The cutter blade is bound and is not moving properly

ERROR CONDITION
CUT ERROR

Possible Cause - 1
Media, adhesive, or external object has stopped the cutter blade from operating.
Resolution
1 — Turn the printer off by holding the power using the POWER button down for 5
seconds. Wait for thee printer to shutdown completely. Turn the printer on.
2 — If the printer does not recover from this error, replace the Cutter.
Cut Warning • There are no operator serviceable parts in the cutter unit. Never remove
the cutter cover (bezel). Never attempt to insert objects or fingers in to the cutter
mechanism.
Note • Using unapproved tools, cotton swabs, solvents (including alcohol), etc. all may
damage or shorten the cutter’s usable life or cause the cutter to jam.

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 Troubleshooting

Alert: PRINTHEAD OVER TEMP

1. The printhead is over temperature and paused to allow the printhead to cool.

PRINTHEAD OVER TEMP

PRINTING HALTED

Possible Cause - 1
The printer is printing a large batch job, typically with large amounts of print.
Resolution
The print operation will resume after the printhead has cooled.

Possible Cause - 2
The ambient temperature at the printers location exceeds the specified operating range.
Sometimes, ambient temperatures in the printer can be higher if it is in direct sunlight.
Resolution
Move the printer location or cool ambient temperature where the printer is operating.

Alert: PRINTHEAD SHUTDOWN

1. The printhead is below operating temperature for proper printing.

PRINTHEAD SHUTDOWN
PRINTING HALTED

Possible Cause - 1
Printhead has had a critical temperature or power failure
Resolution
1 — Turn the printer off by holding the power using the POWER button down for 5
seconds. Wait for thee printer to shutdown completely. Turn the printer on.
2 — If the printer does not recover from this error, replace the Printhead.
3 — Replace the Main PCBA.

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 Troubleshooting

Alert: PRINTHEAD UNDER TEMP

1. The printhead is below operating temperature for proper printing.

PRINTHEAD UNDER TEMP

PRINTING HALTED

THERMISTOR
REPLACE PRINTHEAD

Possible Cause - 1
The ambient temperature at the printers location is below the specified operating range.
Resolution
Turn the printer off. Move the printer location and wait for it to warm naturally. Moisture may
condense in and on the printer if the temperature changes too quickly.

Possible Cause - 2
The printhead thermistor has failed.
Resolution
1 — Turn the printer off by holding the power using the POWER button down for 5
seconds. Wait for thee printer to shutdown completely. Turn the printer on.
2 — If the printer does not recover from this error, inspect the printhead cable.
3 — Replace the Printhead.
4 — Replace the Main PCBA.

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 Troubleshooting

Alert: OUT OF MEMORY

Can not store data in the printer in the specified memory location. There is not enough
memory to perform the function specified on the second line of the error message.

OUT OF MEMORY
STORING GRAPHIC

OUT OF MEMORY
STORING FORMAT

OUT OF MEMORY
STORING BITMAP

OUT OF MEMORY
STORING FONT

Possible Cause - 1
There is not enough memory to perform the function specified on the second line of the
error message.
Resolution 1
1 — Free up some of the printer’s memory by adjusting the label format or printer
parameters to make the print area smaller.
2 — Remove unused graphics, fonts, or formats.
3 — Ensure that the data is not directed to a device that is not installed or is unavailable.

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 Troubleshooting

Resolving Print Issues

This section helps you identify issues with printing or print quality, the possible causes, and
the recommended solutions.

Issue: General Print Quality Issues

The printed image does not look right.
Possible Cause - 1
The printer is set at an incorrect darkness level and/or print speed.
Resolution
Perform the Print Quality Report (FEED self test) to determine the ideal darkness and
speed settings for your application. Do not set print speeds above the manufacturer’s
maximum rated speed for your media (print material and ribbons both).See Print Quality
Report (FEED self test).
Possible Cause - 2
The printhead is dirty.
Resolution
Clean the printhead. See Cleaning the Printhead.
Possible Cause - 3
The platen roller is dirty or damaged.
Resolution
Clean or replace the platen. The platen can wear out or get damaged. See Platen Cleaning
and Replacement.
Possible Cause - 4
The printhead has worn out.
Resolution
Replace the printhead. The printhead can wear out and be damaged. See Replacing the
Printhead.
Possible Cause - 5
Thermal Transfer printing - Printing looks fuzzy, has smudge marks, or has voids or holes
in print with no particular pattern.
Resolution
The print material (wax, wax-resin, or resin) may not match the material (paper, media
coating, or synthetics) in use.
Set the printer for no higher than the maximum recommended print speed of the ribbon
cartridge.

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 Troubleshooting

Possible Cause - 6
You may be using the wrong power supply.
Resolution
Verify you are using the power supply that came with this printer.

Issue: No Print on the Label

The printed image does not look right.
Possible Cause - 1
The media may not be direct thermal media (and is thermal media made for thermal
transfer printers).
Resolution
See the test procedure, Determining Thermal Media Types.
Possible Cause - 2
Media has been loaded incorrectly.
Resolution
The media printable surface must face up towards the printhead.

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 Troubleshooting

Issue: Labels Are Distorted in Size or Print Area Start Position Varies
Includes printed image that skips between labels (mis-registration).
Possible Cause - 1
Media has been loaded incorrectly or the movable media sensor is not set properly.
Resolution
Verify that the sensor is set and positioned correctly for your media type and sensing
location.
Possible Cause - 2
The media sensors are not calibrated for your media length, physical properties, or
sensing type (gap/notch, continuous, or mark).
Resolution
See SmartCal Media Calibration. or if it still skips labels try a Manual Media Calibration.
Possible Cause - 3
The platen (drive) roller is slipping or damaged.
Resolution
Clean or replace the platen. The platen can wear out or get damaged. See Platen Cleaning
and Replacement.
Possible Cause - 4
The printer has communication issues with cables or communication settings.
Resolution
See Communication Issues.

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 Troubleshooting

Communication Issues

This section identifies problems with communications, the possible causes, and the
recommended solutions.

Issue: Label Job Sent, No Data Transfer

A label format was sent to the printer but was not recognized. The DATA light does not flash.

Possible Cause
The communication parameters are incorrect.

Resolution - 1
Check the printer driver or software communications settings (if applicable).
Resolution - 2
Serial Port Only - Check the printer’s handshake protocol and serial port settings. The
setting used must match the one being used by the host computer.
Resolution - 3
The serial cable you are trying to use may not be a standard DTE or DCE type cable, is
damaged, or is too long per the RS-232 Serial ports specifications.

Issue: Label Job Sent, Skips Labels or Prints Bad Content

A label format was sent to the printer. Several labels print, then the printer skips, misplaces, misses,
or distorts the image on the label.

Possible Cause
The serial communication settings are incorrect.
Resolution - 1
Check the printer driver or software communications settings (if applicable). Ensure that
the flow control settings and other serial port handshake setting match the host system.

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 Troubleshooting

Issue: Label Job Sent, Data Transfers, But No Print

A label format was sent to the printer but was not recognized. The DATA light flashes but
no printing occurs.
Possible Cause - 1
The prefix and delimiter characters set in the printer do not match the ones in the label
format.
Resolution
Verify the ZPL programmings prefix (COMMAND CHAR) and delimiter (DELIM./CHAR)
characters. Configuration Setting to Command Cross-reference.
Possible Cause - 2
Incorrect data is being sent to the printer.
Resolution
Check the communication settings on the computer. Ensure that they match the printer
settings.
Possible Cause - 3
Incorrect data is being sent to the printer.
Resolution
Check the label format. See the ZPL Programmer’s Manual for details on printer
programming. For printer links to manuals, see the Online resources available to support
this printer section of this guide.

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 Troubleshooting

Miscellaneous Issues

This section identifies miscellaneous issues with the printer, the possible causes, and the
recommended solutions.

Issue: Settings are Lost or Ignored

Some parameters are set incorrectly.
Possible Cause - 1
Printer settings were changed without saving them.
Resolution
The ZPL ^JU command was not used to save your configuration before turning the printer
off. Cycle the printer OFF and then back ON to verify settings have been saved.
Possible Cause - 2
The label format/form commands or commands sent directly to the printer have syntax
errors or have been used incorrectly.
• A firmware command turned off the ability to change the parameter.
• A firmware command changed the parameter back to default setting.
Resolution
See the ZPL programmer’s guide to verify command usage and syntax. See the Online
resources available to support this printer section for support links. to view the
programmer’ guide for your printer model.
Possible Cause - 3
The prefix and delimiter characters set in the printer do not match the ones in the label
format.
Resolution
Verify the ZPL programming settings of the Control, Command and Delimiter settings are
correct for your system software environment. Print a Configuration Report for these three
(3) settings and compare it the commands in label format/form. See Test Printing with the
Configuration Report and Configuration Setting to Command Cross-reference.
Possible Cause - 4
The Main Logic board may not be working properly. Firmware is corrupted or the Main
Logic board needs replacement.
Resolution
1 — Reset the printer to factory defaults. See Reset Printer Factory Defaults (PAUSE +
FEED Self Test) or use the Zebra Setup Utility.
2 — Reload printer firmware. See Updating Printer Firmware.
3 — If the printer does not recover from this error, replace the Main PCBA.

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 Troubleshooting

Issue: Non-continuous labels act as Continuous labels.

A non-continuous label format with matching media loaded in the printer, was sent to the
printer but prints like it is continuous media.
Possible Cause - 1
The printer was not calibrated for the media being used.
Possible Cause - 2
The printer is configured for continuous media.
Resolution
Set the printer for the correct media type (gap/notch, continuous, or mark) and calibrate
the printer using SmartCal Media Calibration, if necessary use Manual Media Calibration f.

Issue: Printer Locks-Up

All indicator lights are on and the printer locks up or the printer locks up while restarting.
Possible Cause - 1
The printer memory has been corrupted by an unknown event.
Resolution - 1
1 — Reset the printer to factory defaults. See Reset Printer Factory Defaults (PAUSE +
FEED Self Test) or use the Zebra Setup Utility.
2 — Reload printer firmware. See Updating Printer Firmware.
3 — If the printer does not recover from this error, replace the Main PCBA.

Issue: Erroneous Ribbon Cartridge Faults

1 — Ribbon Out warning, but a ribbon cartridge is installed.
2 — Ribbon Cartridge Authentication error, but a Genuine Zebra Ribbon Cartridge is
installed and has not been refurbished or altered.
Possible Cause
The Ribbon Cartridge Sensor Contact Pins or the Ribbon Cartridge’s Smart Chip’s
contacts may be dirty or the chip may be damaged.
Resolution
1 — Clean the ribbon cartridge’s smart chip contact, if they look contaminated, with alcohol
and a lightly moistened cotton. Try a different cartridge if this does not work.
2 — Clean the Ribbon Cartridge Sensor Contact Pins - see Cleaning Ribbon Cartridge
Sensor.
3 — Reload printer firmware. See Updating Printer Firmware.
4 — If the printer does not recover from this error, replace the Ribbon Transport (with the
Cartridge Sensor PCBA).

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 Troubleshooting

Printer Diagnostics

Diagnostic reports, calibration procedures, restoring factory defaults and other diagnostics
provide specific information about the condition of the printer.
Important • Use full-width media when performing self tests. If your media is not wide
enough, the test labels may print on the platen (drive) roller.

Note • Diagnostic Testing Tips:

• When performing these self tests, do not send data to the printer from the host.
If your media is shorter than the label to be printed, the test label continues on the
next label.

• When canceling a self test prior to completion, always reset the printer by turning it
OFF and then ON.

• If the printer is in dispense mode and the liner is being taken up by the applicator, the
operator must manually remove the labels as they become available.

Each self test is enabled by pressing a specific user interface button or combination of
buttons while turning ON the printer power. Keep the button(s) pressed until the first
indicator light turns off. The selected self test automatically starts at the end of the Power-
On Self Test.

Power-On Self Test

A Power-On Self Test (POST) is performed each time the printer power is turned ON.
During this test, the control panel indicators turn on and off to ensure proper operation. At
the end of this self test, only the STATUS indicator remains lit.

69
 Troubleshooting

SmartCal Media Calibration

SmartCal is used to quickly calibrate the printer to the media currently loaded. During
SmartCal, the printer will automatically determine the media sensing type (gap, black line
or notch) and then measure the length of the media.
To activate Smart Calibration, complete these steps:

1. Make sure media is properly loaded, the printer cover is closed, and printer power is
ON.

2. Press and hold PAUSE + CANCEL buttons for two seconds.

3. The printer will FEED and measure several labels. When done, the printer will return
to READY status.

If the printer should fail to recognize and correctly calibrate to the media, please refer to
the Manual Media Calibration procedure later in this section.

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 Troubleshooting

Test Printing with the Configuration Report

Before you connect the printer to a computer, make sure that the printer is in proper
working order. You can do this by printing a configuration report. The information on the
Configuration reports printout that may be helpful with printer installation and with
troubleshooting your printer.
1. Make sure the media and ribbon cartridge (if you are thermal transfer printing) are
loaded properly in the printer and the top cover of the printer is closed.
2. Turn the printer ON.
3. Once the printer is in the ready state (Status indicator is solid green), press and hold
the FEED and CANCEL buttons for two (2) seconds and release.
4. .The Printer and Network Configuration Reports (shown below) will be printed.
5. When the printer stops, the Status indicator will turn solid green.

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 Troubleshooting

Configuration Report (CANCEL Self Test)

The Configuration Report diagnostic prints a set of printer and network configuration
reports.
To print the configuration report, complete these steps:

1. Make sure media is loaded, the printer cover is closed, and printer power is ON.

2. If printer power is OFF, press and hold CANCEL button while turning the printer
power ON. Hold CANCEL button down until the STATUS indicator is the only
indicator lit.
- or -
If printer power is ON, press FEED + CANCEL for two seconds.

3. The Printer and Network Configuration Reports (below) will be printed and the printer
will return to READY status.

Sample Printer Configuration Sample Network Configuration

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 Troubleshooting

Printer Network (and Bluetooth) Configuration Report

ZD-Series printers with Wired or Wireless connectivity options installed will print an
additional printer configuration report. This information needed to establish and trouble
shoot Ethernet (LAN and WLAN), Bluetooth 4.1 and Bluetooth LE network printing. The
following printout is printed with the ZPL ~WL command.

iOS Support Setting

iOS Bluetooth Support

• iOS devices have Bluetooth Classic 4.X (with 3.0 compatibility) when the Wi-Fi
and Bluetooth Classic wireless connectivity option is installed in your printer and is
noted as ‘supported’ on the bottom of the Bluetooth Configuration report.
• Some ZD420 series printers only have the Bluetooth LE (without Wi-Fi and classic
Bluetooth). The iOS setting is noted on the bottom of the Bluetooth Configuration
report as ‘not supported’ when the wireless connectivity option is not installed.

Print Quality Report (FEED self test)

Different types of media may require different darkness settings. This section contains a
simple but effective method for determining the ideal darkness for printing barcodes that
are within specifications.

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 Troubleshooting

During the Print Quality Report (FEED self test), a series of labels are printed at different
darkness settings at two different print speeds. The relative darkness and the print speed
are printed on each label. The barcodes on these labels may be ANSI-graded to check
print quality.
During this test, one set of labels is printed at low speed, and another set is printed at the
high speed. The darkness value starts at three settings lower than the printer’s current
darkness value (relative darkness of –3) and increase until the darkness is three settings
higher than the current darkness value (relative darkness of +3).
The speed at which labels are printed during this print quality test depends on the dot
density of the printhead.
• 300 dpi printers: prints 7 labels at 51mm/sec (2 ips) and 102 mm/sec (4 ips) print
speeds.
• 203 dpi printers: prints 7 labels at 51mm/sec (2 ips) and 152 mm/sec (6 ips) print
speeds.
To perform a Print Quality Report, complete these steps:

4. Print a configuration report to show the printer’s current settings. Press and hold the
FEED and CANCEL buttons for two (2) seconds to print the report.

5. Turn OFF the printer.

6. Press and hold FEED while setting the printer power to ON. Hold FEED until the
Status indicator is the only indicator lit.

The printer prints a series of labels (Figure 1) at various speeds and darkness
settings higher and lower than the darkness value shown on the configuration label.

Figure 1 • Print Quality Report

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 Troubleshooting

7. See Figure 2 and Table 1. Inspect the test labels and determine which one has the
best print quality for your application. If you have a barcode verifier, use it to measure
bars/spaces and calculate the print contrast. If you do not have a barcode verifier, use
your eyes or the system scanner to choose the optimal darkness setting based on the
labels printed in this self test.

Figure 2 • Barcode Darkness Comparison

Table 1 • Visual Darkness Descriptions

Print Quality Description
Too dark Labels that are too dark are fairly obvious. They may be
readable but not “in-spec.”
• The normal barcode bars increase in size.
• The openings in small alphanumeric characters may
appear filled in.
• Rotated barcode have bars and spaces run
together.
Slightly dark Slightly dark labels are not as obvious.
• The normal barcode will be “in-spec.”
• Small character alpha numerics will be bold and
could be slightly filled in.
• The rotated barcode spaces are small when
compared to the “in-spec” code, possibly making the
code unreadable.

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 Troubleshooting

Table 1 • Visual Darkness Descriptions

Print Quality Description
“In-spec” The “in-spec” barcode can only be confirmed by a verifier,
but it should exhibit the following visible characteristics.
• The normal barcode will have complete, even bars
and clear, distinct spaces.
• The rotated barcode will have complete, even bars
and clear, distinct spaces. Although it may not look
as good as a slightly dark barcode, the barcode will
be “in-spec.”
• In both normal and rotated styles, small
alphanumeric characters look complete.
Slightly light Slightly light labels are, in some cases, preferred to slightly
dark ones for “in-spec” barcodes.
• Both normal and rotated barcodes will be in spec,
but small alphanumeric characters may not be
complete.
Too light Labels that are too light are obvious.
• Both normal and rotated barcodes have incomplete
bars and spaces.
• Small alphanumeric characters are unreadable.

8. Note the relative darkness value and the print speed printed on the best test
label.

9. Add or subtract the relative darkness value from the darkness value specified
on the configuration label. The resulting numeric value is the best darkness
value for that specific label/ribbon combination and print speed.

10. If necessary, change the current darkness value to the darkness value on the
best test label.

11. If necessary, change the current print speed to the speed value on the best
test label.

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 Troubleshooting

Reset Printer Factory Defaults (PAUSE + FEED Self Test)

This resets the printer configuration to the factory default values for the non-network printer
settings. Perform a sensor calibration after this procedure. (See Manual Media
Calibration.)
To perform a Reset Printer Factory Defaults procedure, complete these steps:

12. Turn OFF the printer.

13. Press and hold PAUSE + FEED while turning ON the printer.

14. Hold PAUSE + FEED until the STATUS indicator ( ) is the only indicator lit.

The printer configuration is reset to the factory default values. No labels print at the
end of this action.

Note • The printer has a reset button under the printer, see the printer’s User’s Guide.

Reset Network Factory Defaults (PAUSE + CANCEL Self Test)

This procedure resets the network configuration settings only to the factory default values.
To perform a Reset Network Factory Defaults procedure, complete these steps:

15. Turn OFF the printer.

16. Press and hold PAUSE + CANCEL while turning ON the printer.

17. Hold PAUSE + CANCEL until the STATUS indicator ( ) is the only indicator lit.

The printer’s network configuration is reset to the factory default values. No labels
print at the end of this action.

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 Troubleshooting

Reset Button
In addition to the power on configurations described previously, the ZD-Series printer has
a dedicated reset button located on the bottom of the printer which can be pressed with a
paperclip or similar small object.
Pressing the button has the following results based on the length of the button press:

0-1 second No action

1-5 seconds Printer reset – Printer performs a factory reset and will automatically
print a configuration label (and network label if present)
6-10 seconds Network reset – Printer drops connection to the network, and a
network factory default reset occurs. Upon completion of the reset, a
configuration and network configuration label are automatically
printed.
More than 10 seconds Exits the factory defaults function without resetting the printer or
making changes

Reset Access Hole

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 Troubleshooting

Communication Diagnostics Test

The communication diagnostics test is a troubleshooting tool for checking the connection
between the printer and the host computer. When the printer is in diagnostics mode, it
prints all data received from the host computer as straight ASCII characters with the hex
values below the ASCII text. The printer prints all characters received, including control
codes such as CR (carriage return). Figure 3 shows a typical test label from this test.
Note • The test label prints upside-down as it exits the printer.

Figure 3 • Communications Diagnostics Test Label

To use communications diagnostics mode, complete these steps:

18. Ensure media is loaded and printer power is ON.

19. Set the print width equal to or less than the label width being used for the test.

20. Press and hold Pause + FEED for two seconds. When active, the STATUS indicator
will alternate between green and yellow.
The printer enters diagnostics mode and prints any data received from the host
computer on a test label

21. Check the test label for error codes. For any errors, check that your communication
parameters are correct.
Errors show on the test label as follows:

• FE indicates a framing error.

• OE indicates an overrun error.
• PE indicates a parity error.
• NE indicates noise.
22. Press and hold Pause + FEED for two seconds or turn the printer power off (O) and
then back ON to exit this self test and return to normal operation.

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 Troubleshooting

Sensor Profile
Use the sensor profile image (which will extend across several labels or tags) to
troubleshoot the following situations:
• The printer experiences difficulty in determining gaps (web) between labels.
• The printer incorrectly identifies preprinted areas on a label as gaps (web).
• The printer cannot detect ribbon.
With the printer in the Ready state, print a sensor profile in one of these ways:

Using the buttons on the a. Turn OFF the printer.

user interface b. Press and hold FEED + CANCEL while turning ON the printer.
c. Hold FEED + CANCEL until the STATUS indicator ( ) is the
only indicator lit.
Using ZPL d. Send the ~JG command to the printer. See the Zebra
Programming Guide for more information about this command.

Compare your results to the examples shown earlier in this section. If the sensitivity of the
sensors must be adjusted, calibrate the printer (see Manual Media Calibration).

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 Troubleshooting

Media Sensor Profile (Figures 5 and 6)

The line labeled MEDIA (1) on the sensor profile indicates the media sensor readings. The
media sensor threshold settings is indicated by WEB (2). The media out threshold is
indicated by OUT (3).The upward spikes (4) indicate gaps between labels (the web), the
lines between the spikes (5) indicate where labels are located, and the numbered line at
the top (6) provides measurement in dots from the start of the printout.
If you compare the sensor profile printout to a length of your media, the spikes should be
the same distance apart as the gaps on the media. If the distances are not the same, the
printer may be having difficulty determining where the gaps are located.

Figure 4 • Sensor Profile (Gap Media)

4 4 3

2
5 5 5 1

Figure 5 • Sensor Profile (Black Mark Tag Media)

5 5 1

2
4 4
3

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 Troubleshooting

Advanced Mode

Advanced Mode is used to access several manual adjustment modes in the printer. Each
manual adjustment mode is described in detail in the following sections.
To activate Advanced Mode, complete these steps:

1. Ensure media is loaded and printer power is ON.

2. Press PAUSE for two seconds, all indicators will flash yellow.

3. The STATUS indicator ( ) will show solid yellow, indicating the currently selected
mode is:
Manual Media Calibration.

4. Pressing FEED will sequentially cycle through all available modes.

5. Pressing PAUSE will activate the selected mode.

6. Pressing CANCEL will exit Advanced Mode.

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 Troubleshooting

Manual Media Calibration

While in Advanced Mode, pressing PAUSE while the Status indicator ( ) is illuminated
yellow will start Manual Media Calibration.
7. The MEDIA indicator ( ) will flash yellow then the Pause indicator ( ) will flash.
Open the printer and verify the media sensor is in the center position for label gap
(transmissive) sensing. Remove 3 inches or 80mm of labels from the liner. Place the
label-less area of the liner over the platen (drive) roller with the leading edge of the
first label under the media guides.

8. Close the printer and press PAUSE once. The MEDIA indicator ( ) will flash as the
media liner is measured. When complete, the Pause indicator ( ) will begin flashing.

9. Open the printer and reposition the media so that a label is located directly above the
movable sensor. Close the printer.

10. Press PAUSE once. The printer will FEED and measure several labels. If the printer is
able to determine the correct media type (gap, black mark or notch) and measure the
media length, the printer will return to the READY state.

This advanced mode is typically used to calibrate the printer to media that is not correctly
recognized during Smart Calibration. If your media uses black mark or notch sensing,
ensure the media sensor is in to the proper location to “see” the mark or notch. If your
media is pre-printed, either on the front of the label or on the back of the liner, position the
sensor so that it is in a position with minimal printing. You may need to perform Manual
Media Calibration several times, moving the media sensor, until the printer completes the
calibration process and returns to the READY state.

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 Troubleshooting

Manual Print Width Adjustment

While in Advanced Mode, pressing the PAUSE button while the Pause indicator ( ) is
illuminated yellow will start Manual Print Width Adjustment while in Advanced mode, see
Advanced Mode. The printer will print a 16mm (0.63 inch) box and pause momentarily. The
printer will then print a slightly larger box and again pause. When you see the printer print
a box that matches the width of your media, press FEED to set the print width and return
to READY state.
To return to the maximum print width setting, allow the printer to proceed without pressing
the FEED button.

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 Troubleshooting

Manual Print Darkness Adjustment

Pressing PAUSE while the DATA indicator( ) is illuminated yellow will start Manual Print
Darkness Adjustment. The printer will print a test pattern showing the current darkness
number and several barcode patterns and then pause momentarily. The printer will then
repeat the pattern with the next darkness level. When you see the printer print a pattern
with solid even black lines, press FEED to set the darkness value and return to the READY
state.

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 Troubleshooting

Factory Test Modes

The printer includes print modes that are intended for factory test only.
Test mode 1

Initiated by holding PAUSE button while turning ON printer power. When activated, the
printer will begin printing various test patterns used to evaluate printer performance.
Test mode 2

Initiated by holding PAUSE + FEED + CANCEL button for two seconds while printer power
is ON. When activated, the printer will begin printing various test patterns used to evaluate
printer performance.
Note • Both of these test modes will consume a considerable amount of media as the tests
are performed.

You can exit either of these test modes by pressing and holding POWER button until the
printer power is switched OFF.

86
Required Tools

Tools — Make use of the following tools while performing replacement procedures:

• #10 Torx driver (ideally magnetized)

Torque value range: 0.53 +/-0.11 NM = 4.7 inch*lb
• #6 Torx driver (ideally magnetized)
Torque value range: 0.53 +/-0.11 NM = 4.7 inch*lb
• Small flat bladed (slot-head) screwdriver
• Small pliers
• Printhead cleaning pen
• Fiber free swabs
• Lint free wipes, such as Kim-Wipes
• Isopropyl Alcohol – 99% pure solution

87
Replacing Parts

The part replacement procedures in this manual have been broken down into common
procedures and sub-procedures with most aligning to spare parts. Each procedure lists
which procedures and actions must precede it in order to perform the procedure. A “Repair
Path’ flow diagram in on the following page.
In the event you must replace a part, review the repair path flow diagram to see which
procedures to perform. Read the part’s procedure to identify procedures and steps
required to remove the old part and install the new part. Many repair sequences include
simple functionality tests, cleaning or other operations after the spare has been replaced
to verify the repair and printer state.
The Service CD (which also contains this manual) is designed to open this electronic
service manual and it’s associated videos in the proper sequence of procedures and sub-
procedures needed to remove and install a given spare part. The videos and procedures
are broken down into small, easy to follow instructions.

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 Replacing Parts

Repair Procedure Sequence for ZD420 Cartridge Printers

The “Repair Path” flow diagram shows the starting point (green blocks) to the endpoint –
the replacement procedure for your spare part. The diagram does not include any general
repair preparation or post repair operations that may be recommended for the printer.

Latch Cover Control Panel

Assy Assy. PCBA

Inner Lid
(Upper Frame) Ribbon Upper Media
Printhead
incl. Control Sensor (Gap) Sensor
PCBA, etc.

Connectivity
Options Ribbon
(Serial, Transport
Ethernet, etc.)

Hinge
Bezels
(Std., Cutter,
and Dispense)

Print Mech.
Main PCBA
(Lower Frame)
Printer Base
(Not replaceable)

Movable Media
Sensor
Motor
(Lower Gap &
Black Mark)

Head-Up Platen
Feet (4) Window
Sensor Assy.

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 Replacing Parts

Repair Procedure Sequence for Thermal Transfer ZD Printers

The “Repair Path” flow diagram shows the starting point (green blocks) to the endpoint –
the replacement procedure for your spare part. The diagram does not include any general
repair preparation or post repair operations that may be recommended for the printer.

Latch Cover Control Panel

Assy Assy. PCBA

Inner Lid
(Upper Frame) Upper Gap Ribbon
Printhead
incl. Control Array Sensor Sensor
PCBA, etc.

Ribbon
Connectivity
Carriage
Options
(Serial,
Ethernet, etc.)

Hinge
Bezels
(Std., Cutter,
and Dispense)

Print Mech.
Main PCBA
(Lower Frame)
Printer Base
(Not replaceable)

Movable Media
Sensor Ribbon Holder
Motor
(Lower Gap & Hubs
Black Mark)

Head-Up Platen
Feet (4) Window
Sensor Assy.

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 Replacing Parts

Repair Procedure Sequence for Direct Thermal ZD Printers

The “Repair Path” flow diagram shows the starting point (green blocks) to the endpoint –
the replacement procedure for your spare part. The diagram does not include any general
repair preparation or post repair operations that may be recommended for the printer.

Latch Cover Control Panel

Assy Assy. PCBA

Inner Lid
(Upper Frame) Upper Gap
Printhead
incl. Control Array Sensor
PCBA, etc.

Connectivity
Options
(Serial,
Ethernet, etc.)

Hinge
Bezels
(Std., Cutter,
and Dispense)

Print Mech.
Main PCBA
(Lower Frame)
Printer Base
(Not replaceable)

Movable Media
Sensor
Motor
(Lower Gap &
Black Mark)

Head-Up Platen
Feet (4) Window
Sensor Assy.

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 Replacing Parts

How to Determine a Repair Sequence for your Part

Repair procedures are broken down into sub-procedures that mainly align to spare parts.
Many procedures require you to remove other parts to gain access to the part needing
replacement. The green blocks represent stand alone or starting procedures needing to
be performed to access other parts. Use the connecting arrow lines (going backwards and
forward) to determine procedure order for your repair item. One or more starting procedure
paths may be needed to access a given part being replaced. Individual repair procedures
include references (and links) to prerequisite procedures (and the Service CD includes
videos) for each procedure in repair order.
After you have diagnosed and identified the part that needs replacing in your printer, you
can use the repair flow charts to identify the prerequisite repair procedures needed to
complete your repair. Alternately, you may go directly to the part’s repair procedure and
find the “Repair Prerequisites” with the hyper-linked references to the prerequisite
procedures in proper repair sequence.
Repair Path Example
For this example, we have chosen the Main PCBA. It requires multiple paths to complete
the repair.
During the troubleshooting process (for the purposes of this example), we have
determined that the printer has a problem with the Main PCBA (yellow square below). By
following the arrows leading into the Main PCBA repair square, we can see the
Connectivity Options and the Printer Base precede the Main PCBA. The Connectivity
Options procedure square is green to denote a starting procedure. It has no arrows leading
into it, therefore no prerequisite procedures. The Printer Base has an arrow coming from
the Bezel procedure square and it is a prerequisite for both the Printer Base and Main
PCBA repair procedures by following all the arrows to the Main PCBA.

Connectivity
Options Ribbon
(Serial, Transport
Ethernet, etc.)

Hinge
Bezels
(Std., Cutter,
and Dispense)

Print Mech.
Main PCBA
(Lower Frame)
Printer Base
(Not replaceable)

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 Replacing Parts

Repair Preparation and Post Repair Basic Operational Tests

To prevent additional damage or injury, the printer and it’s repair area needs to be
prepared prior to repairing the printer.

Preparation
ESD Caution • Prepare your work area by protecting against static discharge. Your work
area must be static-safe and include a properly grounded conductive cushioned mat to
hold the printer and a conductive wrist strap for yourself.
• The repair surface and area should be clean.
• Use electrostatic protection (grounded mats, ground straps, etc.).
• Remove all media and ribbon cartridges from the printer.
• Disconnect all cables and power from the printer.

Post Repair Cleaning and Basic Testing

1. Clean the printer. This will leave the printer in a optimal state and provide assurance
the contamination has not migrated or been added during handling and repair.
• Cleaning the Printhead
• Sensor Cleaning
• Media Path Cleaning
• Platen Cleaning and Replacement
2. Load a full width roll of labels and a ribbon cartridge into the printer; see the printers
user’s guide for details.
3. Calibrate the media (see SmartCal Media Calibration).
4. Connect the printer to power and turn ON the printer. The printer runs self tests and
configures itself for the options installed.
5. Set the print width to full width printing, if needed after troubleshooting and repair (see
Manual Print Width Adjustment).
6. Print a Configuration Report to test printing and provide information on the status and
configuration of the printer and it’s option (see Test Printing with the Configuration
Report).
7. Attach the printer to Windows PC,

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 Replacing Parts

ZD420 Cartridge Printer: Accessing the Printhead

PRINTHEAD ACCESS Printhead

Actuator Arm
1. Pull both release arms out
(green highlighted black parts).
Backside of
2. Ribbon drive transport drops Printhead
down.

3. Lift printhead actuator arm up

to access the printhead

w


 


Printhead

Ribbon Sensor

Ribbon Cartridge
Authentication and
Status Interface

Ribbon Sensor’s
Reflector

94
 Replacing Parts

ZD Thermal Transfer Printers: Accessing Inside the Cover

Disconnecting the thermal transfer printer’s inner cover top cover for the ribbon carriage
makes it easier to access for repairs. It’s a simple tool-less process to disconnect the two
link arms holding them together.
Disconnecting the Cover from the Ribbon Carriage
1. With the printer’s cover open, slide your hand under the flapper arm (curved part) that
slides into the ribbon carriage and is connected to the inner frame of the cover. Use
your index finger to touch the left link arm where it contacts the inner frame.
2. Push the link arm towards the outside of the printer until it just clears the top of the
post. Slide it up and off the post.
3. Repeat steps 1 and 2 to disconnect the right side link arm.
4. Pull the ribbon carriage down and towards the front of the printer while holding the
cover in the full open position. The flapper arm will come loose and swing down into
the inner cover.

Link Cover Removed to

make it easier to see

Link Link

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Re-connecting the Ribbon Carriage

1. Swing the flapper arm (orange in drawing below) up and the ribbon carriage up so the
two side post slide into the curved channels (green surface highlight channel) on the
inside of the ribbon carriage.

Channel

Flapper
Arm

2. The free ends of the links on the ribbon carriage go back on the posts on the inner
frame of the top cover. Move the link arm and ribbon carriage to get the hole at the
end of the link arm close to alignment and push the link arm up and over the post and
release when centered. The link arm on the other side is now aligned and it is easy to
push it over and on the post.
3. Verify that the top cover now opens and closes with the carriage moving with the
cover.

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Replacing the Printhead

If you need to replace the printhead, read the procedure and review the removal and
installation steps before actually replacing the printhead.

Preparation
ESD Caution • Prepare your work area by protecting against static discharge. Your work
area must be static-safe and include a properly grounded conductive cushioned mat to
hold the printer and a conductive wrist strap for yourself.
Caution • Unplug the printer from the power supply and allow the printer to cool to prevent
injuries or damage to printer circuitry.
Use one of the following model specific procedures to replace the printhead.
• ZD620 and ZD420 Direct Thermal Printhead
• ZD620 and ZD420 Thermal Transfer Ribbon Roll Printhead
• ZD420 Thermal Transfer Ribbon Cartridge Printhead

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ZD620 and ZD420 Direct Thermal Printhead

Removing the Printhead
1. Turn the printer OFF. Open the printer.

Printhead

2. Push the printhead release latch away from the printhead. The right side of printhead
releases.

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3. Swing the loose right side of the printhead out of the printer. Pull it out and to the right
a little to get the left side of the printhead clear. Pull the printhead out and free of the
top cover to gain access to its attached cables on the backside of the printhead. Note,
the red highlights the left side printhead retainer slot.

4. Gently but firmly pull the two printhead cable bundle connectors off of the printhead.
Pull the ground wire off the printhead.

Connectors

Printhead Ground Wire

Printhead Assembly

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Replacing the Printhead

1. Push the right side printhead cable connector into the printhead. The connector is
keyed to only insert one way.
2. Attach the ground wire to the printhead’s ground tab.
3. Push the left side printhead cable connector onto the printhead.

Printhead Ground Wire

Connector with Key

Printhead Ground Tab

Spring Wire Notch

4. Insert the left side of the printhead assembly into the recessed slot (highlighted in red)
on the left side of the printer.

Slot

Tab

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5. Align the Spring Wire Notch on the backside of the printhead to the Spring Wire. Push
the right side of the printhead into the printer until the latch locks the right side of the
printhead into the printer.

Spring Wire in Notch

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6. Verify that the printhead moves up and down freely when pressure is applied
and remains locked when released.

7. Clean the printhead. Use a new pen to wipe body oils (finger prints) and debris
of the printhead. Clean from the center of the printhead to the outside. See
Cleaning the Printhead.
8. Reload media. Plug in the power cord, turn on the printer and print a status
report to ensure proper function. See Test Printing with the Configuration
Report.

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ZD620 and ZD420 Thermal Transfer Ribbon Roll Printhead

Removing the Printhead
1. Turn the printer OFF. Open the printer.

Printhead

2. Push the printhead release latch toward the printhead (shown as green for visibility).
The right side printhead releases down and away from the Printhead Actuator Arm.

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3. Swing the loose right side of the printhead out of the printer. Pull it to the right a little to
get the left side of the printhead clear. Pull the printhead down and free of the ribbon
carriage to gain access to its attached cables.

4. Gently but firmly pull the two printhead cable bundle connectors off of the printhead.

Connectors

Printhead Assembly

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Replacing the Printhead

1. Push the right side printhead cable connector into the printhead. The connector is
keyed to only insert one way.
2. Push the left side printhead cable connector onto the printhead.

3. Insert the center tab on the printhead assembly into the center slot on the Printhead
Actuator Arm.

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4. Insert the left side tab of the printhead assembly into the recessed slot on the left side
of the Printhead Actuator Arm.

Slot

Tab

5. Push the right side of the printhead into the printer until the latch locks the right side of
the printhead into the printer.

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6. Verify that the printhead moves up and down freely when pressure is applied and
remains locked when released.

7. Clean the printhead. Use a new pen to wipe body oils (finger prints) and debris of the
printhead. Clean from the center of the printhead to the outside. See Cleaning the
Printhead.
8. Reload media. Plug in the power cord, turn on the printer and print a status report to
ensure proper function. See Test Printing with the Configuration Report.

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ZD420 Thermal Transfer Ribbon Cartridge Printhead

Printhead Removal
1. Turn the printer OFF. Open the printer.
2. Pull the two (2) Release Arms out to release the Ribbon Drive Transport. See ZD420
Cartridge Printer: Accessing the Printhead for more details.
3. Swing the Printhead Actuator Arm up until it touches the printer’s top cover. Hold the
Printhead Actuator Arm in this position for access to the printhead. Push the printhead
release latch toward the printhead (shown as pink for visibility). The right side
printhead releases down and away from the Printhead Actuator Arm.

4. Swing the loose right side of the printhead out of the printer. Pull it to the right a little to
get the left side of the printhead clear. Pull the printhead down and free of the
Printhead Actuator Arm to gain access to its attached cables.

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5. Gently but firmly pull the two printhead cable bundle connectors off of the printhead.

Connectors

Printhead Assembly

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Replacing the Printhead

1. Push the right side printhead cable connector into the printhead. The connector is
keyed to only insert one way.
2. Push the left side printhead cable connector onto the printhead.
3. Insert the center tab on the printhead assembly into the center slot on the Printhead
Actuator Arm.

Tab Slot

4. Insert the left side tab of the printhead assembly into the recessed slot on the left side
of the Printhead Actuator Arm.

Tab Slots - both sides

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5. Push the right side of the printhead into the printer until the latch locks the right side of
the printhead into the printer.

Slot
Guide

6. Verify that the printhead moves freely into the printer when pressure is applied (see
arrow) and remains locked when pressure is released.

7. Clean the printhead by using a new cleaning pen to wipe body oils (finger prints) and
debris off the printhead. See Cleaning the Printhead.
Reload media. Turn on the printer and print a status report to ensure proper function. See
Test Printing with the Configuration Report.

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Replacing the Platen (Drive) Roller

If you need to replace the platen drive roller assembly, read the procedure and review the
removal and installation steps before actually replacing the platen.
ESD Caution • Prepare your work area by protecting against static discharge. Your work
area must be static-safe and include a properly grounded conductive cushioned mat to
hold the printer and a conductive wrist strap for yourself.

Removal
1. Open the cover (and dispenser door if the dispenser is installed). Remove media from
platen area.
2. Pull the platen bearing latch release tabs on the right and left sides towards the front
of the printer and rotate them up.

Platen Bearings

Platen Bearings

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3. Lift the platen out of the printer’s bottom frame.

Platen Bearings

4. Slide the gear and the two (2) bearings off the shaft of the platen roller.

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Installation
Your new platen may be dirty from shipping and handling. Inspect the platen for dirt and
other contaminates. Clean if necessary.
Clean the platen with a 99% pure Isopropyl Alcohol moistened swab or fiber free cloth.
Clean from the center out. Repeat this process until all of the roller surface has been
cleaned.
1. Make sure the bearings and drive gear are on the shaft of the platen roller.

2. Align the platen with the gear to the left and lower it into the printer’s bottom frame.
3. Rotate the platen bearing latch release tabs down on the right and left sides towards
the rear of the printer and snap them into place.
If you cleaned the platen roller, allow the printer to dry for one minute before closing the
dispenser door, media cover or loading labels.

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Removing and Replacing Connectivity Modules

ESD Caution • Prepare your work area by protecting against static discharge. Your work
area must be static-safe and include a properly grounded conductive cushioned mat to
hold the printer and a conductive wrist strap for yourself.
Connectivity modules can easily be removed for the purpose of reconfiguring a printer or
repair. You should not remove and replace connectivity modules as a general practice.

Removal
1. Turn power off and disconnect the power cable. Remove the interface cables.
2. Remove the module access door. Push down on the top of the door with your finger
tip. This releases the latch. Pull the door away and down to remove.
3. Re-attach an interface cable to the connectivity module and secure the cable.
4. Gently pull on the interface cable that is secured to the connectivity module. Slowly
pull the module out of the printer.

Installation
1. With the module’s access door removed, slide the connectivity module into the
printer. Push the circuit card in slowly but firmly until the card is just past the inside lip
of the access door.
2. Align the bottom of the connectivity module door cover to the bottom lip of the module
access opening. Swing the door up and snap the cover closed.
3. Reconnect power. Turn power on and update the printer firmware which includes
connectivity module updates to synchronize versions.

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Replacing a Front Bezel Option (Tear-off, Dispense, Cut)

ESD Caution • Prepare your work area by protecting against static discharge. Your work
area must be static-safe and include a properly grounded conductive cushioned mat to
hold the printer and a conductive wrist strap for yourself.
All three (3) of the front bezel options (standard tear-off bezel, the dispenser module, and
cutter module) mount in the same way

Removal
1. Turn the printer upside down. Remove the two (2) mounting screws with a Torx T10
driver or wrench. Save the screws.
2. Slide the bezel down the front and pull the loose bezel out.

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Installation
1. Place the front bezel option and printer right side up with the top of the module even
with the bottom of the top cover. Center and push the module into the front of the
printer and slide it up until it stops.
2. Turn the printer upside down and attach the media exit option to the printer with the
two screws using a Torx T10 driver or wrench.

3. Reconnect power. Turn power on and update the printer firmware which includes
connectivity module updates to synchronize versions.

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Removing the Printer Base for Repair Access

The printer base (bottom cover) is not a spare part and must be replaced at a Zebra repair
center.

Repair Prerequisites
You must remove the Front Bezel Option bezels (tear-off, dispenser, or cutter) before you
can remove the printer base. Connectivity option PCBA’s and bezel do not have to be
removed to gain access to remove the base.

Removal
1. Remove the two (2) screws with a Torx T10 driver.
2. Lift the base off the printer.

Installation
1. Place the base on the lower printer’s frame.
2. Secure the base with the two (2) screws using a Torx T10 driver.

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Replacing the Printer’s Feet

Installation
1. Turn the printer over with the bottom facing up.
2. Replace any missing feet as needed. Insert the adhesive backed rubber foot into the
round foot holder (see below).

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Replacing the Window

Repair Prerequisites
Open the printer to gain access to the window release tabs on the inside of the
printer. For better access to the window, use the following:
• ZD420 Cartridge Printer: Accessing the Printhead
• ZD Thermal Transfer Printers: Accessing Inside the Cover

Thermal Transfer Roll and Cartridge Printers

For Direct Thermal Printers see: Direct Thermal Printer Window Replacement

Removal
1. Use your finger to push the window’s release tabs towards the middle area of
the window.

Installation
1. Slide the three (3) tabs on the window part into the three (3) slots in the top
cover at the rear of the printer.
2. Swing the window down into the front of the window recess area and press it
into the cover to latch. You may want to leave the window’s protective cover
on until the printer is installed for use.

Latching Release Tabs

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Direct Thermal Printer Window Replacement

Repair Prerequisites
Open the printer to gain access to the window release tabs on the inside of the printer.
Removal
1. Use push the window out of the top cover. Press the middle of the window on the left
side. Push it out and towards the cover hinge until you can see a gap between the
window and cover. Continue to push while shifting your fingers to the right to side to
release the window.

Gap after pushing

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Installation
1. Slide the window’s tab (window wide) into the slot on the back of the top cover at the
rear of the printer.

Tab

Slot

2. Swing the window down into the front of the window recess area. Push the lip of the
window under the front edge of the window recess. The window lip will slide down and
into place.

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Replacing the Motor

Repair Prerequisites
You must remove the Main PCBA, (Direct Thermal only) Front Bezel Option (tear-off,
dispenser, or cutter) and Printer Base before you can remove the motor.

Screws

Motor’s Cable and

Connectors

Direct Thermal
Printers

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Removal
1. Use a Torx T10 driver to remove the two (2) screws holding the motor to the inner
frame. Pull the motor out of the gears and inner frame.
2. Disconnect the cable from the motor or PCBA on thermal transfer printers.

Installation
1. Connect the cable to the motor on thermal transfer printers.
2. Orient the motor with the cable connector facing the front of the printer for thermal
transfer printers or down towards the inner frame on direct thermal printers. Insert the
motor gear into the inner frame to mesh with the drive train gears. Secure the motor to
the inner frame with the two (2) screws using a Torx T10 driver.

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Replacing the Head-Up Sensor

Repair Prerequisites
You must remove the Front Bezel Option (tear-off, dispenser, or cutter) and Printer Base
before you can remove the Head-Up Sensor.

Head-Up Sensor
Cable

Head-Up Sensor

Thermal Transfer
Printer shown

Removal
1. Use a Torx T10 driver to remove the screw holding the Head-Up Sensor to the inner
frame. Pull the sensor out of the inner frame.
2. Disconnect the cable from the Main PCBA.

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Installation
1. Connect the cable to the Main PCBA.
2. Slide the Head-Up Sensor PCBA into the slot in the inner frame. The PCBA’s switch
will slide in easier if the top cover is not latched to the inner frame. The switch on the
PCBA faces the front of the printer with the cable oriented towards the printer bottom.
Secure it with the screw using a Torx T10 driver
.

Direct Thermal
Printer

Cover and Latch

are open

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Replacing the Main PCBA

Repair Prerequisites
You must remove the Front Bezel Option (tear-off, dispenser, or cutter) and Printer Base
before you can remove the Main PCBA. The Connectivity Option Modules PCBA can be
removed during or prior to this procedure.

Removal
1. Remove any Connectivity option PCBA (Serial, Ethernet, etc.) that may be installed in
the Connectivity slot. Slide it out of the Connectivity slot.

Connectivity
Option Module

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2. Loosen the two (2) screws retaining the Main PCBA. Lift the PCBA off the opposite
side’s mounting post. Slide the Main PCBA side ways, away from the Connectivity
module’s mounting bracket. Carefully lift the Main PCBA away from the printer to
disconnect the wires from the board.
3. Carefully remove each connector from the Main PCBA:
a. Disconnect the PRINTHEAD cable from J23.

b. Disconnect the USER INTERFACE (control panel) cable from J10.

c. Disconnect the GAP (upper media) sensor cable from J22.

d. Disconnect the MOTOR cable from J8.

e. Disconnect the CARTRIDGE (reader) sensor cable from J1.

f. Disconnect the RIBBON sensor cable from J5.

g. Disconnect the CUT/PEEL (media handling option) cable from J9.

h. Disconnect the BLACKLINE (lower media) sensor cable from J14.

i. Disconnect the HEAD UP sensor cable from J16.

j. The Wi-Fi/Bluetooth option antenna must be disconnected at the PCBA.

The other end of the antenna cable is attached to the side wall of the
printer with adhesive backing and should not be removed. Only use fingers
to disconnect and replace the antenna. Gently pull the coupling straight up
(as close as you can get to the coupling).

Only printers with the Wi-Fi radio option have a separate antenna. All other
Link-OS 4 inch Desktopprinters have an on-board antenna for Bluetooth
LE operation.

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Installation
1. Reattach the Antenna if this unit has the Wi-Fi/Bluetooth radio option (see below).
Use your finger only to apply a slow steady pressure directly above the Antenna
Coupling Post.

Wi-Fi Antenna
Do Not Remove

Antenna Coupling
for printer with the
Wi-Fi/Bluetooth
Option

2. Reconnect the cables to the main board in reverse order for easiest access.
3. Slide the Main PCBA into the slot on the outside of the Connectivity PCBA Mounting
Bracket and between the mounting post and loosened screw.
4. Align the Main PCBA to the other mounting post and tighten the loosened screw to
secure the main board to the printer.
5. Finish securing the Main PCBA to print mechanism with a screw to the mounting post
near the motor.

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Replacing the Movable Sensor

Repair Prerequisites
You must remove the Front Bezel Option (tear-off, dispenser, or cutter), Printer Base,
Motor, and the Main PCBA before you can remove the Movable Sensor.

Removal
1. Remove the two (2) roll holder tension springs.

Springs

Spring Post

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2. Use a Torx T10 driver to remove the four screws securing the roll holder cover
bracket.

3. Un-hook the sensor’s cable from the backside of the movable sensor.

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4. Un-snap the two gold prongs on the backside of the movable sensor. Push them
away from the center of the movable sensor body to release the latching prongs.

5. Pull the metal spring-lock and black plastic bracket out of the frame and clear of the
sensor’s cable. Open the printer. The gold sensor body, PCBA and cable can now be
pulled out of the printer’s inner cavity and movable sensor’s recessed slide track.

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Installation
1. Slide the new sensor’s PCBA and cable into the lens bracket for the PCBA. The cable
is on the open end and hangs below the bracket.

2. Snap the PCBA and bracket into the movable sensor body. The lens bracket should
be flush with the top surface of the sensor body.

3. Place the sensor’s cable and connector into sensor guide channel and cable slot.
There is a wider opening on one end to allow the connector to slip through the slot.

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4. Align the (gold plastic) sensor body (with the sensor PCBA inside) to the movable
sensor channel on the inside of the printer. The prongs go into the cable channel. The
arrow point on the sensor body points to the rear of the printer.

Arrow Point

5. Put the sensor’s cable into the center of the metal spring-lock with the metal spring-
lock’s notch facing the inner frame. Put the sensor’s cable into the center of the black
plastic bracket with the black plastic bracket’s cable retainer (hooks) facing away from
the inner frame.
6. Align the black plastic bracket to the metal spring-lock and lock them to the movable
sensor. The prong’s tabs will lock the bracket and spring in place.

Slide the movable sensor from end to end to verify that the bracket is lated properly.

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7. Verify that the Media Stop Arm on the gold thumb wheel‘s threaded shaft are both still
in place on the finner frame.

Media Stop Arm

8. Place the roll holder cover bracket over the movable sensor and roll holder
components. The senor’s cable goes through the larger opening in the roll holder
cover.

9. Use a Torx T10 driver to tighten the four screws securing the roll holder cover bracket
to the inner frame.
10. Replace the two (2) roll holder tension springs.

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Replacing the Hinge in Thermal Transfer Printers

Repair Prerequisites
You must remove the Front Bezel Option (tear-off, dispenser, or cutter) and Printer Base
before you can remove the Hinge. The Main PCBA can be removed to gain better access
to cable connectors on the Main PCBA.

Hinge Lock

Hinge Cap

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Removal
1. Open the printer (with bezel and printer base removed).
2. Remove the two (2) screws securing the hinge cap to the print mechanism (lower
frame) using a Torx T10 driver.
3. Use a small flat bladed screwdriver to pry the two (2) tab locks on the hinge lock
bracket on the inside of the printer. Lift the hinge lock bracket off to free the right hinge
mechanism.

Pry tabs out of

the tab recess

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Installation
1. With the right side inner frame hinge in the right lower frame’s hinge, push the hinge
lock onto the rear wall of the lower inner frame.

Many parts are hidden to help you

identify the primary parts Upper Inner Frame

Lower Inner Frame

Pry tabs out of

the tab recess

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2. Align the cables exiting the center of the inner frames hinge joint and pull them
straight down towards the bottom of the printer.
3. Align the sensor cable exiting the Ribbon Transport OR Ribbon Carriage where it
joins the print mechanism (lower inner frame) and put the cable straight down into the
channel in the print mechanism (lower inner frame) towards the bottom of the printer.

Ribbon Cartridge Printers

Ca
bl
e
Di
re
ct
io
n

Transfer Roll Printers

4. Place the Hinge on the printer and verify that the cables are not pinched between the
inner frames.
5. Secure the Hinge to the frame with the two (2) screws using a Torx T10 driver.

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Replacing the Hinge in Direct Thermal Printers

Repair Prerequisites
You must remove the Front Bezel Option (tear-off, dispenser, or cutter) and Printer Base
before you can remove the Hinge. The Main PCBA can be removed to gain better access
to cable connector on the Main PCBA.

Removal
1. Open the printer (with bezel and printer base removed).
2. Disconnect the printhead cable from the Main PCBA.

Hinge

Printhead Cable

3. Remove the screw securing the hinge cap to the print mechanism (lower frame) using
a Torx T10 driver.
4. Pull the printhead cable out of the hinge.

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Replacement
1. Put the printhead cable in the new hinge.
2. Put the hinge on the top cover and pull the printhead through the hinge to remove
slack in the cable.
3. Align the hinge with the lower frame and swing the square end into the matching
square on the lower frame.
4. Secure the Hinge to the frame with the screw using a Torx T10 driver.
5. Re-attach the printhead cable to the Main PCBA.

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Replacing the Cover Assembly on Thermal Transfer (Roll) Printers

Repair Prerequisites
You must remove the Front Bezel Option (tear-off, dispenser, or cutter), Printer Base, the
Main PCBA, and the Hinge before you can remove the Cover Assembly.

Remova l
1. Pull the Control Panel (User Interface) cable (and connector) out of the Connectivity
Module’s mounting bracket. Turn the connector body parallel to the cable and
remove. Do not remove the bracket.

2. Pull the Cover Assembly out of the left side hinge cap on the lower frame.

Replacement
1. Insert the Cover Assembly into the left side hinge cap on the lower frame.
2. Insert the Control Panel (User Interface) cable and connector through the
Connectivity Module’s mounting bracket and lower frame through to the right side of
the printer. Turn the connector body parallel to the cable to push it through the
bracket. Do not remove the bracket.

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Replacing the Cover Assembly on Cartridge Printers

Repair Prerequisites
You must remove the Front Bezel Option (tear-off, dispenser, or cutter), Printer Base, the,
Main PCBA, and the Hinge before you can remove the Cover Assembly.

Removal
1. Remove the two (2) toroid clamps from the printhead cables exiting the right side
cover hinge. Use a small flat bladed screw driver to gently pry the clamp’s lock open.

2. Pull the Control Panel (User Interface) cable (and connector) out of the Connectivity
Module’s mounting bracket. Turn the connector body parallel to the cable and
remove. Do not remove the bracket.

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3. Pull the printhead cable and connector out through the lower frame’s hinge cap.

Replacement
1. Insert the printhead cable and connector in the lower frame’s hinge cap.
2. Align the Cover Assembly’s left hinge with the lower frame’s hinge cap and pull the
printhead cable out while inserting it in the cover assembly’s hinge.
3. Insert the Control Panel (User Interface) cable and connector through the
Connectivity Module’s mounting bracket and lower frame through to the right side of
the printer. Turn the connector body parallel to the cable to push it through the
bracket. Do not remove the bracket.
4. Replace the two (2) toroid clamps on the printhead cable

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Replacing the Cover Assembly on Direct Thermal Printers

Repair Prerequisites
You must remove the Front Bezel Option (tear-off, dispenser, or cutter), Printer Base,
loosen to access connectors on the Main PCBA, and the Hinge before you can remove the
Cover Assembly.

Removal
1. With the printhead cable disconnected and out of the hinge, disconnect the Control
Panel (interface) cable from the loose Main PCBA (if the Main PCBA has not been
removed).
2. Pull the Control Panel (User Interface) cable (and connector) out of the Connectivity
Module’s mounting bracket. Turn the connector body parallel to the cable and
remove. Do not remove the bracket.

3. Pull the Cover Assembly’s left side hinge and Control Panel (User Interface) cable
(and connector) out of the lower frames hinge cap.

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Replacement
1. Insert the new Cover Assembly’s Control Panel (User Interface) cable (and
connector) into the lower frame’s left side hinge cap.
2. Align the Cover Assembly’s left hinge with the lower frame’s hinge cap and pull the
cable out while inserting it in the cover assembly’s hinge.
3. Insert the Control Panel (User Interface) cable and connector through the
Connectivity Module’s mounting bracket and lower frame through to the right side of
the printer. Turn the connector body parallel to the cable to push it through the
bracket. Do not remove the bracket.
4. Reconnect the Control Panel (interface) cable to the loose Main PCBA (if the Main
PCBA has not been removed).

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Replacing the Cover - Thermal Transfer Printers

ESD Caution • Prepare your work area by protecting against static discharge. Your work
area must be static-safe and include a properly grounded conductive cushioned mat to
hold the printer and a conductive wrist strap for yourself.

Repair Prerequisites
Before you begin this procedure, turn the printer OFF, open the printer, and remove media
or ribbon.
Exploded View Thermal Transfer Printer: Cartridge and Roll Printers are similar

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Removal
1. Slide both of the gold latch release slider buttons towards the front of the top cover.
Stop sliding the gold buttons when they are slightly past the mid point in the slide
channel. Push the button out of the slide channel (and cover) from the inside of the
cover.

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2. Using a Torx T10 driver, remove the screws securing the top cover to the inner lid.
Remove the top cover.

Screws
Screws

Installation
1. Place the new cover on the top inner frame. Align the cover to the mounting holes.
2. Use the mounting screws to secure the cover to the frame.
3. Swing the latch arms up until it touches the front of the cover. Snap the gold latch
release slider buttons into the right and left sides of the cover. Verify they slide freely
an release the latch arm.
4. Close the cover and verify the printer latches closed. Open and close the cover a few
times to verify mechanism and latch function.

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Replacing the Cover - Direct Thermal Printers

ESD Caution • Prepare your work area by protecting against static discharge. Your work
area must be static-safe and include a properly grounded conductive cushioned mat to
hold the printer and a conductive wrist strap for yourself.

Repair Prerequisites
Before you begin this procedure, turn the printer OFF, open the printer, and remove media.

Removal
1. Using a Torx T10 driver, remove the four (4) screws securing the top cover to the
inner lid.
2. Pull the cover off the upper inner frame.

Screws

Installation
1. Place the new cover on the top inner frame. Align the cover to the mounting holes.
2. Use the mounting screws to secure the cover to the frame.
3. Close the cover and verify the printer latches closed. Open and close the cover a few
times to verify mechanism and latch function.

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 Replacing Parts

Replacing a 3-Button Control Panel PCBA

Repair Prerequisites
You must remove the Cover Assembly before performing this procedure.

Removal
1. With the Cover removed, use a Torx T10 driver to remove the screw holding the
Control Panel PCBA to the inner frame.
2. Lift the PCBA off the inner frame and disconnect the cable(s) from the backside of the
PCBA.

Installation
1. Reconnect the cable(s) to the new Control Panel PCBA.
2. Place the PCBA with the connector/cable side facing down onto the two (2) small
guide pins molded into the top of the inner frame.

Guide Pin Hole Guide Pin Hole

Guide Pins

3. Secure the PCBA to the inner frame with the screw using a Torx T10 driver.

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 Replacing Parts

Replacing a LCD Control Panel PCBA

Repair Prerequisites
You must remove the Cover Assembly before performing this procedure.

Removal
1. With the Cover removed, use a Torx T10 driver to remove the 2 screws holding the
LCD Control Panel PCBA to the inner frame.
2. Lift the PCBA off the inner frame and disconnect the cables from the backside of the
PCBA.

Installation
1. Reconnect the cables to the new LCD Control Panel PCBA.
2. Place the PCBA with the connector/cable side facing down onto the two (2) small
guide pins molded into the top of the inner frame.

Guide Pin Hole Guide Pin Hole

Guide Pins

3. Secure the PCBA to the inner frame with the 2 screws using a Torx T10 driver.

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 Replacing Parts

Replacing the Latch Assembly - Thermal Transfer Printers

Repair Prerequisites
You must remove the Cover Assembly on thermal transfer printers before performing this
procedure.

Removal
1. Cartridge Printer - With the Cover removed and inner frame in the full open position,
rotate the latch assembly up and lift it out of the inner frame.
Ribbon Roll Printer - With the Cover removed and inner frame in the full open
position, rotate the latch assembly down and lift it out of the inner frame.

Installation
1. With the inner frame in the full open position, slide the flat surface on the latch
assembly’s pivot bar into the two (2) molded ‘C’ shaped latch bar bearings at the top
of the inner frame. Orient the latch arm assembly

Cartridge Ribbon Roll

Printer Printer

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 Replacing Parts

Replacing the Latch Arm Assembly - Direct Thermal Printers

Repair Prerequisites
You must remove the Cover and the Control Panel PCBA before performing this procedure.

Removal
1. Remove the control panel mounting plate. It is attached to the inner frame by two (2)
Torx T10 screws.

Screws

Control Panel
Mounting Plate

ZD620 only:
Media Dancer
Spring

2. The inner frame may be latched into the inner frame. To release the latch arm
assembly, pull the latch forward and lift the inner frame up.

Lift

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 Replacing Parts

3. Lift one side of the latch assembly out of the inner frame with stead firm pressure. The
spring may pop or fall out. Repeat on the other side of the latch to completely remove
the assembly (latch bar and springs).

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 Replacing Parts

Installation
1. Align and insert the new latch assembly and press it into the inner fame.
2. Insert a latch spring on the small, short post on the front side of each latch arm. Slide
the other end of the spring into the square recesses immediately across from the latch
arms.

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 Replacing Parts

3. ZD620 Printers only: Place the media dancer’s spring on the post (plus sign shape)
in the middle of the inner frame.
4. Take the control panel mounting plate and insert the upper array sensor and control
panel interface cables into the largest opening.
5. ZD620 printers: Align the media dancer spring to the cup on the back of the
mounting plate. Put a small tool in the cup’s hole to guide the spring into the cup.

Media Dancer Cup for

Spring Spring

Control
Panel
Mount

Cables through
mounting plate

Control Spring visible

Panel through panel hole
Mount

6. Place the mounting bracket on the two (2) mounting post on the inner frame and
secure it to the inner frame with two (2) screws.

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 Replacing Parts

Replacing the Upper Array Sensor - Thermal Transfer Printer

Repair Prerequisites
You must remove the Cover Assembly, Control Panel PCBA (3-Button or LCD version)
and Latch Assembly before performing this procedure.The Upper Array sensor is
unplugged Control Panel PCBA.

Press on
Fitting

Mounting Posts

Removal
1. Using a pliers or special tool lift the press on fitting securing the upper array sensor
PCBA to the inner frame. Pull the PCBA of the posts.

Installation
1. Put the Upper Array Sensor PCBA on the two guide pins with the row of LEDs in the
slot and wires on top facing out and on the inside of the printer. Hold the PCBA on the
posts while pressing the fitting on the long post to secure the PCBA to the inner
frame.

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 Replacing Parts

Replacing the Upper Array Sensor - Thermal Transfer Printer

Repair Prerequisites
You must remove the Cover Assembly and the Control Panel PCBA (3-Button or LCD
version) before performing this procedure.The Upper Array sensor is unplugged Control
Panel PCBA.

Guide Pins

Removal
1. Swing the Flapper Arm up. This aligns the flat surfaces on the on the arm’s pivot
posts. The narrower width can slide out of the two slots in the arm’s pivot bracket.
Slide the Flapper Arm out of the bracket.

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 Replacing Parts

2. Pull the sensor cable out of the out of the backside of the flapper arm.
3. Remove the screw securing the sensor cover from the top side of the Flapper Arm.
Set the cover aside. Remove the sensor array PCBA and cable.

Installation
1. Insert the new PCBA’s cable and connector into the hole in the center of the flapper
and route it through the cable channel on the backside of the flapper arm.

2. Put the Upper Array Sensor PCBA on the two guide pins with the row of LEDs in the
slot and wires on top facing out. Hold the PCBA on the posts while pulling the wires
and cable connector to remove slack (out the back of the flapper arm to the top).
3. Place the sensor cover on top of the senor PCBA and secure it with the screw. Verify
that the wires are not pinched and the PCBA is still in place.

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 Replacing Parts

4. Insert the cable and connector through the hole in the inner frame’s flapper arm pivot
bracket. Insert the two flapper arm pivot post into the bracket. Swing the flapper arm
down away from the top of the printer. This will lock the flapper arm in the bracket.
Replace the control panel PCBA and cover to complete reassmbly.

Insert Cable
Here

Pivot Post

Insert Pivot Posts Here

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 Replacing Parts

Replacing the Ribbon Roll Printer’s Ribbon Trailer Sensor PCBA

ESD Caution • Prepare your work area by protecting against static discharge. Your work
area must be static-safe and include a properly grounded conductive cushioned mat to
hold the printer and a conductive wrist strap for yourself.

Removal
1. Open the printer. Remove the ribbon rolls.
2. Turn the printer around. Look down into the top of the ribbon carriage. Use a Torx T10
driver to remove the screw securing the Ribbon Sensor PCBA to the ribbon chassis’s
front cross member.

Ribbon Trailer
Sensor PCBA

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 Replacing Parts

3. Push the PCBA out of the ribbon carriage cross member from the bottom and lift it up.
Note the wire routing. Disconnect the cable’s connector from the PCBA. The black
sensor extending through the cross member is colored orange in this illustration.

Installation
1. Connect the cable to the to the new PCBA.
2. Place the sensor on the PCBA into the square hole in the cross member and secure it
to the cross member with the screw.

Channel

3. Verify the cable’s wiring is routed in the channel (under the tabs).

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 Replacing Parts

Replacing the Cartridge Printer Ribbon Sensor PCBA

Repair Prerequisites
You must remove the Cover Assembly before performing this procedure.

Printhead
Actuator Arm
Cover

Screw

Ribbon Sensor

Removal
1. Pry the cover off the Printhead Actuator Arm with your hand. Grab the sides of the
cover (close to Actuators Arm’s hinge) and lift up. Swing it up and lift the cover out.

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 Replacing Parts

2. Using a Torx T10 driver, remove the screw securing the Ribbon Sensor PCBA to the
Printhead Actuator Arm. Lift the PCBA out. The printhead may be unlatched from the
Printhead Actuator Arm if necessary to gain more clearance from the printhead cable,
see Removing the Printhead

3. Disconnect the cable from the PCBA.

Installation
1. Connect the cable to the Ribbon Sensor PCBA.
2. Place the PCBA with the black sensor body down into the Actuator Arm body. The
connector/cable side is on the outer edge of the Actuator Arm body. Align the PCBA
with the two notches and the screw hole in the Actuator Arm body.
3. Secure the PCBA to the Actuator Arm body with screw using a Torx T10 driver.
4. Place the Actuator Arm’s cover back onto the Actuator Arm body. Slide the notches
on the cover under the tabs on the Actuator Arm body. Swing the narrow end down
into the arm’s hinge. Press the cover into the Actuator Arm body to lock it in place.

Tabs and
Notches

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 Replacing Parts

Replacing the Ribbon Carriage in Thermal Transfer (Roll) Printers

Repair Prerequisites
You must remove the Front Bezel Option (tear-off, dispenser, or cutter), Printer Base, Main
PCBA, and Hinge before you can remove the Ribbon Carriage.

Removal
1. Remove the two (2) toroid clamps from the printhead cables exiting the right side
cover hinge. Use a small flat bladed screw driver to gently pry the clamp’s lock open.

2. Remove the screw and washer on each side of the print mechanism at the Ribbon
Carriage’s hinges using a Torx T10 driver.

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 Replacing Parts

3. Push the Ribbon Carriage’s hinge pin out of the hinge bracket molded into the print
mechanism (lower frame) on the left side. The inner frame and transport both bend to
allow you to get the pin out of the bracket.

4. Pull the Ribbon Carriage up and way from the printer. Gently pull the printhead cables
(and connectors) out of the well in the top of the lower frame.

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 Replacing Parts

Installation
1. Insert the printhead cable (and connector) into the opening between the right cover
hinge and right ribbon carriage hinges.
2. Align the Ribbon Carriage with the two (2) hinge springs with the two (2) hinge spring
wells in the top of the lower inner frame. Lower the springs into the wells until the
carriages hinge pins and hinge brackets are close.

Spring Well

Carriage Cable Carriage Spring

Channel

Ribbon Trailer
Sensor Cable

3. Push the right side transport hinge pin into the right side bracket on the inner frame.
Repeat for the left side.
4. Pull the printhead cable completely through the lower frame to remove slack at the
carriage hinge. Re-attach the two (2) toroid clamps to the two (2) branches of
printhead cables below the hinge area.
5. Secure the Ribbon Carriage hinges to the print mechanism with a screw and washer
on each side of the printer with a Torx T10 driver.

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 Replacing Parts

Replacing the Ribbon Transport

Repair Prerequisites
You must remove the Front Bezel Option (tear-off, dispenser, or cutter), Printer Base, and
Hinge before you can remove the Ribbon Transport. The Main PCBA can be removed to
gain better access to cable connectors on the Main PCBA.

Removal
1. Disconnect the (Ribbon) Cartridge Sensor cable from the Main PCBA. Loosen the
tape holding the Cartridge Sensor and Ribbon Sensor (with toroid clamp) cables to
the bottom of the lower frame.

Tape

Cartridge
Sensor

Ribbon
Sensor

2. Disconnect the Upper (Gap/Web) Media Sensor cable from the Main PCBA.

Upper Media
Sensor Cable

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 Replacing Parts

3. Disconnect the two link arms that connect the Ribbon Transport to the top cover (and
upper frame).

Link Arm

4. Remove the screw and washer on each side of the print mechanism at the Ribbon
Transport’s hinge using a Torx T10 driver.

Hinge Pin

Hinge Bracket

5. Push the Ribbon Transport’s hinge pin out of the hinge bracket molded into the print
mechanism (lower frame) on the left side. The inner frame and transport both bend to
allow you to get the pin out of the bracket.
6. Pull the Ribbon Transport up and out of the printer. Gently pull the Upper Media
Sensor’s cable (and connector) out of the well in the top of the lower frame.

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 Replacing Parts

Installation
1. Align the Ribbon Transport with the two (2) hinge springs with the two (2) hinge spring
wells in the top of the lower inner frame. Lower the springs into the wells until the
transports hinge pins and hinge brackets are close.

Upper Media
Sensor Cable

Spring Well Transport

Cable Well

Transport Spring

2. Push the right side transport hinge pin into the right side bracket on the inner frame.
Repeat for the left side.
3. Insert the Upper Media Sensor cable (and connector) into the larger well on the top of
the inner frame on the left side of the printer.
4. Plug the Cartridge Sensor and Upper Media Sensor cables into the Main PCBA.
5. Re-secure the Cartridge Sensor and Ribbon Sensor cables to the bottom of the print
mechanism with tape.
6. Secure the Ribbon Transport hinge to the print mechanism with a screw and washer
on each side of the printer with a Torx T10 driver.

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 Replacing Parts

Replacing the Upper Media (Gap/Web) Sensor

Repair Prerequisites
You must remove the Front Bezel Option (tear-off, dispenser, or cutter), Printer Base,
Hinge, and Ribbon Transport before you can remove the Upper Media Sensor. The Main
PCBA can be removed to gain better access to cable connectors on the Main PCBA.

Sensor Cover
(and Ribbon
Sensor Reflector)

Upper Media
Sensor PCBA
(has black back –
shown as green here)

Removal
1. With the Ribbon Transport removed from the printer, remove the two (2) screws
securing the lift side panel to the transport using a Torx T10 driver.
2. At the Ribbon Transport’s hinge pin, lift the side panel off the transport. The side
panel has snap to lock features that are holding the panel lightly in place. Continue
lifting all the way around the side panel to release the latches and pull it away from the
transport frame.

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 Replacing Parts

3. Remove the screw securing the Sensor Cover using a Torx T10 driver and remove
the cover.

Cable Capture
Cable Capture Feature
Feature

Upper Sensor
PCBA

4. Locate the cable on side of the transport frame and pull it out. The cable channels
include cable capture features to hold the cable in place during assembly. Pull the
cable around them and then out of the transport frame through the inside of the
transport’s side frame.

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 Replacing Parts

Installation
1. Place the new Upper Media Sensor PCBA on the two (2) guide posts with the four (4)
LEDs in the hole in the transport frame’s cross member. The cable from the sensor
PCBA exits toward the back of the transport (hinges in the back) and the cable sits in
a notch in the cross member.

2. Place the Sensor Cover over the Upper Media Sensor PCBA and secure it and the
PCBA to the frame with a screw using a Torx T10 driver. Verify that the cable is not
pinched between the frame and the cover.
3. Put the cable’s loose end with the connector through the transport’s right inside wall
and route the cable through the channel and under the cable capture feature.
4. From the outside of the transport frame’s right side, gently pull the cable tight and
route it through the cable channel and out over the hinge pin. Push the cable in the
channel and under the cable capture feature. Pull the cable gently tight again to
remove any slack.
5. Align and press the left side transport frame’s cover pack onto the transport. Secure it
to the frame with two (2) screws using a Torx T10 driver.

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 Replacing Parts

Replacing the Print Mechanism or Upper Inner Frame

Repair Prerequisites
You must remove the Front Bezel Option (tear-off, dispenser, or cutter), Printer Base, Main
PCBA, Hinge, and Ribbon Transport before you can remove the Print Mechanism or Upper
Inner Frame.

Removal
1. Remove the two (2) toroid clamps from the printhead cables exiting the right side
cover hinge. Use a small flat bladed screw driver to gently pry the clamp’s lock open.

2. Pull the Control Panel (User Interface) cable (and connector) out of the Connectivity
Module’s mounting bracket. Turn the connector body parallel to the cable and
remove. Do not remove the bracket.

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 Replacing Parts

3. Close the upper frame with the printhead (on the actuator arm) and latch (arms)
pointing towards the front of the printer.

4. Use the small flat bladed screwdriver to gently pry the left side of the rear hinge cover
up from the print mechanism. Repeat for the right side and lift the hinge cover up and
away from the printer.

5. Lift the upper frame assembly out of the right hinge on the print mechanism.

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 Replacing Parts

6. Pull the printhead cables and connector out of the right hinge (and out of the print
mechanism too).

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 Replacing Parts

Installation
1. Insert the printhead cable and connector into the right hinge in the print mechanism.
2. Put the upper frame’s right side hinge into the print mechanism’s mating right side
hinge while pulling the printhead cable through the hinge joint.
3. Close the upper frame with the printhead and latch arms pointing towards the front of
the printer.
4. Slide the rear hinge cover down onto the upper part of the rear panel on the print
mechanism. This will lock the right hinge in place.

5. Push the Control Panel (User Interface) cable and connector through the Connectivity
Module’s mounting bracket and lower frame. Turn the connector body parallel to the
cable to push it through the bracket. Do not remove the bracket.

178
Main PCBA Layout

179
 Main PCBA Layout

Main Printed Circuit Board Assembly

Control Panel
(User Interface)

Printhead
(PH) Wire

Upper (Gap)
Media Sensor

Lithium
Battery
LCD Not
Replaceable
Ribbon
Sensor

Battery

RFID
Head-Up
Sensor
Movable
Sensor

Cartridge
Sensor
Wireless
Radio
Module

Motor Media Option Radio

Interface Antenna
Coupling

Figure 1 • Connectors on the Main Logic Board PCBA

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 Main PCBA Layout

Main Printed Circuit Board Assembly

ZD620 and ZD420c

have these
memory chips on
the back of the
PCBA.
Full memory and
BT LE, etc. board
version

Cover Lock Connector

Figure 2 • Connectors on the Main Logic Board PCBA

181
Cable Routing for ZD420c

ZD420c - Ribbon Cartridge printers

182
Cable Routing for ZD420c

183
Cable Routing for ZD420c

184
Cable Routing for ZD420c

185
Cable Routing for ZD420c

186
Cable Routing for ZD420c

187
Cable Routing for ZD420c

188
Cable Routing for ZD420t

ZD620 and ZD420 Ribbon Roll Printers

189
Cable Routing for ZD420t

190
Cable Routing for ZD420t

191
Cable Routing for ZD420t

192
Cable Routing for ZD420t

193
Cable Routing for ZD420t

194
Cable Routing for ZD420t

195
Cable Routing for ZD420t

196
Cable Routing for ZD420d

ZD420c - Direct Thermal printers

197
Cable Routing for ZD420d

198
Cable Routing for ZD420d

199
Cable Routing for ZD420d

200
Media

This section provides a simple media overview for your printer.

201
 Media

Types of Thermal Media

Important • Zebra strongly recommends the use of Zebra-brand supplies in order to ensure
consistent high-quality printing. A wide range of paper, polypropylene, polyester, and vinyl
stock has been specifically engineered to enhance the printing capabilities of the printer and
to prevent premature printhead wear.
To purchase supplies, go to http://www.zebra.com/howtobuy.
• Your printer can use various types of media:
• Standard media—Most standard (non-continuous) media uses an adhesive
backing that sticks individual labels or a continuous length of labels to a liner.
• Continuous roll media—Most continuous roll media is direct thermal media
(similar to FAX paper) and is used for receipt or ticket style printing.
• Tag stock—Tags are usually made from a heavy paper (up to 0.0075in./0.19mm
thick). Tag stock does not have adhesive or a liner, and it is typically perforated
between tags.
The printer typically uses roll media, but you can use fan-fold or other continuous media
too.

Determining Thermal Media Types

Thermal transfer media requires ribbon for printing while direct thermal media does not.
To determine if ribbon must be used with a particular media, perform a media scratch test.

To perform a media scratch test, complete these steps:

1. Scratch the print surface of the media with a finger nail or pen cap. Press firmly and
quickly while dragging it across the media surface. Direct thermal media is chemically
treated to print (expose) when heat is applied. This test method uses friction heat to
expose the media.

2. Did a black mark appear on the media?

If a black mark... Then the media is...

Appears on the media Direct thermal. No ribbon is required.
Does not appear on the media Thermal transfer. A ribbon is required.
Not supported by this printer.

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 Media

General Media and Print Specifications

• Direct Thermal — Max. Media width: 108mm (4.25 inches)

• Thermal Transfer — Max. Media width: 118mm (4.65 inch)
• All Printers — Min. Media width: 15mm (0.585 inch)
• Media length:
• 990mm (39 inches) max.
• 6.35mm (0.25 inches) min. – Tear Off or Label
• 12.7mm(0.50 inches) min. – Peel
• 25.4mm (1.0 inch) min. - Cutter
• Media thickness:
• 0.06mm (0.0024 inches) min. – all requirements
• 0.1905mm (0.0075 inches) max. – all requirements

• Media Roll Outer Diameter (O.D.) max.: 127mm (5.0 inches)

• Media Roll Core Inner Diameter (I.D.):

• 12.7mm (0.5 inch) I.D. - Standard roll configuration
• 25.4mm (1 inch) I.D. - Standard roll configuration
• 38.1mm (1.5 inches) I.D. - with optional media roll adapter
• 50.8mm (2.0 inches) I.D. - with optional media roll adapter
• 76.2mm (3.0 inches) I.D. - with optional media roll adapter

• Ribbon Rolls - 74 meter

• Ribbon Length - 74 m (243 feet)
• Ribbon Width Max. - 110 mm (4.33 inches)
• Ribbon Width Min. - 33 mm (1.3 inches) ‡
• Ribbon Core I.D. - 12.7mm (0.5 inches)
• Wax, Wax/Resin, and Resin transfer materials

• Ribbon Rolls - 300 meter

• Ribbon Length - 300 m (984 feet)
• Ribbon Width Max. - 110 mm (4.33 inches)
• Ribbon Width Min. - 33 mm (1.3 inches) ‡
• Wax, Wax/Resin, and Resin transfer materials
‡ - Transfer ribbon should always cover the entire width of the media (and liner) to prevent damaging the printhead.

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 Media

• ZD420 Ribbon Cartridges

• Ribbon Length - 74 m (243 feet)
• Ribbon Width Max. - 110 mm (4.33 inches)
• Ribbon Width Min. - 33 mm (1.3 inches) ‡
• Colors available in Black - Wax, Wax Resin, and Resin transfer materials

• Dot pitch:
• 203 dpi: 0.125mm (0.0049 inches)
• 300 dpi: 0.085mm (0.0033 inches)
• Barcode modulus x-dim:
• 203 dpi: 0.005-0.050 inches
• 300 dpi: 0.00327 - 0.03267 inches

Label Dispenser (Peeler)

The printer supports a field installed label dispense option with label taken sensor for batch
processing of labels.
• Paper Thickness:
• Min. 0.06 mm (0.0024 inches)
• Max. 0.1905 mm (0.0075 inches)
• Media Width:
• Min.15 mm (0.585 inches)
• Thermal Transfer Printers Max. 118 mm (4.65 inches)
• Direct Thermal Printers Max. 108 mm (4.25 inches)
• Label Length:
• All Printers Max. (theoretical): 990mm (39 inches)
• Thermal Transfer Printers Max. (tested): 279.4mm (11 inches)
• Direct Thermal Printers Max. (tested): 330mm (13 inches).
• All Printers Min.: 12.7mm (0.5 inches).

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 Media

Standard (Media) Cutter

The printer supports a field installed media cutter option for full width cutting of label liner,
tag or receipt media.
• A medium duty cutter for cutting label liner and light tag media (LINER/TAG). Do
not cut through labels, adhesive or embedded circuitry.
• Paper Thickness:
• Min. 0.06 mm (0.0024 inches)
• Max. 0.1905 mm (0.0075 inches)
• Cut Width:
• Min.15 mm (0.585 inches)
• Thermal Transfer Printers Max. 118 mm (4.65 inches)
• Direct Thermal Printers Max. 109 mm (4.29 inches)
• Minimum distance between cuts (label length): 25.4 mm (1 inch). Cutting shorter
media lengths between the cuts may cause the cutter to jam or error.
• By design, the cutter is self cleaning and does not require preventive maintenance
of the internal cutter mechanism.

Linerless (Media) Cutter - Direct Thermal only

The printer supports a field installed media cutter option for full width cutting of linerless
media.
• A full width linerless media cutter (LINERLESS CUT).
• Paper Thickness:
• Min. 0.06 mm (0.0024 inches)
• Max. 0.1905 mm (0.0075 inches)
• Cut Width:
• Min.15 mm (0.585 inches)
• Max. 118 mm (4.65 inches)
• Minimum distance between cuts (label length): 25.4 mm (1 inch). Cutting shorter
media lengths between the cuts may cause the cutter to jam or error.
• By design, the cutter is self cleaning and does not require preventive maintenance
of the internal cutter mechanism. See Linerless Platen (Drive) Roller cleaning
and Media Path Cleaning to maintain optimal linerless media cut operation.

205
ZPL Configuration

This section provides an overview of managing printer configuration, the Configuring

Status Report, and Printer and Memory Printouts.

Managing the ZPL Printer Configuration

The ZPL printer is designed to allow you to change printer settings dynamically for fast first
label out printing. Printer parameters that are persistent will be retained for future formats
to use. Those settings will remain in effect until they are changed by subsequent
commands, the printer is reset, power is cycled, or when you restore a parameter that has
a factory default by resetting the printer to factory defaults. The ZPL Configuration Update
command (^JU) saves and restores printer configurations to initialize (or re-initialize) the
printer with pre-configured settings.
• To keep settings after a power cycle or printer reset, a ^JUS can be sent to the
printer to save all current persistent settings.
• The values are recalled with a ^JUR command to restore the last saved values to
the printer.
ZPL stores all parameters at once with a single command mentioned above. The legacy
EPL programming language (supported by this printer) changes and saves individual
commands immediately. Most printer settings are shared between ZPL and EPL. For
example, changing the speed setting with EPL will also change the speed set for ZPL
operations. The changed EPL setting will persist even after a power cycle or reset issued
by either printer language.
A printer Configuration Report is available to assist the developer. The Configuration
Report lists operating parameters, sensor settings, and printer status. It can be accessed
by using the procedure in Test Printing with the Configuration Report. The Zebra Setup
Utility and the ZebraDesigner ™ Windows driver also print this report and other printer
reports to help you manage your printer.

206
 ZPL Configuration

ZPL Printer Configuration Format

Managing more than one printer can be done by creating a printer configuration
programming file to send to one or more printers or ZebraNet ™ Bridge can be used to
clone a printer’s setup. Figure 1 below shows the basic structure of a ZPL programming
configuration file.
See the ZPL programmer’s guide and the Configuration Setting to Command Cross-
reference to create a programming file. The Zebra Setup Utility (ZSU) can be used to send
programming files to the printer. Windows Notepad (text editor) can be used to create
programing files.

Figure 1 • Configuration Parameter Format Structure

207
 ZPL Configuration

Configuration Setting to Command Cross-reference

The Printer Configuration Report, shown below, provides a listing of a majority of the
configurations settings that can be set by ZPL command.

Figure 2 • Configuration Report Printout

Sensor Settings
used for
Service Purposes

208
 ZPL Configuration

Table 1 • ZPL Commands and Configuration Report Callout Cross-Reference

Command Listing Name Description
~SD DARKNESS Default: 10.0
— DARKNESS SWITCH LOW (Default), MEDIUM, or HIGH
^PR PRINT SPEED Default: 152.4 mm/s / 6 IPS (max.) - 203 dpi
101.6 mm/s / 4 IPS (max.) - 300 dpi
~TA TEAR OFF Default: +000
^MN MEDIA TYPE Default: GAP/NOTCH
SENSOR SELECT Default: AUTO (^MNA - Auto-Detect)
^MT PRINT METHOD THERMAL-TRANS or DIRECT-THERMAL
^PW PRINT WIDTH Default: 448 (dots for 203 dpi) or
640(dots for 300 dpi)
^LL LABEL LENGTH Default: 1225 (dots) (dynamically updated while
printing)
^ML MAXIMUM LENGTH Default: 39.0IN 989MM
— USB COMM. Connection Status: Connected / Not Connected
^SCa BAUD Default: 9600
^SC,b DATA BITS Default: 8 BITS
^SC,,c PARITY Default: NONE
^SC,,,,e HOST HANDSHAKE Default: AUTO
^SC,,,,,f PROTOCOL Default: NONE
— SGD —** COMMUNICATIONS Default: NORMAL MODE
SER COMM. MODE Default: AUTO
^CT / ~CT CONTROL CHAR Default: <~> 7EH
^CC / ~CC COMMAND CHAR Default: <^> 5EH
^CD / ~CD DELIM./CHAR Default: <,> 2CH
^SZ ZPL MODE Default: ZPL II
— SGD —** COMMAND OVERRIDE Default: INACTIVE
^MFa MEDIA POWER UP Default: NO MOTION
^MF,b HEAD CLOSE Default: FEED
~JS BACKFEED Default: DEFAULT
^LT LABEL TOP Default: +000
^LS LEFT POSITION Default: +0000
~JD / ~JE HEXDUMP Default: NO (~JE)
REPRINT MODE Default: DISABLED

From this point in the Configuration Receipt listing, the printout has sensor settings and
values displayed to troubleshoot sensor and media operations. These are typically used
by Zebra Tech Support to diagnose printer problems.
** - Not supported with a ZPL command, uses the Set Get Do command in the ZPL
manual. See device.command_override.xxxxx in the ZPL Programmer’s manual.
The configuration settings listed here resume after the TAKE LABEL sensor value. These
listings contain printer features seldom changed from default or provide status information.

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 ZPL Configuration

ZPL Commands and Configuration Receipt Callout Cross-Reference

Command Listing Name Description

^MP MODES ENABLED Default: CWF (See ^MP Command)
MODES DISABLED Default: (nothing set)
^JM RESOLUTION Default: 448 8/mm FULL (203 dpi)
640 8/mm FULL (300 dpi)
— FIRMWARE Lists ZPL Firmware Version
— XML SCHEMA 1.3
— HARDWARE ID Lists Firmware Boot-block Version
LINK-OS VERSION
— CONFIGURATION CUSTOMIZED (after first use)
— RAM 2104k........ R:
— ONBOARD FLASH 6144k.........E:
^MU FORMAT CONVERT NONE
RTC DATE Date Displayed
RTC TIME Time Displayed
^JI / ~JI ZBI DISABLED (Requires key to enable)
— ZBI VERSION 2.1 (Displayed if installed)
— ZBI STATUS READY
^JH LAST CLEANED X,XXX IN
^MA HEAD USAGE X,XXX IN
~RO TOTAL USAGE X,XXX IN
RESET CNTR1 X,XXX IN
RESET CNTR2 X,XXX IN
NONRESET CNTR0 (1, 2) X,XXX IN
RESET CNTR1 X,XXX IN
RESET CNTR2 X,XXX IN
SLOT1 EMPTY / SERIAL / WIRED
MASS STORAGE COUNT 0
HID COUNT 0
USB HOST LOCK OUT OFF /ON
— SERIAL NUMBER XXXXXXXXXXX
^JH EARLY WARNING MAINT. OFF

The printer has the ability to set a command or a group of commands once for all receipts
(or labels) that follow. Those settings will remain in effect until they are changed by
subsequent commands, the printer is reset, or you restore factory defaults.

210
 ZPL Configuration

Printer Memory Management and Related Status Reports

To help you manage printer resources, the printer supports a variety of format commands
to manage memory, transfer objects (between memory areas, import and export), object
naming, and provide various printer operating status reports. They are very similar to the
old DOS commands like DIR (directory listing) and DEL (delete file). The most common
reports are also part of the Zebra Setup Utility and ZebraDesigner ™ Windows driver.
It is recommended that a single command be processed within this type of format (form).A
single command is easily reused as a maintenance and development tool.

Many of the commands that transfer objects, manage and report on memory are control
(~) commands. They do not need the be within a format (form). They will be processed
immediately upon receipt by the printer whether in a format (form) or not.

ZPL Programming for Memory Management

ZPL has various printer memory locations that are used to run the printer, assemble the
print image, store formats (forms), graphics, fonts and configuration settings.
• ZPL treats Formats (Forms), Fonts, and Graphics like files; and memory locations
like disk drives in the DOS operating system environment:
• Memory Object Naming: Up to sixteen (16) alphanumeric characters followed
by a three (3) alphanumeric character file extension, for example:
123456789ABCDEF.TTF
Legacy ZPL printers with V60.13 firmware and earlier can only use the 8.3 file
name format verses today’s 16.3 file name format.
• Allows moving objects between memory locations and deleting objects.
• Supports DOS directory style file list reports as printouts or status to the host.
• Allows use of ‘wild cards’ (*) in file access

211
 ZPL Configuration

Object Management and Status Report Commands

Command Name Description

^WD Print Directory Prints a list of objects and resident barcodes and fonts in all
Label addressable memory locations
~WC Print Configuration Prints a configuration Status Receipt (Label)
Label Same as FEED Button mode one flash routine
^ID Object Delete Deletes objects from printer memory
^TO Transfer Object Used to copy an object or group of objects from one
memory area to another.
^CM Change Memory Reassigns a letter designation to a printer memory area.
Letter Designation
^JB Initialize Flash Similar to formatting a disk - erases all objects from the
memory specified memory locations B: or E:.
~JB Reset Optional Similar to formatting a disk - erases all objects from the B:
Memory memory (factory option).
~DY Download Objects Downloads and installs wide variety of printer usable
programming objects: fonts (OpenType and TrueType),
graphics, and other object data types.
Recommendation: Use ZebraNet ™ Bridge for downloading
graphics and fonts in the printer.
~DG Download Graphic Downloads an ASCII Hex representation of a graphic
image. This is used by ZebraDesigner ™ (label creation
application) for graphics.
^FL Font Linking Appends secondary TrueType font or fonts to the primary
TrueType font to add glyphs (characters).
^LF List Font Links Prints a list of the linked fonts
^CW Font Identifier Assigns a single alphanumeric character as an alias to a
font stored in memory.

Important • Some factory installed ZPL fonts in your printer cannot be copied, cloned or
restored to your printer by reloading or updating firmware. If these license restricted ZPL
fonts are removed by an explicit ZPL object delete command, they must be repurchased
and reinstalled via a font activation and installation utility. EPL fonts do not have this
restriction.

212