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zd421 zd621 SM

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ZD621 and ZD421

Link-OS® Desktop Printers

Service Manual

213529-01EN
ZEBRA and the stylized Zebra head are trademarks of Zebra Technologies Corporation, registered in
many jurisdictions worldwide. All other trademarks are the property of their respective owners.
© 2021 Zebra Technologies Corporation and/or its affiliates. All rights reserved.
Information in this document is subject to change without notice. The software described in this document
is furnished under a license agreement or nondisclosure agreement. The software may be used or copied
only in accordance with the terms of those agreements.
For further information regarding legal and proprietary statements, please go to:
SOFTWARE: zebra.com/linkoslegal
COPYRIGHTS: zebra.com/copyright
WARRANTY: zebra.com/warranty
END USER LICENSE AGREEMENT: 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.

Publication Date
September 29, 2021

2
Contents
About this Guide................................................................................................................................. 9
Related Documents and Software ................................................................................... 9
Other Valuable Printer Resources .......................................................................... 10
Zebra OneCare Printer Service and Support ......................................................... 10
Icon Conventions ........................................................................................................... 11

Introduction....................................................................................................................................... 12
How Repairs and Maintenance Procedures Are Documented....................................... 13
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 Supplies .......................................................................................................... 15
Get Zebra Supplies and Accessories for Cleaning Your Printer............................. 15
Recommended Cleaning Schedule................................................................................ 15
Printhead ................................................................................................................ 15
Standard Platen (Drive) Roller................................................................................ 16
Linerless Platen (Drive) Roller ......................................................................... 16
Media Path ............................................................................................................. 16
Interior .................................................................................................................... 16
Exterior ................................................................................................................... 17
Label Dispenser Option .......................................................................................... 17
Cutter Option .......................................................................................................... 17
Cleaning the Printhead.................................................................................................. 18
ZD621/ZD421 Direct Thermal Printers ................................................................... 18

3
Contents

ZD621/ZD421 Thermal Transfer Printers ............................................................... 19

ZD421 Ribbon Cartridge Printers ........................................................................... 20
Media Path Cleaning..................................................................................................... 21
Lower Half of ZD621/ZD421 Printers ..................................................................... 21
Upper Half of ZD621/ZD421 Direct Thermal Printers ............................................. 22
Upper Half of ZD621/420 Thermal Transfer Printers.............................................. 22
Upper Half of ZD421 Thermal Transfer Ribbon Cartridge Printers ........................ 23
Cleaning the Cutter and Label Dispenser Options........................................................ 24
Cleaning the Cutter Option ..................................................................................... 24
Cleaning the Label Dispenser Option .............................................................. 25
Sensor Cleaning............................................................................................................ 26
Lower Half of ZD621/ZD421 Printers ..................................................................... 26
Upper Half of ZD621/ZD421 Direct Thermal Printers ............................................. 27
Upper Half of ZD621/ZD421 Thermal Transfer Printers ......................................... 27
Upper Half of ZD421 Ribbon Cartridge Printers ..................................................... 28
Cleaning Ribbon Cartridge Sensor ......................................................................... 29
Platen Cleaning and Replacement................................................................................ 30
Removing the Platen Roller .................................................................................... 31
Replacing the Platen Roller .................................................................................... 33
Updating Printer Firmware ............................................................................................ 34
USB Host for File Transfers.................................................................................... 34
USB Host Port Uses......................................................................................... 34
Using USB Host for Firmware Updates .................................................................. 35
Flash Drive Preparation and Firmware Update................................................ 35
Run a SmartCal Media Calibration after Repairs .......................................................... 36
SmartCal Procedure ............................................................................................... 36
Test Printing with the Configuration Report .................................................................. 37

Troubleshooting ............................................................................................................................... 38
Resolving Alerts and Errors ........................................................................................... 38
Alert: Printhead Open ............................................................................................. 38
Alert: Media Out...................................................................................................... 39
Alert: Ribbon In (ZD421 Cartridge Printer only)...................................................... 40
Alert: Ribbon Out .................................................................................................... 41
Alert: Ribbon Low (ZD421 Cartridge Printer only) .................................................. 42
Alert: CUT ERROR ................................................................................................. 43
Alert: PRINTHEAD OVER TEMP ........................................................................... 44
Alert: PRINTHEAD SHUTDOWN ........................................................................... 45
Alert: PRINTHEAD UNDER TEMP......................................................................... 45
Alert: OUT OF MEMORY ....................................................................................... 46
Resolving Print Issues................................................................................................... 47

4
Contents

Issue: General Print Quality Issues ........................................................................ 47

Issue: No Print on the Label ................................................................................... 48
Issue: Labels Are Distorted in Size or Print Area Start Position Varies .................. 48
Communication Issues................................................................................................... 49
Issue: Label Job Sent, No Data Transfer ............................................................... 49
Issue: Label Job Sent, Skips Labels or Prints Bad Content ................................... 49
Issue: Label Job Sent, Data Transfers, But No Print .............................................. 50
Miscellaneous Issues ..................................................................................................... 50
Issue: Settings are Lost or Ignored......................................................................... 50
Issue: Non-continuous labels act as Continuous labels. ........................................ 51
Issue: Printer Locks-Up .......................................................................................... 52
Issue: Erroneous Ribbon Cartridge Faults ............................................................. 52
Issue: Battery Has a Red Indicator ......................................................................... 53

Required Tools.................................................................................................................................. 54

Replacing Parts................................................................................................................................. 55
Repair Procedure Sequence for ZD421(c) Cartridge Printers ...................................... 56
Repair Paths for ZD421(d) and ZD621(d) Direct Thermal Printers............................... 57
Repair Paths for ZD421(t) Thermal Transfer Printers ................................................... 58
Repair Paths for ZD621(t) Thermal Transfer Printers ................................................... 59
Repair Paths for ZD621R RFID Thermal Transfer Printers .......................................... 60
How to Determine a Repair Sequence for your Part .............................................. 61
Repair Path Example ....................................................................................... 61
Repair Preparation and Post Repair Basic Operational Tests ...................................... 62
ZD421 Ribbon Cartridge Printer - Accessing the Printhead ................................... 63
Transfer Ribbon Roll Printers: Accessing Inside the Cover .......................................... 64
Replacing the Printhead................................................................................................ 66
ZD621 and ZD421 Direct Thermal Printhead ......................................................... 67
Removing the Printhead................................................................................... 67
Replacing the Printhead................................................................................... 69
ZD621 and ZD421 Thermal Transfer Ribbon Roll Printhead ................................. 71
Removing the Printhead................................................................................... 71
Replacing the Printhead................................................................................... 73
ZD421 Thermal Transfer Ribbon Cartridge Printhead............................................ 76
Printhead Removal........................................................................................... 76
Replacing the Platen (Drive) Roller............................................................................... 80
Replacing Wired Connectivity Modules......................................................................... 83
Replacing the Wireless Connectivity Module ................................................................ 84
Replacing a Front Bezel Option (Tear-off, Dispense, Cut)............................................ 87
Removing the Printer Base for Repair Access.............................................................. 89

5
Contents

Replacing the Printer’s Feet........................................................................................... 90

Installation ........................................................................................................ 90
Replacing the Window .................................................................................................. 91
Repair Prerequisites ............................................................................................... 91
Thermal Transfer Roll and Cartridge Printers......................................................... 91
Direct Thermal Printer Window Replacement ........................................................ 92
Replacing the Motor ....................................................................................................... 94
ZD421(t) and ZD621(t) - Replacing the Head-Up Sensor ...................................... 95
Replacing the Main PCBA ...................................................................................... 98
ZD621R - Replacing the RFID Programming and Antenna PCBA’s........................... 101
Accessing the ZD421(c) Movable Sensor................................................................... 105
Accessing ZD621(d) and ZD421(d) Head-up and Movable Sensors........................... 108
Accessing the ZD621(t) Movable Sensor.................................................................... 111
Accessing the ZD621R Head-up and Movable Sensors............................................. 114
Replacing the Movable Lower Media (Blackmark) Sensor ......................................... 118
Replacing the Hinge in Thermal Transfer Printers ...................................................... 122
Replacing the Hinge in Direct Thermal Printers .......................................................... 127
Replacing the Cover Assembly on Thermal Transfer (Roll) Printers .......................... 128
Replacing the Cover Assembly on Cartridge Printers.................................................. 130
Replacing the Cover Assembly on Direct Thermal Printers ........................................ 131
Replacing the CTD Cover Assembly on ZD621(d) ...................................................... 132
Accessing under the Cover - Thermal Transfer Printers............................................. 133
Accessing under the Cover - Direct Thermal Printers................................................. 136
Replacing a 3-Button Control Panel PCBA ................................................................. 138
Replacing a Color Touch Display Control Panel ......................................................... 139
Replacing the Latch Assembly - ZD421(c), ZD621(t), and Zd621R............................ 140
Replacing the Latch Assembly - ZD421(t) .................................................................. 141
Replacing the Latch Arm Assembly - Direct Thermal Printers ..................................... 142
Replacing the Upper Array Sensor - Thermal Transfer Printer ................................... 146
Replacing the Upper Array Sensor - Thermal Transfer Printer ................................... 147
Replacing the Ribbon Roll Printer’s Ribbon Trailer Sensor PCBA ....................... 150
Replacing the Cartridge Printer Ribbon Sensor PCBA ................................................ 152
Replacing the Ribbon Carriage in Thermal Transfer (Roll) Printers............................ 154
Replacing the Ribbon Transport ........................................................................... 157
Replacing the Upper Media (Gap/Web) Sensor (ZD421C).......................................... 160
Replacing the Print Mechanism .................................................................................. 163

Main PCBA Layout.......................................................................................................................... 164

Main Printed Circuit Board Assembly........................................................................... 165
Main Printed Circuit Board Assembly........................................................................... 166

6
Contents

Cable Routing for ZD421c.............................................................................................................. 167

ZD421c - Ribbon Cartridge printers ............................................................................. 167

Cable Routing for ZD421d.............................................................................................................. 177

ZD421d - Direct Thermal printers................................................................................. 177

Cable Routing for ZD621d.............................................................................................................. 184

ZD621d - Direct Thermal printers................................................................................. 184
Basic 3 Button UI................................................................................................ 184
Color Touch Display UI ...................................................................................... 185
3 Button UI............................................................................................................ 190

Cable Routing for ZD421t............................................................................................................... 192

ZD421t Ribbon Roll Thermal Transfer Printers............................................................ 192

Cable Routing for ZD621t............................................................................................................... 201

ZD621 Ribbon Roll Thermal Transfer Printers............................................................. 201
Basic 3 Button UI................................................................................................ 201
Color Touch Display UI ...................................................................................... 202

Cable Routing for ZD621R ............................................................................................................. 211

ZD621RFID Thermal Transfer Printers ........................................................................ 211
Basic 3 Button UI................................................................................................ 211

Media................................................................................................................................................ 221
Types of Thermal Media .............................................................................................. 221
Determining Thermal Media Types ...................................................................... 221
To perform a media scratch test, complete these steps: ............................... 221
General Media and Print Specifications ............................................................... 222
Label Dispenser (Peeler) ............................................................................... 223
Standard (Media) Cutter................................................................................. 224
Linerless (Media) Cutter - Direct Thermal only .............................................. 224

ZPL Configuration .......................................................................................................................... 225

Managing the ZPL Printer Configuration...................................................................... 225
ZPL Printer Configuration Format......................................................................... 226
Configuration Setting to Command Cross-reference .................................................. 227

7
Contents

Printer Memory Management and Related Status Reports ......................................... 230

ZPL Programming for Memory Management ....................................................... 230

8
About this Guide
This guide provides information about servicing the Zebra Link-OS ZD421 and ZD621 desktop printers.
Use this guide to repair these printers.

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 at Zebra.com:
• 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
• Zebra Savanna ™ Data Intelligence platform - turns raw data from devices (IoT) and sensors into
actionable intelligence for your business
• 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 Zebra Savanna from this Online link: 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: zebra.com/zebraonecare

10
About this Guide

Icon Conventions
The documentation set is designed to give the reader more visual clues. The following graphic icons are
used throughout the documentation set. These icons and their associated meanings are described below.

NOTE: The text here indicates information that is supplemental for the user to know and that is not
required to complete a task.

IMPORTANT: The text here indicates information that is important for the user to know.

CAUTION—EYE INJURY: Wear protective eyewear when performing certain tasks.

CAUTION—PRODUCT DAMAGE: If the precaution is not taken, the product could be damaged.

CAUTION: If the precaution is not heeded, the user could receive minor or moderate injury.

CAUTION—HOT SURFACE: Touching this area could result in burns.

CAUTION—ESD: Observe proper electrostatic safety precautions.

CAUTION—ELECTRIC SHOCK: Disconnect the printer power before performing certain procedures to
avoid the risk of electric shock.

WARNING: If danger is not avoided, the user CAN be seriously injured or killed.

DANGER! If danger is not avoided, the user WILL be seriously injured or killed.

NOTE: This is an icon for wired networking notes.

NOTE: This is an icon for wireless networking notes.

11
Introduction
This manual provides ZD421 and ZD621 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.
To simplify the documentation, the base printer model displayed on the printer has an added model type
identifier in parentheses.
• ZD421(c) represents the ZD421 Thermal Transfer Cartridge Printer
• ZD421(d) represents the ZD421 Direct Thermal Printer
• ZD621(d) represents the ZD621 Direct Thermal Printer
• ZD421(t) represents the ZD421 and ZD421CN Thermal Transfer (Roll) Printer
• ZD621(t) represents the ZD621 Thermal Transfer (Roll) Printer
• ZD621R represents the ZD621R RFID Thermal Transfer (Roll) Printer

12
Introduction

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:
zebra.com/parts

Thermal Printing
CAUTION—HOT SURFACE: 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.
CAUTION—ESD: 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 ZD621 and ZD421 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. For more details on battery replacement,
see the warranty for your printer on the Zebra Website at: zebra.com/warranty.
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.
• Do not heat, disassemble or dispose of battery in fire.
• The printer has a 3 V 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.

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 Supplies
The following printer cleaning supplies are recommended for use with your printer:
• Printhead Cleaning Pens for simple operator printhead cleaning
• 99.7% pure Isopropyl Alcohol (Never re-moisten cleaning materials used to clean the printer).
• Fiber-free Cleaning Swabs for media path, guides, and sensors.
• Cleaning Wipes (lint free) for media path and interior.
• Can of compressed air
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.
• 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.

CAUTION—EYE INJURY: 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

See the Zebra web site at zebra.com/accessories.

Recommended Cleaning Schedule

Printhead
Interval: Clean the printhead after every roll printed.
Procedure: Cleaning the Printhead on page 18.

15
Cleaning and Maintenance

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 on page 30.

NOTE: Standard platen rollers are identified by color: 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 are identified by color: reddish-brown (203 dpi) and brown (300 dpi).
• 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.
• 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 on
page 30 procedure to get better access for particle removal.

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 on page 21.

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
99.7% isopropyl alcohol and a fiber-free cleaning cloth can be used to dissolve contaminants like oils and
grime.

16
Cleaning and Maintenance

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 on page 17 cleaning.

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

CAUTION: Never attempt to insert objects or fingers in to the cutter mechanism. Never remove the cutter
cover (bezel). There are no operator serviceable parts in the cutter unit.

IMPORTANT:
• The blade has a special coating to resist adhesives and wear. Cleaning it may ruin the blade.
• Using unapproved items such as tools, alcohol, solvents, or cotton swabs. They may damage or
shorten the cutter’s usable life or cause the cutter to bind.

17
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.
CAUTION—HOT SURFACE: 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.

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive

components such as circuit boards and printheads.

CAUTION: Do not use the cleaning pens or swabs on the platen (drive) roller or other parts of the printer to
avoid cross contamination and damage to the printhead or printer operation.

ZD621/ZD421 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.

18
Cleaning and Maintenance

ZD621/ZD421 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.

19
Cleaning and Maintenance

ZD421 Ribbon Cartridge Printers

1. Pull the two (2) release arms out to release the ribbon drive transport. See ZD421 Ribbon Cartridge
Printer - Accessing the Printhead on page 63 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.

20
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 ZD621/ZD421 Printers

1. Wipe the inside surfaces of the roll holders (3)and the underside of the media guides (1) with a cleaning
swabs and wipes.
2. Wipe the movable sensor slide channel, but do not clean the sensor (2). Move the sensor to get to all
areas.
3. Wait one minute before closing the printer.
4. Discard used cleaning supplies.

21
Cleaning and Maintenance

Upper Half of ZD621/ZD421 Direct Thermal Printers

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

Upper Half of ZD621/420 Thermal Transfer Printers

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

22
Cleaning and Maintenance

Upper Half of ZD421 Thermal Transfer Ribbon Cartridge Printers

1. Pull the two release arms (3) out to release the ribbon drive transport (3). See ZD421 Ribbon Cartridge
Printer - Accessing the Printhead on page 63 for more details.
2. Wipe the areas (outlined in orange) below the printhead actuator arm (2) and the ribbon drive transport.
Do not clean the array sensor (1)

3. Release the printhead actuator arm (4) and then push the ribbon drive transport (3) 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.

23
Cleaning and Maintenance

Cleaning the Cutter and Label Dispenser Options

This is a continuation of cleaning the media path for either option, if installed.

Cleaning the Cutter Option

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. Using unapproved items such as
tools, alcohol, solvents, or cotton swabs. They may damage or shorten the cutter’s usable life or cause the
cutter to bind.

CAUTION: Never attempt to insert objects or fingers into the cutter mechanism. Never remove the cutter
cover (bezel). There are no operator serviceable parts in the cutter unit.

1. Wipe the ridges and the plastic surfaces of the media entry (inside) and exit slot (outside) of the cutter.
Clean (1) inside the areas outlined in orange.
2. Repeat as necessary to remove any adhesive or contaminate residue after it dries.

24
Cleaning and Maintenance

Cleaning the Label Dispenser Option

1. Open the door and clean the peel bar (1), inner surfaces (5), and ridges (3) on the door.
2. Wipe the roller (2) while rotating it. Discard the swab or cloth.
3. Clean again with a new swab or cloth to remove diluted residue.
4. Clean the Label Taken sensor window (4). The window should be clear of streaks and residue.

1 2 3

25
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 ZD621/ZD421 Printers

1. Clean the movable sensor’s window (1). 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.
.

26
Cleaning and Maintenance

Upper Half of ZD621/ZD421 Direct Thermal Printers

1. Spray the upper web (gap) array sensor (1) 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 ZD621/ZD421 Thermal Transfer Printers

1. Spray the upper web (gap) array sensor (1) below the printhead with a can of compressed air.
Complete sensor cleaning (very rare) requires a service technician.

27
Cleaning and Maintenance

Upper Half of ZD421 Ribbon Cartridge Printers

1. Pull the two release arms (4) out to release the ribbon drive transport (3). See ZD421 Ribbon Cartridge
Printer - Accessing the Printhead on page 63 for more details.
2. Swing the printhead actuator arm (5) 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 (2) under the ribbon drive transport (5) and the ribbon out
sensor (1) 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.

28
Cleaning and Maintenance

Cleaning Ribbon Cartridge Sensor

IMPORTANT: Only clean the Ribbon Cartridge Sensor Pins when the cartridges are failing detection.

1. Clean the Ribbon Cartridge interface pins (1) with a gentle wiping from right to left. Up and down
motions may damage the pins.
.

29
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.
• 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.

30
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 (99.7% 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 (1) latch release tabs on the right and left sides towards the front of the printer
and rotate them up to release the platen (2).

31
Cleaning and Maintenance

3. Lift the platen (2) out of the printer’s bottom frame using the platen bearings (1).

4. Slide the gear (2) and the two platen bearings (1) off the shaft of the platen roller (3).

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.

32
Cleaning and Maintenance

Replacing the Platen Roller

1. Discard the cleaning swabs after use - do not reuse.
2. Make sure the platen bearings (1) and drive gear (2) are on the shaft of the platen roller (3).

1 2

3. Align the platen (3) with the gear (2)to the left and lower it into the printer’s bottom frame.
4. Rotate the platen bearing (1) latch release tabs down on the right and left sides towards the rear of the
printer and snap them into place.

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

33
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 ZD621/ZD421 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 be
downloaded to the printer. Otherwise, the printer waits with the STATUS on green for the next
command or print job. The data indicator will flash green while the new firmware is downloading.
The printer will restart with all indicators flashing. When the firmware update has completed, the
STATUS indicator will display solid Green. The firmware is validated and installation is complete.
A printer configuration report is automatically printed to verify new firmware versions.

USB Host for File Transfers

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.

34
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 Zebra
Programming Manual for more information about mirroring, and the usb.mirror Set-Get-Do commands.
NOTE: See the About this Guide on page 9 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 is different than the version installed on the printer, the firmware will be
downloaded 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. The firmware is validated and installation is complete.
A printer configuration report is automatically printed to verify new firmware versions.
6. Remove the USB Flash drive from the printer.

35
Cleaning and Maintenance

Run a SmartCal Media Calibration after Repairs

The printer needs to set the media parameters for prior to printing optimal operation. The printer will
automatically determine media type (web/gap, black mark/notch, or continuous) and measure media
characteristics.
IMPORTANT: After the initial calibration to a specific media is completed, it is not required to perform
additional calibrations each time the media is replaced. The printer automatically measures the media to
adjust for small changes in the media characteristics while printing. Pressing the FEED (Advance) once
or twice after a new roll of media (same batch) has been installed will synchronize the labels. It is then
ready to continue printing.

SmartCal Procedure
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. Press the POWER button to turn the printer on.
3. Once the printer is in the ready state with the STATUS (1) indicator solid green, then press and hold the
PAUSE and CANCEL button for 2 seconds and release.
The printer will measure a few labels and adjust media sensing levels.
When the printer stops, the Status (1) indicator will turn solid green.

36
Cleaning and Maintenance

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 report may be helpful
with printer installation and troubleshooting.
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 with the STATUS (1) indicator solid green, then press and hold the
FEED and CANCEL buttons for 2 seconds and release.
The Printer and Network Configuration Reports (shown below) will be printed.
When the printer stops, the Status indicator will turn solid green.

If you cannot get these reports to print, go to Troubleshooting on page 38.

37
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.

Possible Cause - 1
The cover is open or has not been closed properly.

Resolution
Close 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-up switch needs service.

38
Troubleshooting

Resolution
Replace the Head-Up switch.
• ZD421(t) and ZD621(t) - Replacing the Head-Up Sensor on page 95
• Accessing ZD621(d) and ZD421(d) Head-up and Movable Sensors on page 108
• Accessing the ZD621R Head-up and Movable Sensors on page 114

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.

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 a 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 printer off or you will lose your print
job.

Possible Cause - 3
Misaligned media sensor.

39
Troubleshooting

Resolution
Check the position of the media sensor. The printer may need to be calibrated for the media after the
adjusting the sensor location.

Possible Cause - 4
The printer is set for noncontinuous (labels or black mark) media, but continuous media is loaded.

Resolution
1. Check the position of the media sensor is in the center default location.
2. The printer may need to be calibrated for the media after the adjusting the sensor location.

Possible Cause - 5
The media sensor is dirty.

Resolution
1. Clean the upper web (gap) sensor array and the lower movable media sensors. See Sensor Cleaning
on page 26.
2. Reload your media, adjust the movable media sensor’s position for your media, and recalibrate the
printer for the media.

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 on page 34.
2. Replace the upper gap array or lower movable (blackmark) sensors. See the following:
• Accessing the ZD421(c) Movable Sensor on page 105
• Accessing ZD621(d) and ZD421(d) Head-up and Movable Sensors on page 108
• Accessing the ZD621(t) Movable Sensor on page 111
• Accessing the ZD621R Head-up and Movable Sensors on page 114
• Replacing the Movable Lower Media (Blackmark) Sensor on page 118
• Replacing the Upper Media (Gap/Web) Sensor (ZD421C) on page 160

Alert: Ribbon In (ZD421 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.

40
Troubleshooting

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 to resume your printing.

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
1. 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. For printer links to manuals, see the section About this
Guide on page 9.
To change this setting:
• Use the printer’s color touch display 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.

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.

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 condition.

41
Troubleshooting

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 (ZD421 Cartridge Printer only)

A ribbon cartridge needs to be loaded in the printer. The printer is set for Thermal Transfer Mode.

Possible Cause - 3 (ZD421 Cartridge Printer only)

The media sensing is not working. There is a 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 ZD421 Thermal Transfer Ribbon
Cartridge Printers on page 23 for cleaning instructions.
4. Reload the printer’s firmware. See Updating Printer Firmware on page 34.
5. Replace the ribbon cartridge sensor. See Replacing the Cartridge Printer Ribbon Sensor PCBA on
page 152.

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 on page 34.
2. Replace the Ribbon Trailer Sensor. See Replacing the Ribbon Roll Printer’s Ribbon Trailer Sensor
PCBA on page 150.

Alert: Ribbon Low (ZD421 Cartridge Printer only)

The printer reports this Alert.

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 ZPL
Programmer’s Manual for details on printer programming. For printer links to manuals, the section Related
Documents and Software on page 9.

42
Troubleshooting

Alert: CUT ERROR

The cutter blade is bound and is not moving properly.

CAUTION: Never attempt to insert objects or fingers in to the cutter mechanism. Never remove the cutter
cover (bezel). There are no operator serviceable parts in the cutter unit.

IMPORTANT: Using unapproved items such as tools, alcohol, solvents, cotton swabs, etc.; all may
damage or shorten the cutter’s usable life or cause the cutter to bind.

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 button down for 5 seconds. Wait for the printer to shutdown
completely. Turn the printer on.
2. If the printer does not recover from this error, call a service technician. This is not a operator
serviceable item.

43
Troubleshooting

Alert: PRINTHEAD OVER TEMP

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

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.

Possible Cause - 1
Printhead has had a critical current or power failure.

Resolution
1. Turn the printer off by holding the power using the POWER button down for 5 seconds. Wait for the
printer to shutdown completely.
Turn the printer on.
2. Replace the printhead.See Replacing the Printhead on page 66.

44
Troubleshooting

Alert: PRINTHEAD SHUTDOWN

The printhead is below operating temperature for proper printing.

Possible Cause - 1
Printhead has had a critical current or power failure.

Alert: PRINTHEAD UNDER TEMP

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

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.

45
Troubleshooting

Resolution
1. Turn the printer off by holding the power button down for 5 seconds. Wait for thee printer to shutdown
completely. Turn the printer on.
2. Replace the printhead.

Alert: OUT OF MEMORY

Data can not be stored in the specified memory location. There are four types of storage memory:
Graphic, Format, Bitmap and Font. There is not enough memory to perform the function specified on the
second line of the error message.

Possible Cause - 1
There is not enough memory to perform the function specified on the second line of the error message.

Resolution
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.

46
Troubleshooting

Resolving Print Issues

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

Possible Cause - 2
The printhead is dirty.

Resolution
Clean the printhead. See Cleaning the Printhead on page 18.

Possible Cause - 3
The platen roller is dirty or damaged.

Resolution
Clean or replace the platen. Platens can wear out or get damaged. See Platen Cleaning and Replacement
on page 30.

Possible Cause - 4
The printhead has worn out.

Resolution
Replace the printhead. The printhead can wear out and be damaged. See Replacing the Printhead on
page 66.

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.

Possible Cause - 6
You may be using the wrong power supply.

47
Troubleshooting

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 on page 221.

Possible Cause - 2
Media has been loaded incorrectly.

Resolution
The media printable surface must face up towards the printhead.

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
1. Run a SmartCal media calibration, see SmartCal Procedure on page 36.
2. If it still skips labels after step 1, try a manual media calibration. See the printers user guide.

Possible Cause - 3
The platen (drive) roller is slipping or damaged.

Resolution
Clean or replace the platen. Platens can wear out or get damaged. See Platen Cleaning and Replacement
on page 30.

48
Troubleshooting

Possible Cause - 4
The printer has communication issues with cables or communication settings.

Resolution
See Communication Issues on page 49.

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.

49
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 command prefix (COMMAND CHAR) and delimiter (DELIM./CHAR) characters.

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 Programming Guide for details on printer programming. For printer
links to manuals, the section Related Documents and Software on page 9.

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.

50
Troubleshooting

Resolution
See the ZPL programmer’s guide to verify command usage and syntax. See the section About this Guide
on page 9 for support links to view the ZPL Programming 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 or use the display Language Menu (if present)
for these three (3) menu items and compare it the commands in label format/form you are trying to print.

Possible Cause - 4
The Main Logic board may not be working properly. Firmware is corrupted or the printer needs service.

Resolution
1. Reset the printer to factory defaults. See System > Settings > Restore Defaults or use the Zebra
Setup Utility and Open Printer Tools > Action > Load printer defaults.
2. Reload printer firmware. See Updating Printer Firmware on page 34.
3. Replace the Main PCBA.

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.

Resolution
Set the movable media for the media in use and run a SmartCal media calibration, see SmartCal
Procedure on page 36.

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
Run a SmartCal Procedure on page 36 and if necessary use Manual Media Calibration for hard to calibrate
media types. See Print > Print Quality > Label Type for ZD621 printers with the display to check and set
media type.

51
Troubleshooting

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 System > Settings > Restore Defaults or use the Zebra
Setup Utility and Open Printer Tools > Action > Load printer defaults.
2. Reload printer firmware. See Updating Printer Firmware on page 34.
3. Replace the Main PCBA.

Issue: Erroneous Ribbon Cartridge Faults

The printer is not detecting the ribbon cartridge properly.
• The printer has a Ribbon Out warning, but a ribbon cartridge is installed.
• Or the printer has as 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 with alcohol and a lightly moistened cotton swab if they
look contaminated.
2. Try a different cartridge.
3. Clean the ribbon cartridge sensor contact pins - see Cleaning Ribbon Cartridge Sensor on page 29.
4. Reload printer firmware. See Updating Printer Firmware on page 34.
5. Replace the ribbon cartridge sensor.

52
Troubleshooting

Issue: Battery Has a Red Indicator

Battery has a fault.

Possible Cause - 1
The battery has reached its usable life or has a general component failure.

Possible Cause - 2
Battery is too hot or too cold

Resolution
1. Remove the battery from the printer and check charge status by charging the battery.
2. Let the battery cool down or warm up to ambient temperature and recheck the battery charge.
3. Replace the battery.

53
Required Tools
TOOLS: Make use of the following tools while performing replacement procedures:

• #10 hexalobular (T10) driver (magnetized)

Torque value range: 0.53 +/-0.11 NM = 4.7 inch*lb
• #6 hexalobular (T6) driver (magnetized)
Torque value range: 0.53 +/-0.11 NM = 4.7 inch*lb
• Small flat-blade (slot-head) screwdriver
• Small pliers
• Printhead cleaning pen
• Fiber free swabs
• Lint free wipes
• Isopropyl Alcohol – 99.7% pure solution

54
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.

55
Replacing Parts

Repair Procedure Sequence for ZD421(c) 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

Window
Assy Assy. PCBA

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

Wired
Ribbon
Connectivity
Transport
Options

Wireless
Connectivity Hinge
Options

Printer Base Print Mech.

Main PCBA
(Not replaceable) (Lower Frame)

Movable Media
Bezels
Sensor
(Std., Cutter, Motor
(Lower Gap &
and Dispense)
Black Mark)
Multi-part Access Procedure

Head-Up Platen
Feet (4)
Sensor Assy.

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Repair Paths for ZD421(d) and ZD621(d) Direct Thermal Printers

Cover Control Panel Latch

Window
Assy. PCBA Assy

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

Wired
Connectivity Print Mech.
Hinge
Options (Lower Frame)

Wireless
Platen
Connectivity Main PCBA
Assy.
Options

Movable Media
Printer Base Sensor
(Not replaceable)
Motor
(Lower Gap &
Black Mark)
Multi-part Access Procedure

Bezels
Head-Up
(Std., Cutter, Feet (4)
Sensor
and Dispense)

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Repair Paths for ZD421(t) Thermal Transfer Printers

Latch Cover Upper Gap

Assy Assy. Array Sensor

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

Wired Ribbon
Connectivity Carriage
Options

Wireless
Connectivity Hinge
Options

Bezels
Print Mech.
(Std., Cutter, Main PCBA
(Lower Frame)
and Dispense)

Movable Media
Printer Base Sensor Ribbon Holder
Motor
(Not replaceable) (Lower Gap & Hubs
Black Mark)

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

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Repair Paths for ZD621(t) Thermal Transfer Printers

Latch Cover Control Panel

Window
Assy Assy. PCBA

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

Ribbon
Hinge
Wired Carriage
Connectivity
Options

Wireless
Print Mech.
Connectivity Main PCBA
(Lower Frame)
Option

Movable Media
Printer Base Head-Up Sensor
Motor
(Not replaceable) Sensor (Lower Gap &
Black Mark)

Multi-part Access Procedure

Bezels
Platen Ribbon Holder
(Std., Cutter, Feet (4)
Assy. Hubs
and Dispense)

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Repair Paths for ZD621R RFID Thermal Transfer Printers

Latch Cover Control Panel

Window
Assy Assy. PCBA

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

Ribbon Holder Ribbon

Hinge
Wired Hubs Carriage
Connectivity
Options

Feet (4)

Wireless
Print Mech.
Connectivity Main PCBA
(Lower Frame)
Options

Movable Media
Printer Base Head-Up Sensor
Motor
(Not replaceable) Sensor (Lower Gap &
Black Mark)

Bezels
RFID Module Platen
(Std., Cutter,
and Antenna Assy.
and Dispense)

Multi-part Access Procedure

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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 to prerequisite procedures 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.

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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Repair Preparation and Post Repair Basic Operational Tests

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

Preparation
CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive
components such as circuit boards and printheads.
• 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 on page 18
• Sensor Cleaning on page 26
• Media Path Cleaning on page 21
• Platen Cleaning and Replacement on page 30
2. Load a full width roll of labels and a ribbon cartridge into the printer; see the printers user’s guide for
details.
3. Connect the printer to power and turn ON the printer. The printer runs self tests and configures itself for
the options installed.
4. Set the print width to full width printing, if needed after troubleshooting and repair.
5. Calibrate the media (see Run a SmartCal Media Calibration after Repairs on page 36).
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 on page 37).

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ZD421 Ribbon Cartridge Printer - Accessing the Printhead

1. Pull both release arms (3) out (lighter gray parts).
2. Ribbon (drive) transport (1) drops down.
3. Lift printhead actuator arm (2) up to access the printhead.

1 - Printhead 2 - Ribbon Sensor

3 - Ribbon Cartridge Authentication 4 - Ribbon Sensor’s Reflector
and Status Interface

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Transfer Ribbon Roll 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 (1) where it contacts the inner frame.
2. Push the link arm (1) 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.

1 1

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Re-connecting the Ribbon Carriage

1. Swing the flapper arm (2 -orange in drawing below) up and the ribbon carriage up so the two side posts
slide into the curved channels (1- green surface highlight channel) on the inside of the ribbon carriage.

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
CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive
components such as circuit boards and printheads.
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.
• ZD621 and ZD421 Direct Thermal Printhead on page 67
• ZD621 and ZD421 Thermal Transfer Ribbon Roll Printhead on page 71
• ZD421 Thermal Transfer Ribbon Cartridge Printhead on page 76

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ZD621 and ZD421 Direct Thermal Printhead

Removing the Printhead

1. Turn the printer OFF.
2. Open the printer to access the printhead (1).

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

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4. 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 of the left side printhead
retainer slot location.

5. Gently but firmly pull the two printhead cable bundle connectors (1) off of the printhead (2). Pull the
ground wire (3) off the printhead (2).

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Replacing the Printhead

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

3. Push the left side printhead cable connector onto the printhead.
4. Insert the left side of the printhead assembly into the recessed slot (1 - highlighted in red) on the left
side of the printer.

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5. Align the Spring Wire Notch (1) 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.

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 (fingerprints) and debris of the printhead. Clean
from the center of the printhead to the outside. See Cleaning the Printhead on page 18.
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 on page 37.

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ZD621 and ZD421 Thermal Transfer Ribbon Roll Printhead

Removing the Printhead

1. Turn the printer OFF.
2. Open the printer to gain access to the printhead (1).

3. 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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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 ribbon carriage to gain access to its
attached cables.

5. Gently but firmly pull the two printhead cable bundle connectors (1) off of the printhead (2).

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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 (1) on the left side of the
printhead’s actuator arm (2).

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.

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ZD421 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 ZD421 Ribbon Cartridge
Printer - Accessing the Printhead on page 63 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 (1) off of the printhead assembly (2).

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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 (1) on the printhead assembly into the center slot (2) on the printhead actuator
arm.

1 2

4. Insert the left side tab of the printhead assembly into the recessed slot (2) on the left side of the
printhead actuator arm.

1 2

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5. Push the right side of the printhead into the slot (1) until the latch locks the right side of the printhead
into the printer.

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 (fingerprints) and debris off the
printhead. See Cleaning the Printhead on page 18.
8. Reload media. Turn on the printer and print a Configuration Status report to ensure proper function.
See Test Printing with the Configuration Report on page 37.

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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.
CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive
components such as circuit boards and printheads.

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

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4. Lift the platen out of the printer’s bottom frame by the platen bearing arms (1).

1 1

5. 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 99.7% 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.
4. 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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Replacing Wired Connectivity Modules

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive
components such as circuit boards and printheads.

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. The connector and PCBA’s
have not been designed for this use.

Removal
1. Turn power off and disconnect the power cable.
2. Remove the interface cables.
3. 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.
4. Reattach an interface cable to the connectivity module and secure the cable.
5. 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 the Wireless Connectivity Module

Use this procedure to install the Wireless Connectivity Module.
CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive
components such as circuit boards and printheads.

NOTE: If you are removing the base of the printer to repair other parts, it is easier to lift the Wireless
Module off the Main PCBA after the base is removed.

No tools are needed for this procedure.

Removal
1. Remove any media from the printer and close the cover.
2. Turn power off and disconnect the power cable.
3. Remove the interface cables, if any.
4. Turn the printer over to access the wireless connectivity door.
5. Open the module access door by pushing the latch at the top of the door with your fingertip. The printer
base has a recessed area for your fingertip. This releases the latch. Lift and swing the door up to
remove it.

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Installation
1. Align the antenna arm (1) of the wireless module into the well. Lower and align the module (2) to the
printer's Wi-Fi connector (3). Push the module (2) in gently but firmly until fully seated.

2. Align the shortest side of the wireless connectivity door (1) to the shortest side of the opening. Swing
the door on the tab (1) in the middle of the door printer and swing the door closed. Push the door to lock
the latch.

NOTE: The wireless connectivity door will not close correctly if the module has not been fully seated. This
is a good test to verify complete insertion.

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3. Place the three (3) Wi-Fi identification labels included on the bottom of the printer. These assist with
printer configuration (and later reconfiguration) of your printer. Mobile apps, use of scanners, and
printer support are aided by these printer configuration labels.
Label Locations for Thermal Transfer Printers

Label Locations for Direct Thermal Printers

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

CAUTION—ESD: Observe proper electrostatic safety precautions when handling static-sensitive
components such as circuit boards and printheads.

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. Remove any media from the printer and close the cover.
2. Turn power off and disconnect the power cable.
3. Remove the interface cables, if any.
4. Turn the printer upside down. Remove the two (2) mounting screws securing the bezel. Save the
screws.
5. 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.

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 bezels using the Replacing a Front Bezel Option (Tear-off, Dispense, Cut) on
page 87 before you can remove the printer base. No need to remove connectivity option PCBA’s and
doors to remove the base.

Removal
1. Remove the two (2) screws.
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.
3. See the Replacing the Wireless Connectivity Module on page 84 or Replacing Wired Connectivity
Modules on page 83 for replacing the connectivity access doors.

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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:
• ZD421 Ribbon Cartridge Printer - Accessing the Printhead on page 63
• Transfer Ribbon Roll Printers: Accessing Inside the Cover on page 64

Thermal Transfer Roll and Cartridge Printers

For direct thermal printers see: Direct Thermal Printer Window Replacement on page 92.

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. The window has 2 latching tabs (1).
Press them into the cover to latch. You may want to leave the window’s protective cover on until the
printer is installed for use.

1 1

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Direct Thermal Printer Window Replacement

Removal
1. Open the printer to gain access to the window release tabs on the inside of the printer.
2. 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 (1) between the window and cover. Continue to
push while shifting your fingers to the right to side to release the window.

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Installation
1. Slide the window’s tab (1 - window wide) into the slot (2) on the back of the top cover at the rear of the
printer.

2. Swing the window down into the front of the window recess area. Push the lip of the window (1) 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.

1
2

Removal
1. Remove the two screws (2) holding the motor (1) to the inner frame. Pull the motor out of the gears and
inner frame. Note the location of the connector motor.
2. Disconnect the cable from the motor or from the main 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:
• ZD421(t) - connector is positioned towards the rear of the printer.
• ZD421(d) and ZD621(d) - connector is positioned away from the bottom, towards to the inner frame.
• ZD421(c), ZD621(t), and ZD621R - connector is positioned to the front of the printer.
Correct motor cable positioning is important to keep the media sensor’s cabling loose.
3. Secure the motor to the inner frame with the two (2) screws.

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ZD421(t) and ZD621(t) - 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 this head-up sensor.

2
3

Removal
1. Disconnect the head-up sensor cable (1) from the main PCBA.
2. Remove the screw (2) holding the head-up sensor (3) in the inner frame. Pull the sensor out of the inner
frame.

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3. Disconnect the cable from the main PCBA. The ZD621(t) has a cable hook

Installation
1. Connect the cable to the Main PCBA.
2. ZD621(t) - attach the cable to the cable hook on the side of the Wi-Fi mounting tower.

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3. 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 (3). The switch on the PCBA faces the front of the printer
with the cable oriented towards the printer bottom. Secure it with the screw.
.

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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 can be removed during or prior to this
procedure.

Removal
1. Remove any wired and wireless connectivity modules (1) that may be installed.

2. Remove the one or two screws used to retain the Main PCBA.

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3. Lift the PCBA off the one or 2 mounting posts (1). The second screw (2) and mounting post (2) are only
with ZD621(t) and ZD421(c) models, 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.

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4. Carefully remove each connector from the Main PCBA. See Main PCBA Layout on page 164 for
illustrated connector for both side of the Main PCBA.
a. Disconnect the CUT/PEEL (media handling option) cable J25 on the backside of the PCBA.
b. ZD621 printers with color touch display - Disconnect the LCD cable J23 on the backside of the
PCBA.
c. Disconnect the BLACKLINE (movable media) sensor cable from J17 on the backside of the PCBA.
d. Disconnect the USER INTERFACE (control panel) cable from J4.
e. Disconnect the CARTRIDGE (reader) sensor cable from J3.
f. Disconnect the RFID (reader/programming module) cable from J2.
g. Disconnect the MOTOR cable (number hidden).
h. Disconnect the LOCK (lock switch) cable from J15.
i. Disconnect the HEAD UP (switch) sensor cable from J14.
j. Disconnect the RIBBON sensor cable from J16.
k. Disconnect the two PRINTHEAD cables at J20 and the single ground wire at J11 next to the
printhead connectors.

Installation
1. Reconnect the cables to the main board in reverse order for easiest access.
2. Slide the main PCBA into the slot on the outside of the Connectivity PCBA mounting bracket and
between the mounting post and loosened screw.
3. Align the main PCBA to the other mounting posts and tighten the loosened screw to secure the main
board to the printer.
4. ZD421(c) and ZD621(t) - Finish securing the main PCBA to print mechanism with a screw to the
mounting post near the motor.

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ZD621R - Replacing the RFID Programming and Antenna PCBA’s

Repair Prerequisites
You must remove the front bezel option (tear-off, dispenser, or cutter) and printer base before you can
remove this RFID programming PCBA.

Removal
1. Disconnect the RFID cable from the Main PCBA.
2. Remove the two (2) screws holding the RFID programming PCBA (1). Lift the PCBA out and let it hang
off the front of the printer by the antenna’s coupling cable. Do not disconnect the cable.

3. Push the release tab on the antenna cover (1).

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4. Flip the printer over and gently set it down. Open the media compartment. Lift the loose antenna cover
off the inside of the printer.

5. Lift the Antenna PCBA (1) up. Turn it sideways and slide it through the antenna access hole.

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Installation
1. With the RFID antenna and programming model PCBA’s connected with the antenna coupling cable,
slide the Antenna PCBA up from the bottom and through the antenna access hole.

2. Set the loose Antenna PCBA (2)into the inner frame. Snap the Antenna Cover (1) into the inner frame
to lock it in place.

3. Flip the printer over and close the cover.

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4. Attach the RFID programming module (1)to the media sensor’s cover with 2 screws.
.

5. Connect the RFID cable from the RFID programming to the main PCBA.

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Accessing the ZD421(c) Movable Sensor

Repair Prerequisites
You must remove the front bezel option (tear-off, dispenser, or cutter) and printer base before proceeding.

Removal for Access

1. Remove the wired and wireless connectivity options installed.

2. Remove the two screws holding the main PCBA to the inner frame. Disconnect the cables from the
main PCBA.

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3. Remove the two screws holding the motor (2) to the inner frame. Pull the motor out. Note the location of
the of the motors cable connector.

4. Remove the two media roller tensioning springs (1).

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1. Remove the four screws securing the roll holder cover that retains the roll holder parts and covers the
movable of sensor. Many roll holder parts are loose and will fall out if you are not careful.

2. The movable media sensor is now accessible. Note the sensor’s cable exits toward the inside of the
printer for ZD421(c) printer model.

Re-assemble
1. Reverse the ‘Removal for Access’ sequence. Remember to replace any connectivity options that were
installed.

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Accessing ZD621(d) and ZD421(d) Head-up and Movable Sensors

Repair Prerequisites
You must remove the front bezel option (tear-off, dispenser, or cutter) and printer base before proceeding.

Removal for Access

1. Remove the wired and wireless connectivity options installed.

2. Remove the screw holding the main PCBA to the inner frame. Disconnect the cables from the main
PCBA.

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3. Remove the two screws holding the motor (1) to the inner frame. Pull the motor out. Note the location of
the of the motors cable connector.

4. Remove the screw securing the media sensor cover (1) that covers the movable of sensor (2) and
holds the main PCBA. Pull the media cover out of the motor mount wall on the inner frame of the
printer.

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5. The movable media sensor is now accessible. Note the sensor’s cable exits toward the front of the
ZD621(d) and ZD421(d) printer models.

The head-up sensor can be lifted out of the inner frame now that the media sensor cover is removed.
See Accessing ZD621(d) and ZD421(d) Head-up and Movable Sensors on page 108 for reference.

Re-assemble
1. Reverse the ‘Removal for Access’ sequence. Remember to replace any connectivity options that were
installed.

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Accessing the ZD621(t) Movable Sensor

Repair Prerequisites
You must remove the Front Bezel Option (tear-off, dispenser, or cutter) and printer base before
proceeding.

Removal for Access

1. Remove the wired and wireless connectivity options installed.

2. Remove the two screws holding the main PCBA to the inner frame. Disconnect the cables from the
main PCBA.

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3. Remove the two screws holding the motor (1) to the inner frame. Pull the motor out. Note the location of
the of the motors cable connector.

4. Remove the two media roller tensioning springs (1).

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5. Remove the four screws securing the roll holder cover that retains the roll holder parts and covers the
movable of sensor. Many roll holder parts are loose and will fall out if you are not careful.

6. The movable media sensor is now accessible. Note the sensor’s cable exits toward the inside of the
printer for ZD621(t) printer model.

Re-assemble
1. Reverse the ‘Removal for Access’ sequence. Remember to replace any connectivity options that were
installed.

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Accessing the ZD621R Head-up and Movable Sensors

Repair Prerequisites
You must remove the Front Bezel Option (tear-off, dispenser, or cutter) and printer base before
proceeding.

Removal for Access

1. Remove the wired and wireless connectivity options installed.

2. Remove the screw holding the main PCBA to the inner frame. Disconnect the cables from the main
PCBA.

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3. Remove the two screws holding the motor (1) to the inner frame. Pull the motor out. Note the location of
the of the motors cable connector.

4. Remove the two screws holding the RFID programming PCBA (1). Lift the PCBA out and let it hang off
the front of the printer by the antenna’s coupling cable. Do not disconnect the cable.

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5. Remove the two media roller tensioning springs (1).

6. Remove the four screws securing the roll holder cover (1) that retains the roll holder parts and covers
the movable of sensor. Many roll holder parts are loose and will fall out if you are not careful.

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7. The movable media sensor is now accessible. Note the sensor’s cable exits toward the inside of the
printer for ZD421(c) printer model.

Re-assemble
1. Reverse the ‘Removal for Access’ sequence. Remember to replace any connectivity options that were
installed.

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Replacing the Movable Lower Media (Blackmark) 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. Unhook the sensor’s cable from the backside of the movable sensor.

2. ZD421(c), ZD621(t), ZD621R: Release the two gold prongs holding the movable sensor. Pinch them
toward the center of the movable sensor. Push down into the bracket when the prongs release at
holding the black plastic bracket.

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ZD421(d), ZD621(d), ZD621(t): Release the two gold prongs holding the movable sensor. Push them
away the center of the movable sensor. Push down on the prongs into the bracket and lift the black
plastic bracket and metal spring-lock up.

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

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

Models: ZD421(c), ZD621(t), ZD621R

Models: ZD421(d), ZD621(d), ZD621(t)

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1. Snap the PCBA and bracket into the movable sensor body. The lens bracket should be flush with the
top surface of the sensor body. The arrow on the sensor body points toward the rear of the printer.

2. 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.
3. 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 (1) on the sensor body
points to the rear of the printer.

4. 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.

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5. 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 locked properly.

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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.

Removal
1. Open the printer (with bezel and printer base removed).
2. Disconnect the link arms if you are replacing the cover assembly or the print mechanism (the lower
frame). See Disconnecting the Cover from the Ribbon Carriage on page 64.
3. Lift the hinge lock bracket (2) off to free the right hinge mechanism. Use a small flat bladed screwdriver
to pry the two tab locks (1) on the hinge lock bracket on the inside of the printer.

1 1 2

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4. Remove the two screws securing the hinge cap (2) to the print mechanism (lower frame).

5. Remove the loose hinge cap (2) and disconnect the 2 links (1) connecting the upper inner frame to the
ribbon carriage.

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Installation
1. Insert the right side of the upper inner frame hinge (1) in the right lower frame’s hinge (2). Push the
hinge lock bracket (3) down onto the rear wall of the lower inner frame. Many parts are hidden in the
illustration to help you identify the primary parts.

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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 Transfer Roll Printers

with standard 3 button interface

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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 screws.

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Replacing the Hinge in Direct Thermal Printers

Removal
1. Open the printer (with bezel and printer base removed).
2. Remove the screw securing the hinge cap to the print mechanism (lower frame). Rotate the loose hinge
cap and pull it out of the hinge
3. Disconnect the outside printhead cable with the black wires and the ground wire from the Main PCBA.

4. Remove the ferrite clamp. Push the printhead connector and cable out of the hinge.

Replacement
5. Put the printhead cable in the new hinge.
6. Put the hinge on the top cover and pull the printhead through the hinge to remove slack in the cable.
7. Align the hinge with the lower frame and swing the square end into the matching square on the lower
frame.
8. Secure the hinge to the frame with the screw.
9. 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.

Removal
1. Disconnect the link arms connecting the cover to the ribbon carriage assembly. See Disconnecting the
Cover from the Ribbon Carriage on page 64.

2
1

2. Release the LDC (CTD - Color Touch Display) flexible circuit cable (1) from the main PCBA. Unwind
the flex cable from the toroid block.
3. Disconnect the control panel (USER IF) cable (2) from the main PCBA and remove its ferrite clamp (3).
Use a small flat bladed screw driver or a fingernail to release the latches on the side of the clamp body.

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4. Pull the control panel (USER IF) cable (2) out from between the inner frame (4) and connectivity
module bracket (5).

5. Pull the cover assembly (6) out of the left side hinge cap (7) on the lower frame.

Replacement
1. Reverse the removal process to install the new cover.

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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 ferrite clamps (3) attached to the printhead cables by gently prying the clamp’s lock
open.

1 2

3 4

2. Disconnect the two wire connector (3)near the right hinge.

3. Cut the cable tie (2) securing the ribbon sensor cable onto the inner frame.
4. Remove the ferrite clamp (1) on the ribbon sensor cable (placed next to the tie).
5. Slide the right side of the cover out of the hinge on the printer.

Replacement
1. Reverse the removal process to install the new cover.

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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, main PCBA, and the
hinge before you can remove the cover Assembly.
Does not include the ZD621 direct thermal printer with a color touch display.

Removal
1. With the hinge and the main PCBA removed, the slide the cover assembly out of the left side hinge cap.

Replacement
1. Reverse the removal process to install the new cover. Note the ferrite (1) locations below to verify
placement after the new cover assembly, hinge, and main PCBA have been reinstalled.

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Replacing the CTD Cover Assembly on ZD621(d)

Repair Prerequisites
You must remove the front bezel option (tear-off, dispenser, or cutter), printer base, main PCBA, and the
hinge before you can remove the cover assembly.

Removal
1. Unwind the LDC (Color Touch Display) flexible circuit cable (1) out of the toroid block(3).

1
1
2
1
2
1

3
1

2. Remove the ferrites clamps (2) from the printhead and control panel cables.
3. Gently pull the flex circuit off the side of the inner frame.

4. Slide the cover out of the left side hinge cap.

Replacement
1. Reverse the removal process to install the new cover.

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Accessing under the Cover - Thermal Transfer Printers

CAUTION—ESD: 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. Note the ZD421(t) printer has a different latch
and is mounted on the ribbon carriage instead.

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2. Remove the screws (1) securing the top cover to the inner lid. Remove the top cover.

Screws
1
1

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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Accessing under the Cover - Direct Thermal Printers

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

Removal
1. Remove the four screws (1) securing the top cover to the inner lid.
2. Pull the cover off the upper inner frame.

3. ZD621(d) with a Color Touch Display - The power and printer control buttons are now loose.

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Installation
1. ZD621(d) with a Color Touch Display - Place the power and printer control buttons on the control panel.
Use the alignment pins.

1
2

2. Place the new cover on the top inner frame. Align the cover to the mounting holes.
3. Use the mounting screws to secure the cover to the frame.
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 a 3-Button Control Panel PCBA

Repair Prerequisites
You must remove the cover before performing this procedure.

Removal
1. With the cover removed, 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 with the two small guide holes (1) to guide
pins (2) molded into the top of the inner frame.

1 1

2 2

3. Secure the PCBA to the inner frame with the screw.

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Replacing a Color Touch Display Control Panel

Repair Prerequisites
You must remove the cover assembly before performing this procedure.

Removal
1. With the cover removed, lift the power (1) and printer control (3) buttons
2. Remove the 2 screws holding the CTD control panel PCBA and bracket (2) to the inner frame.
3. 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 CDT control panel PCBA.
2. Place the PCBA with the connector/cable side facing down onto the top of the inner frame.

3
1

3. Secure the PCBA to the inner frame with the 2 screws.

4. Place the power and printer control buttons on the control panel. Use the alignment pins.

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Replacing the Latch Assembly - ZD421(c), ZD621(t), and Zd621R

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 to lift and remove.
• 1 - Ribbon Cartridge Printers
• 2 - Ribbon Roll Printers

1 2

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Replacing the Latch Assembly - ZD421(t)

Repair Prerequisites
None

Removal
1. Open the printer. Locate the latches on the side of the ribbon carriage. Remove the screw holding the
latch arm (1), washer, and spring (1) on both sides of the printer. Pull it off the post. The spring is loose
now.

1 2

Installation
2. Place the spring on the spring post of the latch.

3. Align the latch with the latch post on the ribbon carriage. As the latch and spring near the post align the
top of the spring with spring post on the side of the ribbon carriage.
4. Push the latch on the post while rotating the latch counterclockwise to get the latch to clear the latch
stop feature. Let the latch rest on the stop.
5. Use the washer and screw to finish securing the latches to the ribbon carriage.

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Replacing the Latch Arm Assembly - Direct Thermal Printers

Repair Prerequisites
You must remove the cover and the control panel PCBA before performing this procedure. The latch on
ZD421(d) models is all plastic version.

Removal
1. Remove the control panel mounting plate (2). It is attached to the inner frame by two screws (1). ZD621
models have a media dancer spring that may come loose (3).

2. The inner frame may be latched into the inner frame. To release the latch arm assembly (4), pull the
latch forward and lift the inner frame up.

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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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Installation
1. Align and insert the new latch assembly and press it into the inner frame.
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.

3. ZD621 Printers only: Place the media dancer’s spring on the post (plus sign shape) in the middle of the
inner frame.

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4. Take the control panel mounting plate and insert the upper array sensor and control panel interface
cables (3) into the largest opening.
5. ZD621 printers: Align the media dancer spring (1) to the cup (2) on the back of the mounting plate. Put
a small tool in the cup’s hole to guide the spring into the cup.

1 2

4
1

6. Place the mounting bracket on the two mounting posts (4) on the inner frame and secure it to the inner
frame with two screws.

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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.

Removal
1. Using a pliers or special tool lift the press-on fitting (1) securing the upper array sensor PCBA (2) to the
inner frame. Pull the PCBA off the sensor mounting posts (3).

Installation
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 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 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.

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.

2. Pull the sensor cable out of the out of the backside of the flapper arm (1).

3. Remove the screw securing the sensor cover (2) from the top side of the flapper arm (1). Set the cover
aside. Remove the sensor array PCBA and cable.

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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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4. Insert the cable and connector through the hole (1) in the inner frame’s flapper arm pivot bracket.
5. Insert the two flapper arm pivot posts (2) into the bracket (3). Swing the flapper arm down away from
the top of the printer. This will lock the flapper arm in the bracket.
6. Replace the control panel PCBA and cover to complete reassembly.

3 3

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Replacing the Ribbon Roll Printer’s Ribbon Trailer Sensor PCBA

Removal
1. Open the printer. Remove the ribbon rolls. Note the sensor is in slightly different spots on each model
type.
2. Turn the printer around. Look down into the top of the ribbon carriage.
3. Remove the screw securing the Ribbon Sensor PCBA (1) to the ribbon chassis’s front cross member.

1
1

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4. 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 (1)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.

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

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Replacing the Cartridge Printer Ribbon Sensor PCBA

Repair Prerequisites
You must remove the cover assembly before performing this procedure.

3 3

Removal
1. Pry the cover (1) 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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2. Remove the screw (2) securing the ribbon sensor PCBA (3) 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 on page 71.

3. Disconnect the cable from the PCBA.

Installation
1. Connect the cable to the ribbon sensor PCBA (3).
2. Place the ribbon sensor PCBA (3) 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.
4. Place the actuator arm’s cover back onto the actuator arm body. Slide the notches on the cover under
the tabs (4) 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.

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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 screw and washer (1) on each side of the print mechanism at the ribbon carriage’s hinges.

1
1

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2. 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.

3. 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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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 hinge springs (2) with the two hinge spring wells (1) in the top of
the lower inner frame. Lower the springs into the wells until the carriages hinge pins and hinge brackets
are close.

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 oroid clamps to the two 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.

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Replacing the Ribbon Transport

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 transport.

Removal
1. Loosen the tape (1) holding the cartridge sensor cable (2) to free the cable.

2. Disconnect the upper (gap/web) media sensor cable (3) in the right hinge area. The printhead cables
with ferrite's are just out of this picture.

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3. Disconnect the two link arms (1) that connect the ribbon transport to the top cover (and upper frame).

4. Remove the screw and washer on each side of the print mechanism at the ribbon transport’s hinge.
5. Push the ribbon transport’s hinge pin out (3) of the hinge bracket (2) 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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Installation
1. Align the ribbon transport with the two hinge springs with the two hinge spring wells in the top of the
lower inner frame. Lower the springs (2) into the spring wells (3) until the transports hinge pins and
hinge brackets are close.

3 4

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 (1) into the larger well (4) 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.

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Replacing the Upper Media (Gap/Web) Sensor (ZD421C)

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.

2
3

Removal
1. With the ribbon transport removed from the printer, remove the two screws securing the lift side panel
(3) to the transport.
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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3. Remove the screw securing the sensor cover and remove the cover.

1
1

4. Locate the cable on side of the transport frame and pull it out. The cable channels include cable capture
features (1) 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 to release the upper sensor PCBA (2).

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Installation
1. Place the new upper media sensor PCBA on the two guide posts with the four 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. 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.

162
Replacing Parts

Replacing the Print Mechanism

Repair Prerequisites
You must remove the front bezel option (tear-off, dispenser, or cutter), printer base, main PCBA, hinge,
and cover assembly (cover and inner upper frame) before you can remove the print mechanism.

Removal and Installation

1. ZD421(d) and ZD621(d): Cover assembly (cover and inner upper frame) releases the print mechanism
for replacement.
2. ZD421(t), ZD621(t), and ZD621R: Cover assembly (cover and inner upper frame) releases the print
mechanism. See Replacing the Ribbon Carriage in Thermal Transfer (Roll) Printers on page 154 to
remove and connect it to the new print mechanism.
3. ZD421(c): Cover assembly (cover and inner upper frame) releases the print mechanism with the ribbon
transport. See Replacing the Ribbon Transport on page 157 to remove and connect it to the new print
mechanism.

163
Main PCBA Layout
This section shows the Main PCBA and its connector locations from the top and bottom sides of
the circuit board assembly.

164
Main PCBA Layout

Main Printed Circuit Board Assembly (Top View)

5 6 1 - Lithium Battery Not
Replaceable
1
2 - Head-up Sensor
3 - Ribbon Sensor
7
4 - Printhead has 2 cables
8 and a ground wire
5 - Media Option Interface
(back)
6 - Movable (Blackline)
9 Sensor (back)
7 - Lock
8 - Motor
9 - RFID
10
10 - Cartridge Sensor
11 - LCD (back)
12 - Control Panel (User IF)
2
11

3 12

165
Main PCBA Layout

Main Printed Circuit Board Assembly (Back View)

1 - Printhead and ground

2 - Ribbon Sensor
3 - Head-Up
4 - Wireless Connectivity
Connector
5 - Hardware Option
1 Connector
(Cutter- Peeler-Tear)
6 - Movable Media Sensor
(Blackline)
7 - Control Panel (USER IF)
8 - LCD (back)
9 - Cartridge Sensor
10 - RFID
11 - Motor
7 12 - Lock
2

4
11

5 6

166
Cable Routing for ZD421c
This section provides a visual printer reference for service personnel if wiring and components have shifted
or come loose during repairs. The printer is shown with the cover and base removed.

ZD421c - Ribbon Cartridge printers

167
Cable Routing for ZD421c

168
Cable Routing for ZD421c

169
Cable Routing for ZD421c

170
Cable Routing for ZD421c

171
Cable Routing for ZD421c

172
Cable Routing for ZD421c

173
Cable Routing for ZD421c

174
Cable Routing for ZD421c

175
Cable Routing for ZD421c

176
Cable Routing for ZD421d
This section provides a visual printer reference for service personnel if wiring and components have shifted
or come loose during repairs. The printer is shown with the cover and base removed.

ZD421d - Direct Thermal printers

177
Cable Routing for ZD421d

178
Cable Routing for ZD421d

179
Cable Routing for ZD421d

180
Cable Routing for ZD421d

181
Cable Routing for ZD421d

182
Cable Routing for ZD421d

183
Cable Routing for ZD621d
This section provides a visual printer reference for service personnel if wiring and components have shifted
or come loose during repairs. The printer is shown with the cover and base removed.

ZD621d - Direct Thermal printers

Basic 3 Button UI

184
Cable Routing for ZD621d

Color Touch Display UI

185
Cable Routing for ZD621d

1 - Color Touch Display Cable

186
Cable Routing for ZD621d

187
Cable Routing for ZD621d

188
Cable Routing for ZD621d

189
Cable Routing for ZD621d

3 Button UI

190
Cable Routing for ZD621d

191
Cable Routing for ZD421t
This section provides a visual printer reference for service personnel if wiring and components have shifted
or come loose during repairs. The printer is shown with the cover and base removed.

ZD421t Ribbon Roll Thermal Transfer Printers

192
Cable Routing for ZD421t

193
Cable Routing for ZD421t

194
Cable Routing for ZD421t

195
Cable Routing for ZD421t

196
Cable Routing for ZD421t

197
Cable Routing for ZD421t

198
Cable Routing for ZD421t

199
Cable Routing for ZD421t

200
Cable Routing for ZD621t
This section provides a visual printer reference for service personnel if wiring and components have shifted
or come loose during repairs. The printer is shown with the cover and base removed.

ZD621 Ribbon Roll Thermal Transfer Printers

Basic 3 Button UI

201
Cable Routing for ZD621t

Color Touch Display UI

202
Cable Routing for ZD621t

203
Cable Routing for ZD621t

204
Cable Routing for ZD621t

205
Cable Routing for ZD621t

206
Cable Routing for ZD621t

207
Cable Routing for ZD621t

208
Cable Routing for ZD621t

209
Cable Routing for ZD621t

210
Cable Routing for ZD621R
This section provides a visual printer reference for service personnel if wiring and components have shifted
or come loose during repairs. The printer is shown with the cover and base removed.

ZD621RFID Thermal Transfer Printers

Basic 3 Button UI

211
Cable Routing for ZD621R

Color Touch Display UI

212
Cable Routing for ZD621R

213
Cable Routing for ZD621R

214
Cable Routing for ZD621R

215
Cable Routing for ZD621R

216
Cable Routing for ZD621R

217
Cable Routing for ZD621R

218
Cable Routing for ZD621R

219
Cable Routing for ZD621R

220
Media
This section provides a simple media overview for your printer.

Types of Thermal Media

IMPORTANT: 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 fingernail 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 direct thermal printers.

221
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.

222
Media

• ZD421 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).

223
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 on page 16 cleaning and Media Path Cleaning on
page 21 to maintain optimal linerless media cut operation.

224
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 on page 37. The Zebra Setup Utility and the ZebraDesigner ™ Windows
driver also print this report and other printer reports to help you manage your printer.

225
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.
Refer to the ZPL programmer’s guide and the Configuration Setting to Command Cross-reference on
page 227 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

226
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

1 - Sensor Settings used for Service Purposes

227
ZPL Configuration

Table 1 ZPL Commands and Configuration Report Listing 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 report 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. Refer to
device.command_override.xxxxx in the ZPL Programmer’s manual.

228
ZPL Configuration

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.

Table 2 ZPL Commands and Configuration Report Listing Cross-Reference

Command Listing Name Description
^MP MODES ENABLED Default: CWF (refer to ^MP Command)
MODES DISABLED Default: (nothing set)
^JM RESOLUTION Default: 448 8/mm (203 dpi); 640 8/mm (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
~RO HEAD USAGE X,XXX IN
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 reports (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.

229
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

230
ZPL Configuration

Table 3 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 report (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.

231
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