Zebra ZT111 How To Replace The Printhead

Watch the video below.

Step-By-Step Instructions To Replace The Printhead On The Zebra ZT111

What you’ll need

• The correct replacement printhead for ZT111 (for example part number P1123335-012/P1123335-056 for 203 dpi, or P1123335-013 for 300 dpi)
• Anti-static wrist strap or ensure you’re grounded (ESD can damage the printhead)
• Clean work area, lint-free swab, 99.7% isopropyl alcohol for cleaning before/after replacement
• Screwdriver if necessary to remove panels (refer to service manual)

Step-by-Step Replacement

1. Power down and unplug the printer. Let the printhead cool if it was recently printing (it can get hot).
2. Open the media cover and raise the printhead assembly. On ZT111 you need to release the printhead lever so the head pivots up.
3. Remove ribbon and media from the path (if installed). This ensures no obstruction when you remove the old head.
4. Disconnect the printhead cables: carefully unplug the connectors that go to the printhead. Pay attention to their orientation.
5. Remove the old printhead:
• On many Zebra models you’ll gently lift the old head out once cables are disconnected.
• In the ZT111 service guide it describes printhead being replaced and part numbering etc.
6. Install the new printhead:
• Align it properly in the carriage.
• Re-connect the cables firmly and correctly.
• Lower the printhead assembly and lock the lever down to the closed position.
• Make sure the head sits flush and is locked in place.
7. Clean the printhead right after installation: use a swab soaked in isopropyl alcohol, wipe the brown strip (or the heating element contact area) from end to end. Allow to dry.
8. Close the media cover, reinstall ribbon and media (if applicable), power up the printer.
9. Calibrate and test: run a calibration and print test labels to verify print quality and correct operation. If the head isn’t closed correctly you may get “Head Open” errors.
10. If your printer shows errors like “printhead replaced with non-genuine” or status lights indicating head open, ensure the part is genuine and seated correctly.

Important Tips & Precautions

• Use only genuine Zebra parts for the ZT111 to maintain performance and warranty compliance.
• Be careful of electrostatic discharge (ESD) — touch the metal frame to discharge yourself before handling the printhead.
• Make sure the printhead lever is fully locked — an unlocked head may result in uneven prints or sensor errors.
• After replacement, monitor print quality. Blank lines, fading or inconsistent print can indicate head installation issues, pressure problems, or a damaged head.
• Pay attention to ribbon/media compatibility and head pressure settings — wrong media path tension or dirty head will shorten printhead life.