HP 1020 series printer problem with printing PDF files

by on Mar.25, 2010, under Fix IT, Windows

One of the interesting problem I encountered while setting up a new computer for a end user was printing PDF file. Here is how it went down and how I fixed it:

Windows XP Professional SP3

1.The end user first said that he wasn’t able to print anything at all.
2.At first the print spooler service was down. I restarted the print spooler service and it crash again.
3.Taking a look at the event viewer under system, found an interesting error “Faulting application spoolsv.exe, version 5.1.2600.5512, faulting module ZSR.DLL, version 6.20.1625.0, fault address 0×0001f979?

4.Googled the error message, it seems to be related with HP 1020 series printer
5.Many people had the same exact problems with different solutions offered
6.Seems to be related to the ZSR.dll file that was causing the print spooler service to crash
7.The HP 1020 printer was worked fine previous computer, so there must be something different with the driver on the new computer compare to the old computer
8.Pull up the old computer and compared the print drivers, to locate the print driver, go to
C:\WINDOWS\system32\spool\drivers\w32×86 and select the printer
9.Looking at date modified, the old computer had an older version of the print driver compare to the new computer.
10.Upon closer inspection, the old computer had no ZSR.dll files while the new print driver contain ZSR.dll
11.At this point I decided to completely uninstall the printer, print driver and Adobe Reader from the new computer
12.To completely remove the print driver, go to Start – Printer and Faxes – File – Server Properties
13.Click on the driver tab and remove the Problem Printer Driver (If your unable to start print spooler service, detach the printer USB cable connecting to your computer and try again, if that doesn’t work you will need to restart your computer)
14.Click Remove and Select OK
15.Now you will need to clean the Print Spooler registry
16.Download and Install from this website http://www.microsoft.com/downloads/details.aspx?FamilyID=9d467a69-57ff-4ae7-96ee-b18c4790cffd&DisplayLang=en
17.Run cleanspl.exe
18.When you run, it will ask you if you want to remove some things that are actually delivered and install by default on your windows computer, you want to answer No to those prompts, do not remove Standard TCP/IP port or the BJ Language Monitor
19.Restart your computer
20.After I have restarted the computer, I went ahead and installer the old printer driver, ( it was a HP 1020 series USB driver last modified was in 2006 version)
21.Let it auto detect and manually install using the print driver’s INF file
22.Perform a test print to make sure it is able to print
23.Install Adobe Reader or Acrobat
24.Print different PDF file to make sure the print spooler doesn’t crash
25.Check to make sure the ZSR.dll does not exist
By replacing the current HP 1020 series print driver with a older 2006 version of print driver that does not contain ZSR.dll I was able to stop the print spooler from crashing. I know there is a lot of people having this similar problem, hopefully my resolution may help you guys.

*Update* Downloading the Hp Full Package Printer Software will also solve this problem since it does not contain the ZSR.dll file

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