Hi Thys,
Regarding the Font issue - I think it depends on your PDF tool. Tracker has an option to "Enable Font Embedding". I don't know if the Clarion one has something similar. Another option you have is to send the barcode into an image control (using Draw, or, I think, standard Clarion) then displaying the image control in your PDF. More work, and it won't scale as well, but it should work.
Regarding the printer - does the report come out ok when you run the server as an Exe (not a service) on the machine?
cheers
Bruce