We also tried creating a brand new document with 8 pages and tried to create a booklet. It gave the same error about paper size for the cover sheet, but printed fine without a cover.
Per your suggestion, I tried to run the job using regular paper for the cover and it still gave an error message about paper size. (For reference, this would be 22 pages including the cover of regular paper). It seems to be confused about the orientation when grabbing the cover sheet and not the amount of pages.
Did you read the full post?
25 pages assuming light weight, and you added a heavyweight cover, that will drop the total count by about 5 pages (20 ish pages)
You gave not enough information in your post and I went ahead and explained all scenarios and included examples in mine, even showing how to work around the issue while seeing if it is a hardware limit, ie, lie and say both stocks are plain paper.
The paper is loaded with the correct orientation. This can shown by successfully printing a booklet without a cover. The problem only shows up when the cover page is added. Both tray 3 (regular paper) and tray 4 (heavyweight) are in the same orientation within the trays. The booklet is 22 physical pages, so it is under the 25 page limit you mentioned.
Paper must be loaded Short Edge Feed (SEF/Landscape) to be folded.
And depending on the finisher, and the amount of pages, you may not be able to fold the paper type you have set as the cover.
The best/biggest finisher does 25 physical sheets fold/stapled, but only on plain 61-80 GSM
81-90 is 20 sheets
91-176 is 10
177-220 is 5
So basically, If the body is 90 GSM (20 sheets) but the cover is 120 GSM (10 sheets) it means the entire book can only be about 15 physical sheets.
And some finishers will not fold Gloss/Coated stock at all.
In short, set the paper in tray 4 as SEF plain 81-90GSM and see if it works then. If it does, your job was out of spec of the hardware
We have a Xerox D95A MFP and are trying to make booklets. We have the document in both Word (.docx) and PDF formats. We go into the printer properties and choose the following:
Booklet (fold and staple)
-Front and Back Same
-Tray 4 (this has the heavyweight cover paper)
-Print on both sides
-Tray 3 (this holds the regular paper)
We have used these options before to make numerous booklets without any issues. On the most recent print job, we are having an issue with adding the cover page. We get an error every time that the printer holds the jobs asking for 11x8.5 for the cover page in tray 4 (the tray is aligned 8.5x11 for the booklet creation). We tried printing it without a cover page and it prints just fine using the regular paper for the entire job, but we really wanted to have a nice cover.
We tried using both the Word and PDF versions in case it was a strange formatting issue, but the problem occurs with both. We also tried a test with choosing "pre-printed" for the cover page, but it still is looking for 11x8.5 and holds the job. There doesn't seem to be a way to change this and it seems to be an issue with the printer. We tried using the PS driver to see it would behave any different from the PCL6 driver, but no luck.
Anyone familiar with Xerox booklet creations?