Problem

When I tried to create a stand-alone media – USB drive, the wizard fail because image size is larger than 4095 MB.

When I checked CreateTsMedia.log I found the following:

OS image has a size 7987 Mb exceeding max file size 4095 Mb

Cause

Unfortunately System Center 2012 Configuration Manager will not allow create USB stand-alone media if image size is larger than 4095 MB.

Solution

As a work around, task sequence media wizard will success when create ISO stand-alone media regardless what is the size of your image, The wizard splits the .WIM files into multiple files smaller than 4095 MB.

You can use the following steps to copy from ISO that you create to USB:

1. Open Command Prompt with administrative privalge and run diskpart tool commands:

diskpart

list disk

select disk 1 (Select disk number according to list disk result, in this example Disk 0 is my HDD, and Disk 1 is USB Flash disk)

clean

create partition primary

select partition 1

format fs=fat32 quick

active

assign

2. Mount the ISO file that was created to virtual disk (I’m using MagicISO Virtual CD/DVD Manager )

3. Run xcopy command to copy all files including booting files from virtual CD/DVD to USB Flash:

xcopy f:*.* /s /e /f g:

F:  = Source (Virtual Disk)

G: Destination (USB FLASH DISK)

Abduljalil Abolzahab