Is the printer file *AFPDS or is it *SCS with an AFP overlay? If it's *SCS you will need to modify your report definition. Use the OnDemand plug-in in iSeries Navigator to change the definition. Click on the Retrieve tab and specify the printer file to use (the *SCS with the AFP overlay) and then be sure to check both boxes that tell OD to use the archived AFP overlay.
If the printer file is *AFPDS, the overlay will automatically be viewed and also printed.
Another thing...remember that V5R4 is the last supported release for Spool File Archive, so you need to migrate to Common Server when you can.
Hope this helps.