Sometimes the design is just a teeny bit off center and that puts it over the 4x4 size. Try re centering your design and then try it again on your machine. Another problem could be one stray stitch is out of your 4x4 design area. If so carefully look at your design in your software program by enlarging it and look over the entire design area to see if there is a stray stitch. Just a few things that might help you.