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The answer is simple, get a 2 GB memory for the Reader. By your description your 4 GB gives only ~ 1 GB of space. This is perhaps an internal memory allocation table that the Reader cannot load all of from the 4 GB memory card and therefore files become corrupted. There may also be a disconnect between the size the memory card thinks a file allocation unit is and the size the Reader thinks it is. I don't know the internals of the Reader or the specific formatting of the memory card you are using so this is at best a guess.
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