I assume you're talking about a Print Replica book (AZW4)? Are just unpacking the Kindlebook, or are you using the "Extract PDF" feature?
If you launch calibre from the command-line in debug mode:
calibre-debug -g (from a command prompt/terminal window)
lots of output will be printed to that terminal when you try to use the plugin normally. You can paste that output in a post (put it in spoiler tags if it's particularly length) for me to look at.
Also ... if the original Kindlebook is huge, you may want to make sure you're using a 64-bit version of calibre on a 64-bit machine -- or even using the stand alone KindleUnpack tool.
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