Hey Zetec, I have just managed to successfully download and install configurator V3.0.0 and it all works fine for me. So this is certainly turning out difficult, but bare with it.
Try this simple loop back test for confidence in max232a and serial lead
http://zone.ni.com/devzone/cda/tut/p/id/3450#toc2
To setup your hardware for this test, remove the processor chip (carefully, use a small flat screwdriver and slowly wiggle it under the chip a bit from each side at a time. The pins are delicate), connect sockets 11 and 12 together with a thin piece of wire. Have the serial cable connected up and hyperterminal open, then apply power to the mjlj unit. Once the settings are correct in the hyperterminal as per below.
Bits per Second: 4800
Data Bits: 8
Parity: None
Stop Bits: 1
Flow Control: none
You should be able to test the connectivity by just typing anything and it should appear in the screen as explained in the link i have given you.
To identify the sockets, for pin 11 and 12, use this
http://www.kpsec.freeuk.com/components/ic.htm as its the best way i can explain it.
I'll PM you my number so give you can give me a bell anytime after 1900 tomorrow.
Fingers crossed

1310 A-series Mini, lightened and built myself. V4 board and loving it
Rasputin22 - The Mini Forum
Rasputin22 - MK1 Golf Forum
Megajolt repair for the UK available