Giant 20' x 3' x 2' router build

[JAZZCNC]

These are the settings I have for the z. I am struggling to load a driver for the USB to 232 cable for windows 8 that I got from zapp. The cd it came with says windows 8 but it's all in Chinese. We have just swapped the drivers back and re running the file to see if the problem comes back

Charlie your all cocked up on the settings both on the drives and in Mach3.
You have the amps set wrong on drives because your using RMS settings not peak so they are getting too many amps. This will make them get hotter than should also you have the stand by current set to off so they will get hot when stood still.
So set up Dip switches like this and then try.
1=OFF 2=OFF 3=ON This will give 4.6A which is slightly higher than motors are rated and normally I'd say use next lowest but in your case it won't hurt for now. Thou I would set it correctly in protune at first chance.
4= ON
5 /6/7 Leave as set for now thou I would normally use higher than 400 micro steps for smoother motor movement. But you have the steps per set wrong in Mach3 which i'll come to next.
8=ON

With Mach you need the steps per setting to 200. This is because you have applied a ratio and now your affective pitch as gone from 5mm to 2mm per Rev.
So 400 / 2= 200 steps per millimeter.

Try these new settings and see how goes.