Dave, if you are using the DOS driver for the KCT, DRV.COM you may be having a problem with the KCT not sensing the rotor is turning which will then give the stalled message. There must be a changing voltage fed back to the KCT on pin 13 (Horizontal Analog Input) of the KCT DB25 plug within a designated time limit or the KCT will assume the rotor is stalled. Measure this voltage and see if it starts changing with the rotor movement.
This problem can also occur when the rotor is set fully CCW and the sensed voltage is very low or zero. When the rotor starts turning it sometimes takes a few seconds for the rotor pot wiper to contact the wire wound resistance wire in the rotor pot causing the KCT to assume the rotor is stalled. This can be adjusted for in this case by setting the STALL timer value in the DRV.COM parameters. It defaults to a value of 18 which allows a two second time limit for the rotor to be found moving. See page 14(?) in the KCT manual.
As of now there is no repair facility for the KCT. There are schematics for it on the AMSAT web site.
Let me know what you find.
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Roy