Electromechanical 

Systems

Our electric motor repair capabilities include bearing and brush replacement, commutator resurfacing, armature balancing, and stator winding inspection or rewinding when required. Each motor undergoes insulation resistance and hi-pot testing, along with load verification on dynamometers to confirm torque, speed, and current performance meet specifications.

We also provide brush and commutator maintenance to prevent electrical noise, wear, and efficiency loss. When failures stem from upstream electrical issues such as voltage irregularities or control faults, our system-level diagnostics identify root causes to prevent recurrence and extend service life.

Our solenoid valve repair services address coil degradation, armature wear, seal and spring failures, and connector corrosion. Each valve undergoes ultrasonic cleaning, detailed dimensional inspection, coil and seal replacement, and bench testing to confirm electrical integrity, response time, and flow performance.

We also perform electromechanical control unit testing for systems that manage actuators and motors. Using specialized test stands that simulate aircraft loads and signals, our technicians validate control logic, fault detection, and output accuracy - performing authorized component-level repairs to restore full operational reliability.

Each actuator and motor undergoes functional load testing that simulates real-world conditions to verify torque, speed, and feedback accuracy. Our dynamometer and load stand testing confirm efficiency and current behavior across the full operating range.

Electrical testing validates voltage and current performance, insulation resistance, and frequency response for both AC and DC systems. High-potential (hi-pot) testing confirms insulation integrity against voltage spikes typical of aircraft electrical systems, identifying issues before they lead to in-service failures.

As an EASA- and FAA-certified overhaul station, Four Star services electromechanical components for aircraft worldwide using approved technical data and airworthiness certifications (FAA Form 8130-3 or EASA Form 1). Our engineering expertise extends beyond standard overhaul, enabling us to support both current and legacy systems with approved repair solutions when OEM parts or designs are no longer available.

With decades of platform experience, we understand the evolution of electromechanical systems across aircraft generations and apply proven insights from thousands of repairs to deliver reliable, compliant, and enduring performance for every fleet we serve.