Fault Card

A Fault Card captures what the field knows about one fault on one machine type: the symptoms Technicians report, the checks that found the cause, in the order the causes were actually seen, and what to do when the fix doesn't work. It merges the records from every unit into one card, with pictures. For how Fault Cards fit with the other card types, see Field Cards.

This page shows a complete Fault Card, explains what each section captures, and then shows how to create one with the InSkill Field Card Creator skill.

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Note

The example is built from fictional AZ Copper Works records and the AZ Machine Works AM-650 manuals. Its pictures are illustrations marked For demo purposes only.

The Example Card

What Each Section Covers

The card follows the same order every time, so a Technician always knows where to look. Sections 1 to 9 are numbered on the card.

Example Questions

These questions were asked in Ask on Copilot (Truck) with the card uploaded, and InSkill GPT answered them correctly. Use them to check the card after you upload it.

How to Create a Fault Card

Fault Cards are created in Claude with the InSkill Field Card Creator skill. You give it the source records, and it reads them, counts how often each cause was found, writes the card, and checks it before handing it over.

Follow these five stages in order:

1. Gather the source data
2. Run the skill
3. Review the card
4. Upload to InSkill
5. Test the card in Ask

Gather the source data

Use the records Technicians already keep: shift logs, work orders, maintenance notes and photos, in any language, typed or handwritten. Add the maker's manuals so the skill can tag values it can confirm.

The source for this example is a handwritten shift log page:

The skill reads the handwriting into text and gives every entry a source ID, so each statement on the card can be traced back:

The rest of the records came from the typed field log for the same period:

id,date,shift,unit,tech,area,entry
E0015,2026-08-03,Night,B43113,DR,Hoist,"Hoist Locked - Truck Moving at Dump 1. Truck creeping on the dump grade. Operator stopped fully and applied the park brake; body raised normally. No fault."
E0024,2026-08-26,Night,B43558,DR,Hoist,"Body lowered with the ML screw during an electrical repair with the engine off. Next shift: slow raise and AM-4018. ML screw open. Closed and torqued lock nut 18 lb-ft. Added 'ML screw closed and torqued' to the shop sign-off sheet."
E0025,2026-08-27,Day,B43113,BS,Hoist,"AM-4030 after overnight rain, lever ignored. EHL boot torn; water in the EHL connector. Replaced the boot, dried the connector, EHL calibration done. Cleared after a full haul cycle."
E0028,2026-09-04,Day,B43558,AL,Hydraulic,"Scheduled return filter change. Bronze-colored flakes in the bottom of the right housing. Reported to supervisor. Oil sample taken. Bypass indicators not reset after the change."
E0029,2026-09-08,Day,B43558,JM,Hoist,"Hoist slow, raise time 17 s, AM-4018 inactive. ML screw closed. TP-2 210 psi in HOLD. Raise solenoid 730 mA at full RAISE. Flow meter at pump: 52 gpm at 2,100 rpm and 1,000 psi. Replaced hoist pump 650-4305-00. Flow 73 gpm. Relief 2,500 psi. TP-6 450 psi. EHL calibration done. Raise 11 s, lower 13 s."

The manuals used were the AMW-SM-650-25 Service Manual (hoist diagnosis on page 33, fault codes on page 39) and the AMW-MP-650-25 Maintenance and Parts Manual (ML screw and prop pin on page 13, flow meter kit on page 52).

Run the skill

In Claude, attach the source files, the manuals and the customer logo, and use a prompt like this:

Use the InSkill Field Card Creator skill.

Create a fault card for "Hoist slow or will not raise" on the AMW AM-650 haul truck.
- Copilot: Copilot (Truck)
- Site: AZ Copper Works (prefix ACW)
- Keep the card generic to the AM-650: no unit numbers; note model-year differences
- Source: the attached shift log page and field log, July to September 2026
- Check every value against the attached AMW-SM-650-25 Service Manual and
  AMW-MP-650-25 Maintenance and Parts Manual, and cite the page
- Header: the attached AZ Machine Works logo
- Order the diagnosis by how often each cause appears in the records

The skill works out the site, period, equipment and language from the sources. It asks only for what it can't find, such as the customer logo or which fault to cover. If a fault needs more than about eight steps with settings, measurements or branching, the skill recommends a full Task instead.

Review the card

Before you upload the card, check:

• Every page reads cleanly, no heading is stranded at the bottom of a page, and the card ID fits the header.
• Every field value appears in the source records, and every source ID on the card exists.
• Every value taken from the manual cites its page.
• The To be confirmed list names every gap, and who should close it.
• The settings file has InSkill GPT Answers, App and Web all on.

Upload to InSkill

Field cards are uploaded with InSkill GPT Answers, App and Web all on. With App and Web off, InSkill GPT still uses a card, but doesn't show it as a resource in the answer.

1. Open the copilot, here Copilot (Truck), and open its Resources tab.
2. Click Bulk Upload and add the PDF.
3. Under Configure defaults for uploaded files, leave Published on. Under Visibility, leave App, Web and InSkill GPT Answers selected. Under InSkill GPT, leave Searchable and Parse selected.
4. Click Create 1 Resources, then Done.
5. Open the new resource and set Name, Keywords and Description from the settings file. Leave Prompt empty. Click Save. See Editing Resource Attributes.

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Note

Claude can do step 5 for you through the InSkill MCP Server: ask it to apply the .inskill.json settings file to the uploaded resource.

In this example the resource name is Field Card (Fault) | Hoist slow or will not raise.

Test the card in Ask

Ask the example questions in Ask on the copilot and check the answers against the card.

Output Reference

Files

The skill writes two files for each card:

The skill writes the card in English, even when the source records are in another language. It writes another language version, for example ACW-AZMachineWorks-AM650-Truck-F-001-ES.pdf, only when you ask for one. On request, it also delivers a kit with the template, builder, content files and images, so the card can be rebuilt after edits.

Card ID

Every card ID follows the pattern <Site>-<Brand>-<Model>-<MachineType>-<Code>-<Number>, and each language version adds a suffix:

Value tags

Every value on the card is tagged so Technicians and InSkill GPT know how far to trust it:

Status, version and review

Settings file

The settings file for this Fault Card:

{
  "card_id": "ACW-AZMachineWorks-AM650-Truck-F-001",
  "resource_title": "Field Card (Fault) | Hoist slow or will not raise",
  "language": "en",
  "base_language": "en",
  "is_base": true,
  "translation_group": "ACW-AZMachineWorks-AM650-Truck-F-001",
  "card_type": "fault",
  "status": "field",
  "version": "0.1",
  "review_date": "2027-01-29",
  "owner": "To be assigned",
  "copilot": "Copilot (Truck)",
  "visibility": {"vis_mvn": true, "vis_web": true, "vis_app": true},
  "keywords": ["hoist slow", "hoist will not raise", "body won't go up", "slow dump", "hoist dead", "AM-4018", "AM-4030", "Hoist Locked", "hoist lever fault", "EHL", "hoist joystick", "dump lever", "ML screw", "manual lowering screw", "yellow screw", "bleed-down screw", "hoist pump", "TP-2", "raise time", "AM-650", "haul truck"],
  "mvn_desc": "Hoist slow or will not raise. Fault card for the AMW AM-650 rigid haul truck.",
  "source_entries": "E0001, E0002, E0006, E0008, E0010, E0015, E0024, E0025, E0028, E0029 (AZ Copper Works field log, Jul–Sep 2026, fictional demo data). Manuals: SM pp. 22, 25, 33, 39; MP pp. 10, 13, 35–36, 49, 52, 57. SM = AMW-SM-650-25 Rev. A Service Manual, MP = AMW-MP-650-25 Rev. A Maintenance and Parts Manual.",
  "file": "ACW-AZMachineWorks-AM650-Truck-F-001-EN.pdf"
}