backend/src/features/ocr/api/ocr.controller.ts

@@ -336,6 +336,112 @@ export class OcrController {
     }
   }
 
+  /**
+   * POST /api/ocr/extract/manual
+   * Submit an async manual extraction job for PDF owner's manuals.
+   * Requires Pro tier (document.scanMaintenanceSchedule).
+   */
+  async extractManual(
+    request: FastifyRequest,
+    reply: FastifyReply
+  ) {
+    const userId = (request as any).user?.sub as string;
+
+    logger.info('Manual extract requested', {
+      operation: 'ocr.controller.extractManual',
+      userId,
+    });
+
+    const file = await (request as any).file({ limits: { files: 1 } });
+    if (!file) {
+      logger.warn('No file provided for manual extraction', {
+        operation: 'ocr.controller.extractManual.no_file',
+        userId,
+      });
+      return reply.code(400).send({
+        error: 'Bad Request',
+        message: 'No file provided',
+      });
+    }
+
+    const contentType = file.mimetype as string;
+    if (contentType !== 'application/pdf') {
+      logger.warn('Non-PDF file provided for manual extraction', {
+        operation: 'ocr.controller.extractManual.not_pdf',
+        userId,
+        contentType,
+        fileName: file.filename,
+      });
+      return reply.code(400).send({
+        error: 'Bad Request',
+        message: `Manual extraction requires PDF files. Received: ${contentType}`,
+      });
+    }
+
+    const chunks: Buffer[] = [];
+    for await (const chunk of file.file) {
+      chunks.push(chunk);
+    }
+    const fileBuffer = Buffer.concat(chunks);
+
+    if (fileBuffer.length === 0) {
+      logger.warn('Empty file provided for manual extraction', {
+        operation: 'ocr.controller.extractManual.empty_file',
+        userId,
+        fileName: file.filename,
+      });
+      return reply.code(400).send({
+        error: 'Bad Request',
+        message: 'Empty file provided',
+      });
+    }
+
+    // Get optional vehicle_id from form fields
+    const vehicleId = file.fields?.vehicle_id?.value as string | undefined;
+
+    try {
+      const result = await ocrService.submitManualJob(userId, {
+        fileBuffer,
+        contentType,
+        vehicleId,
+      });
+
+      logger.info('Manual extract job submitted', {
+        operation: 'ocr.controller.extractManual.success',
+        userId,
+        jobId: result.jobId,
+        status: result.status,
+        estimatedSeconds: result.estimatedSeconds,
+      });
+
+      return reply.code(202).send(result);
+    } catch (error: any) {
+      if (error.statusCode === 413) {
+        return reply.code(413).send({
+          error: 'Payload Too Large',
+          message: error.message,
+        });
+      }
+      if (error.statusCode === 400) {
+        return reply.code(400).send({
+          error: 'Bad Request',
+          message: error.message,
+        });
+      }
+
+      logger.error('Manual extract failed', {
+        operation: 'ocr.controller.extractManual.error',
+        userId,
+        error: error.message,
+      });
+
+      return reply.code(500).send({
+        error: 'Internal Server Error',
+        message: 'Manual extraction submission failed',
+      });
+    }
+  }
+
   /**
    * POST /api/ocr/jobs
    * Submit an async OCR job for large files.

backend/src/features/ocr/api/ocr.routes.ts

@@ -29,6 +29,12 @@ export const ocrRoutes: FastifyPluginAsync = async (
     handler: ctrl.extractReceipt.bind(ctrl),
   });
 
+  // POST /api/ocr/extract/manual - Manual extraction (Pro tier required)
+  fastify.post('/ocr/extract/manual', {
+    preHandler: [requireAuth, fastify.requireTier({ featureKey: 'document.scanMaintenanceSchedule' })],
+    handler: ctrl.extractManual.bind(ctrl),
+  });
+
   // POST /api/ocr/jobs - Submit async OCR job
   fastify.post('/ocr/jobs', {
     preHandler: [requireAuth],

backend/src/features/ocr/domain/ocr.service.ts

@@ -5,6 +5,8 @@ import { logger } from '../../../core/logging/logger';
 import { ocrClient, JobNotFoundError } from '../external/ocr-client';
 import type {
   JobResponse,
+  ManualJobResponse,
+  ManualJobSubmitRequest,
   OcrExtractRequest,
   OcrJobSubmitRequest,
   OcrResponse,
@@ -278,6 +280,66 @@ export class OcrService {
     }
   }
 
+  /**
+   * Submit an async manual extraction job for PDF owner's manuals.
+   *
+   * @param userId - User ID for logging
+   * @param request - Manual job submission request
+   * @returns Manual job response with job ID
+   */
+  async submitManualJob(userId: string, request: ManualJobSubmitRequest): Promise<ManualJobResponse> {
+    // Validate file size for async processing (200MB max)
+    if (request.fileBuffer.length > MAX_ASYNC_SIZE) {
+      const err: any = new Error(
+        `File too large. Max: ${MAX_ASYNC_SIZE / (1024 * 1024)}MB.`
+      );
+      err.statusCode = 413;
+      throw err;
+    }
+
+    // Manual extraction only supports PDF
+    if (request.contentType !== 'application/pdf') {
+      const err: any = new Error(
+        `Unsupported file type: ${request.contentType}. Manual extraction requires PDF files.`
+      );
+      err.statusCode = 400;
+      throw err;
+    }
+
+    logger.info('Manual job submit requested', {
+      operation: 'ocr.service.submitManualJob',
+      userId,
+      contentType: request.contentType,
+      fileSize: request.fileBuffer.length,
+      hasVehicleId: !!request.vehicleId,
+    });
+
+    try {
+      const result = await ocrClient.submitManualJob(
+        request.fileBuffer,
+        request.contentType,
+        request.vehicleId
+      );
+
+      logger.info('Manual job submitted', {
+        operation: 'ocr.service.submitManualJob.success',
+        userId,
+        jobId: result.jobId,
+        status: result.status,
+        estimatedSeconds: result.estimatedSeconds,
+      });
+
+      return result;
+    } catch (error) {
+      logger.error('Manual job submit failed', {
+        operation: 'ocr.service.submitManualJob.error',
+        userId,
+        error: error instanceof Error ? error.message : 'Unknown error',
+      });
+      throw error;
+    }
+  }
+
   /**
    * Get the status of an async OCR job.
    *

backend/src/features/ocr/domain/ocr.types.ts

@@ -79,3 +79,49 @@ export interface OcrJobSubmitRequest {
   contentType: string;
   callbackUrl?: string;
 }
+
+/** Request to submit a manual extraction job */
+export interface ManualJobSubmitRequest {
+  fileBuffer: Buffer;
+  contentType: string;
+  vehicleId?: string;
+}
+
+/** Vehicle info extracted from a manual */
+export interface ManualVehicleInfo {
+  make: string | null;
+  model: string | null;
+  year: number | null;
+}
+
+/** A single maintenance schedule item extracted from a manual */
+export interface MaintenanceScheduleItem {
+  service: string;
+  intervalMiles: number | null;
+  intervalMonths: number | null;
+  details: string | null;
+  confidence: number;
+  subtypes: string[];
+}
+
+/** Result of manual extraction (nested in ManualJobResponse.result) */
+export interface ManualExtractionResult {
+  success: boolean;
+  vehicleInfo: ManualVehicleInfo;
+  maintenanceSchedules: MaintenanceScheduleItem[];
+  rawTables: unknown[];
+  processingTimeMs: number;
+  totalPages: number;
+  pagesProcessed: number;
+  error: string | null;
+}
+
+/** Response for async manual extraction job */
+export interface ManualJobResponse {
+  jobId: string;
+  status: JobStatus;
+  progress?: number;
+  estimatedSeconds?: number;
+  result?: ManualExtractionResult;
+  error?: string;
+}

backend/src/features/ocr/external/ocr-client.ts

@@ -2,7 +2,7 @@
  * @ai-summary HTTP client for OCR service communication
  */
 import { logger } from '../../../core/logging/logger';
-import type { JobResponse, OcrResponse, ReceiptExtractionResponse, VinExtractionResponse } from '../domain/ocr.types';
+import type { JobResponse, ManualJobResponse, OcrResponse, ReceiptExtractionResponse, VinExtractionResponse } from '../domain/ocr.types';
 
 /** OCR service configuration */
 const OCR_SERVICE_URL = process.env.OCR_SERVICE_URL || 'http://mvp-ocr:8000';
@@ -265,6 +265,61 @@ export class OcrClient {
     return (await response.json()) as JobResponse;
   }
 
+  /**
+   * Submit an async manual extraction job for PDF owner's manuals.
+   *
+   * @param fileBuffer - PDF file buffer
+   * @param contentType - MIME type of the file (must be application/pdf)
+   * @param vehicleId - Optional vehicle ID for context
+   * @returns Manual job submission response
+   */
+  async submitManualJob(
+    fileBuffer: Buffer,
+    contentType: string,
+    vehicleId?: string
+  ): Promise<ManualJobResponse> {
+    const formData = this.buildFormData(fileBuffer, contentType);
+    if (vehicleId) {
+      formData.append('vehicle_id', vehicleId);
+    }
+
+    const url = `${this.baseUrl}/extract/manual`;
+
+    logger.info('OCR manual job submit request', {
+      operation: 'ocr.client.submitManualJob',
+      url,
+      contentType,
+      fileSize: fileBuffer.length,
+      hasVehicleId: !!vehicleId,
+    });
+
+    const response = await this.fetchWithTimeout(url, {
+      method: 'POST',
+      body: formData,
+    });
+
+    if (!response.ok) {
+      const errorText = await response.text();
+      logger.error('OCR manual job submit failed', {
+        operation: 'ocr.client.submitManualJob.error',
+        status: response.status,
+        error: errorText,
+      });
+      throw new Error(`OCR service error: ${response.status} - ${errorText}`);
+    }
+
+    const result = (await response.json()) as ManualJobResponse;
+
+    logger.info('OCR manual job submitted', {
+      operation: 'ocr.client.submitManualJob.success',
+      jobId: result.jobId,
+      status: result.status,
+      estimatedSeconds: result.estimatedSeconds,
+    });
+
+    return result;
+  }
+
   /**
    * Check if the OCR service is healthy.
    *

backend/src/features/ocr/tests/unit/ocr-manual.test.ts

@@ -0,0 +1,213 @@
+/**
+ * @ai-summary Unit tests for OCR manual extraction endpoint
+ */
+
+import { OcrService } from '../../domain/ocr.service';
+import { ocrClient } from '../../external/ocr-client';
+import type { ManualJobResponse } from '../../domain/ocr.types';
+
+jest.mock('../../external/ocr-client');
+jest.mock('../../../../core/logging/logger');
+
+const mockSubmitManualJob = ocrClient.submitManualJob as jest.MockedFunction<
+  typeof ocrClient.submitManualJob
+>;
+
+describe('OcrService.submitManualJob', () => {
+  let service: OcrService;
+
+  const userId = 'test-user-id';
+
+  const mockManualJobResponse: ManualJobResponse = {
+    jobId: 'manual-job-123',
+    status: 'pending',
+    progress: 0,
+    estimatedSeconds: 45,
+    result: undefined,
+    error: undefined,
+  };
+
+  const mockCompletedJobResponse: ManualJobResponse = {
+    jobId: 'manual-job-123',
+    status: 'completed',
+    progress: 100,
+    result: {
+      success: true,
+      vehicleInfo: {
+        make: 'Honda',
+        model: 'Civic',
+        year: 2023,
+      },
+      maintenanceSchedules: [
+        {
+          service: 'Engine Oil Change',
+          intervalMiles: 5000,
+          intervalMonths: 6,
+          details: 'Use 0W-20 full synthetic oil',
+          confidence: 0.95,
+          subtypes: ['oil_change'],
+        },
+        {
+          service: 'Tire Rotation',
+          intervalMiles: 7500,
+          intervalMonths: 6,
+          details: null,
+          confidence: 0.90,
+          subtypes: ['tire_rotation'],
+        },
+      ],
+      rawTables: [],
+      processingTimeMs: 45000,
+      totalPages: 120,
+      pagesProcessed: 120,
+      error: null,
+    },
+    error: undefined,
+  };
+
+  beforeEach(() => {
+    jest.clearAllMocks();
+    service = new OcrService();
+  });
+
+  describe('valid manual job submission', () => {
+    it('should return 202-style response with jobId for PDF submission', async () => {
+      mockSubmitManualJob.mockResolvedValue(mockManualJobResponse);
+
+      const result = await service.submitManualJob(userId, {
+        fileBuffer: Buffer.from('fake-pdf-data'),
+        contentType: 'application/pdf',
+      });
+
+      expect(result.jobId).toBe('manual-job-123');
+      expect(result.status).toBe('pending');
+      expect(result.progress).toBe(0);
+      expect(result.estimatedSeconds).toBe(45);
+      expect(result.result).toBeUndefined();
+    });
+
+    it('should pass vehicleId to client when provided', async () => {
+      mockSubmitManualJob.mockResolvedValue(mockManualJobResponse);
+
+      await service.submitManualJob(userId, {
+        fileBuffer: Buffer.from('fake-pdf-data'),
+        contentType: 'application/pdf',
+        vehicleId: 'vehicle-abc',
+      });
+
+      expect(mockSubmitManualJob).toHaveBeenCalledWith(
+        expect.any(Buffer),
+        'application/pdf',
+        'vehicle-abc'
+      );
+    });
+
+    it('should call client without vehicleId when not provided', async () => {
+      mockSubmitManualJob.mockResolvedValue(mockManualJobResponse);
+
+      await service.submitManualJob(userId, {
+        fileBuffer: Buffer.from('fake-pdf-data'),
+        contentType: 'application/pdf',
+      });
+
+      expect(mockSubmitManualJob).toHaveBeenCalledWith(
+        expect.any(Buffer),
+        'application/pdf',
+        undefined
+      );
+    });
+  });
+
+  describe('completed job result', () => {
+    it('should return completed result with maintenanceSchedules', async () => {
+      mockSubmitManualJob.mockResolvedValue(mockCompletedJobResponse);
+
+      const result = await service.submitManualJob(userId, {
+        fileBuffer: Buffer.from('fake-pdf-data'),
+        contentType: 'application/pdf',
+      });
+
+      expect(result.status).toBe('completed');
+      expect(result.result).toBeDefined();
+      expect(result.result!.success).toBe(true);
+      expect(result.result!.maintenanceSchedules).toHaveLength(2);
+      expect(result.result!.maintenanceSchedules[0].service).toBe('Engine Oil Change');
+      expect(result.result!.maintenanceSchedules[0].intervalMiles).toBe(5000);
+      expect(result.result!.maintenanceSchedules[0].subtypes).toEqual(['oil_change']);
+      expect(result.result!.vehicleInfo.make).toBe('Honda');
+    });
+  });
+
+  describe('error handling', () => {
+    it('should throw 400 for non-PDF file (JPEG)', async () => {
+      await expect(
+        service.submitManualJob(userId, {
+          fileBuffer: Buffer.from('fake-image-data'),
+          contentType: 'image/jpeg',
+        })
+      ).rejects.toMatchObject({
+        statusCode: 400,
+      });
+    });
+
+    it('should throw 400 for non-PDF file (PNG)', async () => {
+      await expect(
+        service.submitManualJob(userId, {
+          fileBuffer: Buffer.from('fake-image-data'),
+          contentType: 'image/png',
+        })
+      ).rejects.toMatchObject({
+        statusCode: 400,
+      });
+    });
+
+    it('should throw 400 for text/plain', async () => {
+      await expect(
+        service.submitManualJob(userId, {
+          fileBuffer: Buffer.from('not a pdf'),
+          contentType: 'text/plain',
+        })
+      ).rejects.toMatchObject({
+        statusCode: 400,
+      });
+    });
+
+    it('should throw 413 for oversized file', async () => {
+      const largeBuffer = Buffer.alloc(201 * 1024 * 1024); // 201MB
+
+      await expect(
+        service.submitManualJob(userId, {
+          fileBuffer: largeBuffer,
+          contentType: 'application/pdf',
+        })
+      ).rejects.toMatchObject({
+        statusCode: 413,
+      });
+    });
+
+    it('should accept file at 200MB boundary', async () => {
+      mockSubmitManualJob.mockResolvedValue(mockManualJobResponse);
+      const exactBuffer = Buffer.alloc(200 * 1024 * 1024); // exactly 200MB
+
+      const result = await service.submitManualJob(userId, {
+        fileBuffer: exactBuffer,
+        contentType: 'application/pdf',
+      });
+
+      expect(result.jobId).toBe('manual-job-123');
+    });
+
+    it('should propagate OCR service errors', async () => {
+      mockSubmitManualJob.mockRejectedValue(
+        new Error('OCR service error: 500 - Internal error')
+      );
+
+      await expect(
+        service.submitManualJob(userId, {
+          fileBuffer: Buffer.from('fake-pdf-data'),
+          contentType: 'application/pdf',
+        })
+      ).rejects.toThrow('OCR service error: 500 - Internal error');
+    });
+  });
+});