mcs150: fill all checkboxes/radios correctly + stamp explicit checkmarks

Fixes a batch of missing fields the FMCSA census does not provide and the
filler was mis-mapping:

- Corrected the question->field mapping to match the actual form: Q22 =
  COMPANY OPERATIONS (interstate/intrastate, 22xBox), Q23 = OPERATION
  CLASSIFICATIONS (for-hire/private/govt, 23xBox). These were swapped, and
  the bogus entity-type->23xBox map (no entity-type question exists on this
  form revision) was removed.
- Added proper radio-group handling for Reason for Filing (Biennial Update),
  Mailing-address (Same as principal vs below), and Q28 USDOT-revoked, with
  correct option indices (these are /0../n radios, not /Yes checkboxes; the
  old code set them to /Yes and never selected the right option).
- Map interstate/intrastate from the FMCSA census carrierOperationCode, and
  populate email/phone/mileage/cargo from intake.
- AcroForm checkbox/radio appearances use a ZapfDingbats glyph that
  poppler/Preview fail to render (value set but box looks empty). Now stamp
  an explicit X overlay into the page content for every 'on' box so it shows
  in every viewer and in the faxed output.

scripts/document_gen/templates/mcs150_pdf_filler.py

@@ -44,24 +44,37 @@ FORMS = {
 
 # ── Field mappings ────────────────────────────────────────────────────
 
-# Question 22: Carrier Operation (checkboxes)
+# Question 22: COMPANY OPERATIONS (interstate / intrastate classification).
-CARRIER_OP_MAP = {
+# A=Interstate Carrier, B=Intrastate Hazmat Carrier, C=Intrastate Non-Hazmat
-    "authorized_for_hire": "22aBox",
+# Carrier, D=Interstate Hazmat Shipper, E=Intrastate Hazmat Shipper.
-    "exempt_for_hire":     "22bBox",
+COMPANY_OPERATION_MAP = {
-    "private_property":    "22cBox",
+    "interstate":            "22aBox",
-    "private_passengers":  "22dBox",
+    "intrastate_hazmat":     "22bBox",
-    "us_mail":             "22eBox",
+    "intrastate_non_hazmat": "22cBox",
 }
 
-# Question 23: Entity Type (checkboxes)
+# Question 23: OPERATION CLASSIFICATIONS (how the carrier operates).
-ENTITY_TYPE_MAP = {
+# A=Authorized For-Hire, B=Exempt For-Hire, C=Private Property,
-    "sole_proprietorship": "23aBox",
+# D=Private Passengers (Business), E=Private Passengers (Non-Business),
-    "partnership":         "23bBox",
+# F=Migrant, G=U.S. Mail, H=Federal Govt, I=State Govt, J=Local Govt,
-    "corporation":         "23cBox",
+# K=Indian Tribe.
-    "llc":                 "23dBox",
+CARRIER_OP_MAP = {
-    "other":               "23kBox",
+    "authorized_for_hire": "23aBox",
+    "exempt_for_hire":     "23bBox",
+    "private_property":    "23cBox",
+    "private_passengers_business":     "23dBox",
+    "private_passengers_non_business": "23eBox",
+    "migrant":             "23fBox",
+    "us_mail":             "23gBox",
+    "federal_government":  "23hBox",
+    "state_government":    "23iBox",
+    "local_government":    "23jBox",
+    "indian_tribe":        "23kBox",
 }
 
+# (legacy synonyms kept so older intake values still map sensibly)
+CARRIER_OP_MAP.setdefault("private_passengers", "23dBox")
+
 # Question 24: Cargo Types (checkboxes — a through z, aa through dd)
 CARGO_TYPE_MAP = {
     "general":            "24aBox",
@@ -108,6 +121,50 @@ def determine_form_type(intake: dict) -> str:
     return "mcs150"
 
 
+def _stamp_check_marks(writer, marks: list) -> None:
+    """Draw an explicit "X" mark inside each (page, rect) in ``marks``.
+
+    AcroForm checkbox/radio appearances render inconsistently across viewers
+    (poppler, Preview), so we burn the mark into the page content to guarantee
+    it shows on screen and in the faxed/printed output. Grouped per page so we
+    merge a single overlay onto each affected page.
+    """
+    if not marks:
+        return
+    try:
+        import io
+        from reportlab.pdfgen import canvas as _canvas
+        from pypdf import PdfReader as _PdfReader
+    except Exception as exc:  # reportlab missing — fall back to AcroForm only
+        LOG.warning("Checkmark overlay unavailable (%s); relying on AcroForm", exc)
+        return
+
+    # Group rects by their page object's index in the writer.
+    page_index = {id(p): i for i, p in enumerate(writer.pages)}
+    by_page: dict[int, list] = {}
+    for page, rect in marks:
+        idx = page_index.get(id(page))
+        if idx is not None:
+            by_page.setdefault(idx, []).append(rect)
+
+    for idx, rects in by_page.items():
+        page = writer.pages[idx]
+        pw = float(page.mediabox.width)
+        ph = float(page.mediabox.height)
+        buf = io.BytesIO()
+        c = _canvas.Canvas(buf, pagesize=(pw, ph))
+        c.setLineWidth(1.3)
+        for (x0, y0, x1, y1) in rects:
+            # Draw an "X" that fills most of the box with a small inset.
+            inset = max(1.2, (x1 - x0) * 0.18)
+            c.line(x0 + inset, y0 + inset, x1 - inset, y1 - inset)
+            c.line(x0 + inset, y1 - inset, x1 - inset, y0 + inset)
+        c.save()
+        buf.seek(0)
+        overlay = _PdfReader(buf).pages[0]
+        page.merge_page(overlay)
+
+
 def fill_mcs150(intake: dict, order_number: str = "") -> str:
     """Fill the official MCS-150 PDF form.
 
@@ -186,30 +243,54 @@ def fill_mcs150(intake: dict, order_number: str = "") -> str:
     elif interstate in ("intrastate_hazmat", "intrastate_non_hazmat"):
         field_updates["intraWithin"] = str(intake.get("annual_miles", ""))
 
-    # ── Checkbox fields ──────────────────────────────────────────────
+    # ── Checkbox fields (on/off, value /Yes) ─────────────────────────
     checkbox_on = {}
 
-    # Carrier operation
+    # Q22 Company operations (interstate / intrastate classification)
+    company_op = intake.get("interstate_intrastate", "")
+    if company_op in COMPANY_OPERATION_MAP:
+        checkbox_on[COMPANY_OPERATION_MAP[company_op]] = True
+
+    # Q23 Operation classifications (for-hire / private / government / etc.)
     carrier_op = intake.get("carrier_operation", "")
     if carrier_op in CARRIER_OP_MAP:
         checkbox_on[CARRIER_OP_MAP[carrier_op]] = True
 
-    # Entity type
+    # Q24 Cargo types
-    entity_type = intake.get("entity_type", "")
-    if entity_type in ENTITY_TYPE_MAP:
-        checkbox_on[ENTITY_TYPE_MAP[entity_type]] = True
-
-    # Cargo types
     for cargo in intake.get("cargo_types", []):
         if cargo in CARGO_TYPE_MAP:
             checkbox_on[CARGO_TYPE_MAP[cargo]] = True
 
-    # Reason for filing — biennial update
+    # The bottom certification ("I ... certify ...") box is always checked --
-    checkbox_on["Reason Button"] = True  # Biennial update
+    # the client signs the perjury certification.
-
-    # Certify box
     checkbox_on["certifyBox"] = True
 
+    # ── Radio-button groups (value /0../4, not /Yes) ─────────────────
+    # These are single-select radio fields; the selected option index is the
+    # field value.
+    radio_values = {}
+
+    # Reason for filing (form REASON FOR FILING). 0=New Application,
+    # 1=Biennial Update or Changes, 2=Out of Business, 3=Reapplication,
+    # 4=Reactivate. Map the service slug / explicit reason to the index.
+    reason_map = {
+        "new_application": "0",
+        "biennial_update": "1",
+        "out_of_business": "2",
+        "reapplication":   "3",
+        "reactivate":      "4",
+    }
+    reason = intake.get("reason_for_filing", "biennial_update")
+    radio_values["Reason Button"] = reason_map.get(reason, "1")
+
+    # Mailing address: 0 = same as principal place of business, 1 = different
+    # address provided below.
+    radio_values["Mailing Button"] = "1" if intake.get("mailing_street") else "0"
+
+    # Q28 Is USDOT registration currently revoked? On this form the options
+    # render Yes (index 0) then No (index 1), so No = "1".
+    radio_values["Revoke Button"] = "0" if intake.get("usdot_revoked") == "yes" else "1"
+
     # ── Apply fields to PDF ──────────────────────────────────────────
     # Apply text-field values to every page. The template ships with only the
     # fillable FORM pages (the FMCSA instruction pages are trimmed off the
@@ -226,24 +307,73 @@ def fill_mcs150(intake: dict, order_number: str = "") -> str:
         except Exception as exc:
             LOG.debug("Form field apply on page failed: %s", exc)
 
-    # Apply checkbox fields
+    # Apply checkbox fields (value /Yes) and radio groups (value /0../n) by
+    # walking the widget annotations. For radios, the selected option is the
+    # kid whose appearance state (/AP /N) contains the chosen index; we set the
+    # parent /V and each kid's /AS so the correct circle renders filled.
+    # ``marks`` collects (page, rect) of every "on" widget so we can stamp an
+    # explicit checkmark overlay (AcroForm appearances render inconsistently).
+    marks: list = []
+
+    def _set_button(field_name: str, on_value: str) -> None:
+        """Set a /Btn field (checkbox or radio) to ``on_value`` (e.g. 'Yes' or
+        '1'). Handles both flat widgets and parent/kid radio groups."""
+        target = "/" + on_value.lstrip("/")
+        for page in writer.pages:
+            for annot in page.get("/Annots", []) or []:
+                obj = annot.get_object()
+                # Resolve the field name from this widget or its parent.
+                name = obj.get("/T")
+                parent = obj.get("/Parent")
+                pobj = parent.get_object() if parent else None
+                if name is None and pobj is not None:
+                    name = pobj.get("/T")
+                if name is None or str(name) != field_name:
+                    continue
+                # Determine the appearance state this widget represents.
+                ap = obj.get("/AP")
+                on_states = []
+                if ap:
+                    n = ap.get_object().get("/N")
+                    if n is not None:
+                        on_states = [str(k) for k in n.get_object().keys() if str(k) != "/Off"]
+                # Set the field value on the field object (parent for radios).
+                field_obj = pobj if pobj is not None else obj
+                field_obj[NameObject("/V")] = NameObject(target)
+                # The widget is "on" only if its own appearance state matches.
+                if target in on_states or (not on_states and target == "/Yes"):
+                    obj[NameObject("/AS")] = NameObject(target)
+                    # Record the on-widget rectangle + page so we can draw the
+                    # mark directly onto the page content (see overlay below).
+                    # AcroForm /AP appearances are unreliable across viewers
+                    # (poppler/Preview regenerate them and lose the ZapfDingbats
+                    # checkmark), so we stamp our own mark to guarantee it shows.
+                    rect = obj.get("/Rect")
+                    if rect is not None:
+                        marks.append((page, [float(x) for x in rect]))
+                else:
+                    obj[NameObject("/AS")] = NameObject("/Off")
+
     for field_name, checked in checkbox_on.items():
         if checked:
             try:
-                # Find the field across all pages and set it
+                _set_button(field_name, "Yes")
-                for page in writer.pages:
-                    if "/Annots" in page:
-                        for annot in page["/Annots"]:
-                            obj = annot.get_object()
-                            if obj.get("/T") and str(obj["/T"]) == field_name:
-                                obj.update({
-                                    NameObject("/V"): NameObject("/Yes"),
-                                    NameObject("/AS"): NameObject("/Yes"),
-                                })
-                                break
             except Exception as e:
                 LOG.debug("Checkbox %s set failed: %s", field_name, e)
 
+    for field_name, value in radio_values.items():
+        try:
+            _set_button(field_name, value)
+        except Exception as e:
+            LOG.debug("Radio %s set failed: %s", field_name, e)
+
+    # Stamp an explicit checkmark onto every "on" checkbox/radio. AcroForm /AP
+    # appearances for these boxes use a ZapfDingbats glyph that poppler/Preview
+    # fail to render reliably (the value is set but the box looks empty). Drawing
+    # the mark directly into the page content guarantees it shows in every
+    # viewer and in the faxed/printed output.
+    _stamp_check_marks(writer, marks)
+
     # Force viewers to (re)generate field appearance streams from the values we
     # set. Without /NeedAppearances, pypdf leaves the template's blank /AP streams
     # in place, so the typed values are present in /V but the viewer renders the

scripts/workers/services/mcs150_update.py

@@ -460,6 +460,23 @@ class MCS150UpdateHandler:
             "power_units":  s(c.get("totalPowerUnits")),
             "drivers":      s(c.get("totalDrivers")),
         }
+
+        # Interstate vs intrastate (form Q26/27). The census exposes this as
+        # carrierOperation.carrierOperationCode: A=Interstate, B=Intrastate
+        # Hazmat, C=Intrastate Non-Hazmat.
+        op = c.get("carrierOperation") or {}
+        code = (op.get("carrierOperationCode") or "").strip().upper()
+        if code == "A":
+            out["interstate_intrastate"] = "interstate"
+        elif code == "B":
+            out["interstate_intrastate"] = "intrastate_hazmat"
+        elif code == "C":
+            out["interstate_intrastate"] = "intrastate_non_hazmat"
+
+        # Passenger carrier flag (form Q29 passenger compliance cert).
+        if s(c.get("isPassengerCarrier")).upper() == "Y":
+            out["is_passenger_carrier"] = "yes"
+
         return {k: v for k, v in out.items() if v}
 
     def _check_current_status(self, dot_number: str) -> str: