From 73e5bb763530047627d1ff628695aca44295cddf Mon Sep 17 00:00:00 2001
From: Tak Hoffman <781889+Takhoffman@users.noreply.github.com>
Date: Sun, 22 Feb 2026 17:04:30 -0600
Subject: [PATCH] Cron: apply timeout to startup catch-up runs (#23966)

* Cron: apply timeout to startup catch-up runs

* Changelog: add cron startup timeout catch-up note
---
 CHANGELOG.md                               |  1 +
 src/cron/service.issue-regressions.test.ts | 41 +++++++++++++++++++++-
 src/cron/service/timer.ts                  |  2 +-
 3 files changed, 42 insertions(+), 2 deletions(-)

diff --git a/CHANGELOG.md b/CHANGELOG.md
index 2aaf763a8..a950f1c76 100644
--- a/CHANGELOG.md
+++ b/CHANGELOG.md
@@ -67,6 +67,7 @@ Docs: https://docs.openclaw.ai
 - Cron/Delivery: route text-only announce jobs with explicit thread/topic targets through direct outbound delivery so forum/thread destinations do not get dropped by intermediary announce turns. (#23841) Thanks @AndrewArto.
 - Cron: honor `cron.maxConcurrentRuns` in the timer loop so due jobs can execute up to the configured parallelism instead of always running serially. (#11595) Thanks @Takhoffman.
 - Cron/Run: enforce the same per-job timeout guard for manual `cron.run` executions as timer-driven runs, including abort propagation for isolated agent jobs, so forced runs cannot wedge indefinitely. (#23704) Thanks @tkuehnl.
+- Cron/Startup: enforce per-job timeout guards for startup catch-up replay runs so missed isolated jobs cannot hang indefinitely during gateway boot recovery.
 - Cron/Schedule: for `every` jobs, prefer `lastRunAtMs + everyMs` when still in the future after restarts, then fall back to anchor scheduling for catch-up windows, so NEXT timing matches the last successful cadence. (#22895) Thanks @SidQin-cyber.
 - Cron/Service: execute manual `cron.run` jobs outside the cron lock (while still persisting started/finished state atomically) so `cron.list` and `cron.status` remain responsive during long forced runs. (#23628) Thanks @dsgraves.
 - Cron/Timer: keep a watchdog recheck timer armed while `onTimer` is actively executing so the scheduler continues polling even if a due-run tick stalls for an extended period. (#23628) Thanks @dsgraves.
diff --git a/src/cron/service.issue-regressions.test.ts b/src/cron/service.issue-regressions.test.ts
index a0838b6f6..c089449ea 100644
--- a/src/cron/service.issue-regressions.test.ts
+++ b/src/cron/service.issue-regressions.test.ts
@@ -8,7 +8,7 @@ import { CronService } from "./service.js";
 import { createDeferred, createRunningCronServiceState } from "./service.test-harness.js";
 import { computeJobNextRunAtMs } from "./service/jobs.js";
 import { createCronServiceState, type CronEvent } from "./service/state.js";
-import { onTimer } from "./service/timer.js";
+import { onTimer, runMissedJobs } from "./service/timer.js";
 import type { CronJob, CronJobState } from "./types.js";
 
 const noopLogger = {
@@ -820,6 +820,45 @@ describe("Cron issue regressions", () => {
     cron.stop();
   });
 
+  it("applies timeoutSeconds to startup catch-up isolated executions", async () => {
+    vi.useRealTimers();
+    const store = await makeStorePath();
+    const scheduledAt = Date.parse("2026-02-15T13:00:00.000Z");
+    const cronJob = createIsolatedRegressionJob({
+      id: "startup-timeout",
+      name: "startup timeout",
+      scheduledAt,
+      schedule: { kind: "at", at: new Date(scheduledAt).toISOString() },
+      payload: { kind: "agentTurn", message: "work", timeoutSeconds: 0.01 },
+      state: { nextRunAtMs: scheduledAt },
+    });
+    await writeCronJobs(store.storePath, [cronJob]);
+
+    let now = scheduledAt;
+    const abortAwareRunner = createAbortAwareIsolatedRunner();
+    const state = createCronServiceState({
+      cronEnabled: true,
+      storePath: store.storePath,
+      log: noopLogger,
+      nowMs: () => now,
+      enqueueSystemEvent: vi.fn(),
+      requestHeartbeatNow: vi.fn(),
+      runIsolatedAgentJob: vi.fn(async (params) => {
+        const result = await abortAwareRunner.runIsolatedAgentJob(params);
+        now += 5;
+        return result;
+      }),
+    });
+
+    await runMissedJobs(state);
+
+    expect(abortAwareRunner.getObservedAbortSignal()).toBeDefined();
+    expect(abortAwareRunner.getObservedAbortSignal()?.aborted).toBe(true);
+    const job = state.store?.jobs.find((entry) => entry.id === "startup-timeout");
+    expect(job?.state.lastStatus).toBe("error");
+    expect(job?.state.lastError).toContain("timed out");
+  });
+
   it("retries cron schedule computation from the next second when the first attempt returns undefined (#17821)", () => {
     const scheduledAt = Date.parse("2026-02-15T13:00:00.000Z");
     const cronJob = createIsolatedRegressionJob({
diff --git a/src/cron/service/timer.ts b/src/cron/service/timer.ts
index cb403762b..36e0ff454 100644
--- a/src/cron/service/timer.ts
+++ b/src/cron/service/timer.ts
@@ -547,7 +547,7 @@ export async function runMissedJobs(
     const startedAt = state.deps.nowMs();
     emit(state, { jobId: candidate.job.id, action: "started", runAtMs: startedAt });
     try {
-      const result = await executeJobCore(state, candidate.job);
+      const result = await executeJobCoreWithTimeout(state, candidate.job);
       outcomes.push({
         jobId: candidate.jobId,
         status: result.status,