1.) FMLA *may* apply if both he and the employer fit the definitions of a covered employee and a covered employer. You are, however, not correctly defining a serious health condition. The little blurb you posted the link to is only a summary. See the link below for a full definition. Although taken from a state board, it shows the full Federal definition.
http://www.cs.state.ny.us/attendance...5-01_att_A.pdf
1a.) On the first day of his leave.
2.) The employer is not required by any law to provide light duty for him or to make up a job that he can do with his restrictions. If the employer has no light duty available, the employer is not required to allow him to return to work until he is able to perform his full duties, and let him go if the time he is out exceeds the 12 weeks. Note that in a workers comp situation, it benefits the employer to have him back to work as quickly as possible even in a light duty situation, so it is unlikely that they would fail to bring him back to work if they are able to accomodate his restrictions.
3.) There is nothing he can do now that will force the employer to return him to work. IF he is fired AND IF he has a valid and supportable reason to believe that his termination violates the law, which is by no means clearly established by your post, he can consult with an employment attorney at that time.
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