As someone who’s worked in the fall arrest equipment industry for over a decade—first as a field technician, then as a supplier—I can tell you that nothing breaks my heart more than hearing about a preventable fall. I’ve been on jobsites where a technician questioned whether their fall arrester was “working right” but didn’t know how to check, and on others where a unit was clearly past its safe use-by date but still in daily use. The good news? Troubleshooting a fall arrester isn’t as complicated as it sounds—if you know what to look for, and how to approach it safely. This guide is built from real-world scenarios, the industry standards we follow at our team, and lessons we’ve learned from helping hundreds of clients keep their crews safe.
First, let’s start with a critical foundational point: fall arresters (sometimes called fall blocks, self-retracting lanyards, or SRLs) aren’t one-size-fits-all. Before you even begin troubleshooting, confirm you’re working with the right equipment for the task. If you’re working on a ladder, a standard fall arrester won’t offer the same stabilization as a purpose-built ladder fall protection device. If you’re working at height in an elevator shaft, a heavy duty fall arrest block is non-negotiable for the weight and space constraints of that work. For general industrial access, our personal fall arrest equipment line is tested to meet OSHA and ANSI standards for everyday use. If you’re ever unsure whether you’re using the right gear, double-check the unit’s labeling or reach out to a specialist—using the wrong type of fall arrester is a common, fixable mistake that leads to most preventable issues.
Now, let’s break troubleshooting into step-by-step checks, ordered from the easiest, most visual inspections (no tools required) to more detailed tests that need training. I always tell my team to start with the “walkaround check” before doing anything else—this is the fastest way to catch obvious issues that signal your fall arrester is unsafe.
The first visual check: examine the entire unit for visible damage. Fall arresters are built to absorb sudden impact, but repeated exposure to harsh conditions (extreme temperatures, corrosive materials, sharp edges) wears them down over time. Start with the housing: for a fall arrest block, the casing should be free of cracks, dents, or warping. A cracked housing means internal components could be exposed to debris or misaligned, which would cause the unit to lock up unexpectedly during a fall. Next, check the webbing or cable: if you’re working with a webbing-based SRL, look for fraying, cuts, discoloration (which signals UV damage—webbing left out in direct sun for months will become brittle), or melted fibers. For cable-based units, check for kinks, bends, or broken strands. Even a single small kink in a cable can prevent the internal locking mechanism from engaging when it needs to, turning a reliable fall arrester into a dangerous liability. Also, inspect the attachment points: the carabiner and anchor hooks must be free of bends, rust, or worn gate springs. A gate that doesn’t fully close, or a hook that’s twisted out of shape, can accidentally disengage from the anchor mid-use. I once saw a client skip this check: their hook was slightly bent, and during a sudden lurch, it slipped off the anchor—luckily, the crew member wore a backup lanyard, but it was a close call.
Next, check the retraction and locking function, which is the core of a fall arrester’s job. This is where a lot of users go wrong—they don’t test the lock regularly, assuming it works because it worked last time. To test this safely, find a flat, stable surface, and extend the fall arrester slowly and evenly. If it’s working properly, the webbing or cable should retract smoothly and without jerking when you let go. If it drags, sticks, or retracts too fast, that’s a red flag. Now, test the emergency lock: pull the webbing or cable out quickly (simulating a fall). A working fall arrester should lock immediately—you’ll feel a hard, sudden stop in the unit, and it won’t retract any further. If it doesn’t lock, or locks sluggishly, that means internal components (the spring, the pawl, or the locking cam) are worn, dirty, or misaligned. Don’t use the unit until it’s inspected or repaired by a professional—this is a critical function, and a failed lock can mean the difference between a minor scare and a serious injury.
One area that’s often overlooked is cleaning and maintenance. Fall arresters get dirty—dust, paint splatter, construction debris, even chemicals from industrial work can build up on internal parts over time, causing the unit to malfunction. We have a rule with our clients: if your fall arrester is exposed to any harsh materials, you should clean it after every use, and give it a deep maintenance check every 6 months (depending on usage). To clean a fall arrest block, you can use a soft brush, mild soap, and water—never use high-pressure washers, which can force water into the internal housing and damage the spring or locking mechanism. For cable units, wipe down the cable regularly to remove dirt that can cause kinking during retraction. If you notice the unit is sticking after cleaning, don’t try to take it apart yourself—internal components are calibrated for safety, and improper disassembly can void the warranty and make the unit unsafe. Our team offers on-site maintenance checks for clients in high-use industries, so don’t hesitate to reach out if you’re unsure how to proceed.
Another common issue is expiration. Every fall arrester has a service life, even if it looks brand new. Manufacturers (including our team) stamp an expiration date on the housing or a label on the unit—usually 5 to 10 years from the date of manufacture, depending on the type. This isn’t a arbitrary number: plastics degrade, springs lose tension, and webbing loses strength over time, even if the unit is never used. I’ve seen clients use a 10-year-old fall arrester that looked in perfect condition, only to have it snap under the weight of a fall. Always check the expiration date before using any unit, and never use an expired fall arrester—no visual test can confirm internal components are still functional beyond that date.
Now, let’s talk about when a fall arrester is beyond repair. There are a few signs that mean you need to retire the unit, not troubleshoot it. If your fall arrester has been involved in a fall (even a small one), you must replace it immediately—fall arresters are designed to absorb the energy of a fall, and that damage isn’t always visible. A unit that’s been through a fall could have a weakened spring, a bent locking cam, or a cracked housing that will fail on the next use. Other retirement signs: if it’s exposed to extreme temperatures (below -20°F or above 120°F) for extended periods, if it’s been in contact with corrosive materials that have eaten through the housing or webbing, or if it’s failed any safety test during inspection. Trying to repair a fallen fall arrester is never worth the risk—you’re putting your crew at unnecessary danger.
Let me also share a few troubleshooting mistakes I see clients make all the time. First, don’t ignore small issues. A slight drag in retraction today could turn into a complete lock failure next week, especially if the unit is used daily. Second, don’t use makeshift repairs. Taping a frayed webbing, bending a carabiner back into shape with pliers, or lubricating the internal mechanism with oil (which can attract dirt and cause buildup) are all dangerous fixes. Only use manufacturer-approved replacement parts, and never modify a fall arrester—any alteration voids safety certifications. Third, don’t skip regular inspections. We recommend daily pre-use checks (the walkaround we talked about), monthly functional checks, and annual professional inspections for most units. For fall arrest blocks used in high-traffic areas, we suggest even more frequent checks to catch issues early.
If you’re working on a specific application, like ladder access or elevator construction, your troubleshooting steps will have small tweaks. For ladder fall protection devices, pay extra attention to the mounting brackets—loose brackets can cause the unit to misalign during use, so check the bolts every time you use it. For heavy duty fall arrest blocks in elevator shafts, the cable length should be matched to the shaft height; if the cable is too long or too short, it can lock up during deployment, so confirm the unit is the right size for your space. For general personal fall arrest equipment, always ensure the anchor point is rated for at least 5,000 pounds per person—an unrated anchor will fail, no matter how good your fall arrester is.
At the end of the day, troubleshooting a fall arrester is about balancing routine checks with respect for the equipment’s purpose. It’s not a complex science, but it does require consistency. If you’re unsure about any step, or if your unit fails any test, don’t take chances—reach out to our team to connect with a specialist. We work with contractors, industrial teams, and facility managers to make sure they have the right equipment, the right maintenance plans, and the support to keep their crews safe. Whether you’re looking for a fall arrest block 15m for medium-height access, a heavy duty unit for elevator work, or a ladder-specific device, we have solutions built to meet the demands of real jobsites.
If you have questions about troubleshooting your fall arrester, or if you’re ready to order new equipment for your team, don’t hesitate to get in touch. We’re here to help you stay safe, one well-functioning fall arrest device at a time.
References
- Occupational Safety and Health Administration (OSHA). (2022). Personal Fall Protection Systems. Retrieved from OSHA website
- American National Standards Institute (ANSI). (2021). ANSI Z359.1, Safety Requirements for Personal Fall Arrest Systems, Subsystems, and Components
- Fall Protection Equipment Manufacturers Association (FPEMA). (2023). Best Practices for Fall Arrester Maintenance and Troubleshooting
- National Institute for Occupational Safety and Health (NIOSH). (2022). Preventing Falls in Construction: A Guide for Employers and Workers
