first of all i'd advice you to try to debug that "falling". just use debug mode and when (approximately) the falling time comes, use pause and frame staeps (scroll lock key button during pause). when he finally starts to fall, check his state number, bound state (p2 will indicate him as target for a second), and everything else what could be possible to catch in slow motion.
my only guess so far is that he transfers to some non=existing state which causes him to fall if not performed correctly.
try and make a screenshot in debug mode (collisions on) of the very instant he starts to fall.