Narrative:

During phase inspection of aircraft; a rigging pin was installed to set the elevator cable tension and was inadvertently left in the elevator bell crank by the a&P mechanic and returned to service. The lack of full elevator control was missed during the preflight run up and takeoff and wasn't acknowledged until attempting to level off at cruise. Pitch control pressure on the yolk was extremely heavy and the aircraft was hard to control. The aircraft was operating under part 91 and the left seat was occupied by a low time trainee. The trainee performed a control check but failed to detect the problem. The right seat was occupied by the captain or non flying pilot; who failed to notice that the control check was not full and complete. During the attempt to level off; the heavy control pressure was brought to the attention of the captain; who assumed control and returned to the field. Although the elevator control was minimal; the pitch control of the aircraft was controllable to some degree. A combination of available pitch; electric stabilizer trim; approach flaps and power was used to make a long; slow descent to a safe landing. Upon inspection; the rigging pin was found in the bell crank (bent); removed and the aircraft was returned to service. No damage to the aircraft was found.the flying pilot noticed the aircraft was difficult to rotate but didn't abort the takeoff. The non flying pilot noticed the climb out profile was erratic but failed to ask why. The trainee perceived the aircraft to be 'flyable' and continued the flight for seventeen miles. Trainee had low time in aircraft and both pilots wanted to complete the mission.

Related reports:

Google
 

Original NASA ASRS Text

Title: A rigging pin was found in the elevator control bell crank of a BE99 after the aircraft returned from a training flight where pitch control was found to be difficult.

Narrative: During phase inspection of aircraft; a rigging pin was installed to set the elevator cable tension and was inadvertently left in the elevator bell crank by the A&P Mechanic and returned to service. The lack of full elevator control was missed during the preflight run up and takeoff and wasn't acknowledged until attempting to level off at cruise. Pitch control pressure on the yolk was extremely heavy and the aircraft was hard to control. The aircraft was operating under Part 91 and the left seat was occupied by a low time trainee. The trainee performed a control check but failed to detect the problem. The right seat was occupied by the Captain or non flying pilot; who failed to notice that the control check was not full and complete. During the attempt to level off; the heavy control pressure was brought to the attention of the Captain; who assumed control and returned to the field. Although the elevator control was minimal; the pitch control of the aircraft was controllable to some degree. A combination of available pitch; electric stabilizer trim; approach flaps and power was used to make a long; slow descent to a safe landing. Upon inspection; the rigging pin was found in the bell crank (bent); removed and the aircraft was returned to service. No damage to the aircraft was found.The flying pilot noticed the aircraft was difficult to rotate but didn't abort the takeoff. The non flying pilot noticed the climb out profile was erratic but failed to ask why. The trainee perceived the aircraft to be 'flyable' and continued the flight for seventeen miles. Trainee had low time in aircraft and both pilots wanted to complete the mission.

Data retrieved from NASA's ASRS site as of April 2012 and automatically converted to unabbreviated mixed upper/lowercase text. This report is for informational purposes with no guarantee of accuracy. See NASA's ASRS site for official report.