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If you think a proper interlock is expensive, You haven't considered the life of someone. Using lockout is known as an administrative control. These are usually avoided because they are easy to defeat. always design based on the lowest common idiot.
I had one recently too, Annoying thing it was caused by a tree limb, That I called in to duke as a hazard, That they looked at and said it wasnt.. But yes they are getting too expensive to run, So far I only used what I had on hand, dreading having to refill my cans.
At this time I would also like to point out that when you disconnect this bond leave the generator hooked up. running it disconnected from the house and the bond disconnected will give you weird voltages (floating neutral).
Just something to keep in mind.
No ground rod to the frame. While it can be done without adversely impacting the way the ground is meant to work its nest to not alter your house grounding.
White wire to L0 Green/bare wire to chassis Line 1 to L1 line 2 to L3
The bond is usually wired off of L0 to the chassis.
Start by getting into the manuals (TM tap at the top of the page)
When you hold the switch to start, you are bypassing the voltage regulator (this is the flash circuit, its what gets the head going to excite the regulator) You might have a bad AVR but that requires testing to confirm.