A relay is a rather simple device. The only way rattling can occur is if the coil of the relay is defective (unlikely) or the supplied voltage to the coil is too low to entirely overcome the return spring pressure of the coil causing it to bounce up and down which is your rattling. As you mentioned, this happens when higher loads are applied to the generator which leads me to believe your generator is not producing the power it once did or as mentioned above, some AC device is drawing too much juice.
Watch your voltage meter when the A/C kicks in while on the genny, my guess is it will drop to 90 or less when you hear the rattling and move up to 110+ once the rattling stops.
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Need electrical help
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Midnightsun
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