The only purpose for a current regulator is to prevent the generator from overloading itself when charging a VERY low battery. Once the output of the generator drops below 30-35 amps, depending on which generator you have, the current regulator should not be operating at all. It's in series with the voltage regulator points, so it's an either/or situation- - - -voltage and current regulation DOES NOT work at the same time. It might be possible to turn on enough accessories such as electric wipers, high beam headlights, high speed heater fan, and maybe a cigarette lighter (all at once) to use up the full output of the generator, but that's the only situation I can imagine where the current regulator would be operating other than when recharging the battery immediately after a long cranking session with the starter. If you've got a major difference between the armature voltage and the voltage present at the battery posts, you've got some dirty connections somewhere between the regulator and the battery, or maybe some burned cutout relay points. Heat indicates resistance, so if the cutout is getting hot, that's your voltage drop point. Clean 'em up or go back to the original-equipment type regulator.
Jerry
