Just went through this. You can have 7.5 volts at the battery while running, but be putting 40 amps into it! That will boil it. Regulator has 3 coils in it. Cut out, voltage and current coils. They have to sense the battery condition, and turn on and off the charge being sent to the battery by the generator. A amp gauge shows what's being sent to the battery with change in engine RPM. A voltage meter does not show this. Just how many volts are there. Your regulator is the problem, or your wiring is not hooked up correctly. You also need clean contacts in the regulator and a good ground. John