could be a possible manufacturing error. Visually put the two couplers next to each other and check all thicknesses. If you have a micrometer, that will give you percise measurments. There has to be something physically wrong with the coupler if one will go on and one wont. This rules out the keg valve.
Check, DOuble check, and triple check all the sizes of anything that makes contact with the keg valve.
Sorry I cant help you out any better.
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DKC645BLS (Jan. 08 Production)
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