I bought a spare "untested" i40 off ebay this weekend. It'll be two weeks till it arrives but ill try this in the meantime.
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I had the same problem years ago. when I finally got it right I created this thread: https://forums.arcade-museum.com/showthread.php?t=276996
perhaps this will help you.
So to summarize current situation. All buttons work, all directions on p4 are stuck, and no player directions work for p1-p3? The wiring looks correct when compared to mecha's pic.
Have you verified +5 to all joysticks?
couple of suggestions YMMV. Unplug player 4 and what do you get? plug player 3 into player 4 and see if problem (directions stuck on) follows to p3.
I also had the second fuse block like yourself and I removed a bit of wiring and did it just like you.I had the same problem years ago. when I finally got it right I created this thread: https://forums.arcade-museum.com/showthread.php?t=276996
perhaps this will help you.
So to summarize current situation. All buttons work, all directions on p4 are stuck, and no player directions work for p1-p3? The wiring looks correct when compared to mecha's pic.
Have you verified +5 to all joysticks?
Ok, so I checked the i40 board, it's getting 5v.Yes, unplug the connector or just probe the back side of connector.
Looks like you have it wired up correctly. However, when I am not certain about connections, I verify which pin is gnd by probing/continuity checking known gnd (like a chip or gnd pad) to the pins and known +5v point to pins. Just to be certain.
The i40 measured 5v with all joysticks connected.is that with joysticks connected or not connected? I am guessing but maybe one of the joysticks has a short. I would try measuring with all joysticks disconnected at the joystick. do you get +5v at the harness that plugs into the joysticks. If so, then plug joysticks in one at a time and verify you still have +5v etc. If not, and the i40 is putting out +5v to the joysticks on its headers, then you have a wiring issue or fuse issue getting +5v to joysticks.