Cheat the front door and check to see if the toner bottle is actually turning. If you are using OEM toner you should see the bottle turning when the machine tries to add toner. On rare occasions the toner bottle clutch will go goofy and it won't turn the bottle to drop toner into the pump.
When you say you replaced the PCDU, do you meant the whole thing (Developer unit/developer)? With fresh developer it should not ask for toner as the premix in the developer is enough to set the developer and make a few copies before the premix runs out.
This is what makes me think he just has a cover open somewhere. An "add toner" screen will always sit on top of a "cover open" window.
I have worked on this model for years, and 9 times out of 10 "add toner" indicates a faulty toner pump. Put another one in and be sure and vacuum the supply tube. Also make sure the toner pump connector is seated, as it is difficult to get to (K pump).
NEVER ASSUME ANYTHING
The last time Ricoh updated most of the color machines, they went to different part numbers for each color toner pump. The new pumps include a new supply tube that is the correct length that color. Most of the time when I tried to vacuum the tube, it would clog again in a couple of months. Also, while the tube is disconnected from the nozzle, place a rag or piece of paper below the nozzle and rotate the bottle. If no toner comes out of the nozzle, replace the nozzle.
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