Following are the reasons for the problem that I identified during long session of conversations.
Crystal 9.0 is basically a managed code but it can be used as COM objects in VB 6.0 applications. So instead of runtime libraries we need complete of reusable DLL files which is around 26 files
Crystal Report 9.0 have almost 7 services packs due to huge number of problems in this first release of managed code we need to make sure that we have latest services pack on developers machine before creating a setup of the project.
create a new installer including all files mentioned below and then install on client machine.
above files are included basically in PD wizard