60 gig iPod Photo won't sync

I have a 60 gig iPod Photo that has stopped being recognized by the computer. I tried a new USB cable. Sometimes it will charge when connected to the computer, sometimes not. It will charge when plugged in to 12V source. I have tried it on more than one Mac, but no dice. Any suggestions/help would be appreciated. And yes, we have tried the reset several times!

Since you tried it on multiple Macs with a different cable, you've mostly eliminated the +bad docking cable+, +bad USB port+, and +something wrong with the Mac's system+ possibilities.
Question: When you have it connected to the power adapter, does it operate properly as an iPod? So does it display its screen menu and play songs?
If it does, then the hard drive is probably OK and not the problem. The problem may be that the dock connector on the iPod side has become worn or otherwise damaged. There are many pins on the connector, so it is possible for it to charge yet not connect for data.
If it does not work as an iPod (play music), for iPods with a hard drive, the hard drive is the most common failure point. So it is possible that the hard drive in your iPod has become faulty. Other possibilities are problem on the logic board and problem in the connection between the logic board and hard drive.
If the iPod does not get recognized by Disk Utility, the only other idea I can think of is to open it up. You can try disconnecting the battery and see if it connects to the Mac with no battery. You can try disconnecting the hard drive, inspecting the two connection points between the hard drive and logic board, and reconnecting.
Here is a helpful guide.
http://www.ifixit.com/Guide/iPod/iPod-4th-Generation/93
When opening the 4G iPod, it is easiest to start from the seam at the top end, because there are no clips there. Be careful at the top left corner (looking at the iPod from the front) because there is a delicate ribbon cable there connecting the two halves of the case. You do not want to yank it open at that corner. If possible, leave that connection alone; it can easily get damaged when trying to disconnecting the ribbon cable. You should be able to lay the iPod open, like a book, from the right side.
Be sure to use plastic tools to open the iPod. Metal tools will damage the case.

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