Based on it working here (plain vanilla Windows 7 laptop & PC) I'd say... 1st, you might try another download, just in case. Maybe uninstall/reinstall. I'm not sure, but HTC Sync might also require VCast (and updated over the web). Make sure you have the drivers (when you get that silly pop-up select "install"). Also, check your system. Firewalls? App not "permitted" to run by AV software? Etc. Did the "old" version ever work on that machine?htc.exe crashes every time I choose the HTC Sync option on my Thunderbolt while it's connected via USB.
Edit: Now that I look, I don't see any "HTC.exe" like you referenced. Mine is "htcUPCTLoader.exe". Where are you seeing HTC.exe?
-Frank
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