Certainly, give the new firmware and Java console a try. Whether you're using the new firmware or old firmware, however, the following instructions apply ...
One of the problems we're occasionally seeing is interference with the Zigbee radio channels, perhaps from other WiFi radios in the 2.4GHz range. Before checking this, try unplugging and replugging the ARM7 processor card (the red PCB) a few times to make certain there isn't an intermittent connection between the processor and controller. If that doesn't help, you'll need to check the radio modules. To do this, you'll need to use a PC. Download the radio configuration program - X-CTU from
http://www.maxstream.net/support/setup_xctu_4.9.8.exe and the radio firmware from
http://www.surveyor.com/srvdownload/xbee_v1090.zip Make certain the robot is turned off, because the configuration program gets screwed up if another module is transmitting.
Start X-CTU, set the baud rate to 115200, and try Test/Query. You may have to run the Test a few times before the radio is recognized. Then change to the Modem Configuration screen, and Read the radio configuration. Under Networking, the first parameter is Channel. Change from Channel C to Channel E. Then Write the radio configuration.
Do this with both radios (the one in the USB board and the one in the robot).
If you get an error message about the version 1090 firmware not being found, click on Download New Versions, then load the xbee_v1090.zip file.
Let us know if this helps.