we have 18 3020's recently upgraded from 9.0.9 and all are OK so not sure what the difference is with yours.
just downloaded both 9.10 and 9.1.6 and then installed 9.1.6.
we have a mixture of SA and HA all managed by panorama and most are GP gateways but all went well.
I know that doesn't really help you but must be something else going on here... what version were they on when you upgraded?
Very thankful for this post. Are most actually running 9.1 in production environments now - or is 9.0 the norm?
We've got some 5250s, 5220s, 3220s, 3020s and 220s. I haven't put 9.1.X on the 3020s or 220s yet, but 9.1.X is on the others. We ran into a NAT oversubscription issue on the 3220s, but other than that the code seems stable. (docs.paloaltonetworks.com/pan-os/9-0/pan-os-admin/networking/nat/dynamic-ip-and-port-nat-oversubscription.html)
9.1 has been fine for us so far. The GP logs are a great feature too.
We have found the issue was with the previous version, not 9.1.6.
Fixed an issue where the panlogs directory reached 100% utilization on the firewall due to early calculation of the .size file.
This bug fills the panlogs and causes the fw to fail during the upgrade. We have only noticed it with the PA-220 due to the smaller storage availability.
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