I have to write a how to document for commutator maintenance and running inspections. My superintendant is happy with all the content but requires actual pictures of bad conditions which I am having trouble finding. Can anyone help????

They aren't photographs per se, but Helwig Carbon has a PDF file which may be helpful which shows commutator condition, and Reliance Electric (now Baldor) has a fairly good textural explanation of sparking conditions.

http://www.helwigcarbon.com/pdf/Commutator_brochure.pdf

http://www.reliance.com/prodserv/motgen/c7090/

I have a .AVI video of one of our motors that had fairly severe sparking (on the order of level 4 or 5 per Reliance's grading scheme), but I don't have it online, and the quality isn't what is could be (taken with a hand held camera), but I could sent it to you.