Living In Germany as an Australian?

Australians between 18-30 can apply for a working holiday visa for Germany. This is a 1 year visa with no limits on work. This will at least give you time to figure stuff out and perhaps find a way to residence.

http://www.australien.diplo.de/Vertretung/australien/en/Visa/Working-Holiday.html

well he is 40, unfortunately :)

Ok, then you need to get married or have him in a career where he is better than anyone in the EU at something so he can get a work visa.
Or get the Australian government to 'send him' there, somehow.

Being married is only the start of that option. It is a new requirement in Germany that a non-EU national married to a German and wanting to live together in Germany needs to (within 90 days for Australians arriving in Germany) either:
1) pass the Deutsch A1 language test, or
2) find a job in Germany.

Either of these options will allow your spouse to remain in Germany as a permanent resident. Being married and passing the language test is probably the surest option given the high unemployment rate currently in Berlin. Having permanent residency will then allow your spouse to find work in Germany at a later stage.

Ok.
A1 is part of the Common European Framework of Reference for Languages, and is the lowest level...it should be quite easy, especially as you've been together long enough to be considering living together and so would have spent time studying each other's languages to at least a basic level (though Germans tend to be good at English anyway, for various reasons).

if your relationship is serious enough to move together to another country, why is it not serious enough for marriage?

#6, really?
Marriage is a a debatable process even if you live in the same village all your lives; there are plenty who travel the world as partners and feel they don't need to be 'forced' into a marriage. Many countries simply recognise partners and their rights to stay together.

she said she wants to move to Germany, not that she wants to travel. Travelling and living permanently in one place is a difference.

I would just say, these are the rules. Either you can play that game (and i know people who did not get married becuase of some spiritual connection but simply because it allows them to stay in one place) or you find a country where you don´t have to adapt in that way.

I don´t see a force here. She wants to go home and take him with. Alternative: Distance relationship untill they feel ready. But all this feeling is something which I would neglect for practical reasons if it comes not a romantic date but a lifelong bound.

You still seem to be arguing that a relationship is only 'real' if it involves marriage.
Many would argue that this is not so.