Abstract Introduction The main goal of radiation therapy is to eradicate all cancer cells and minimize the damage to healthy tissues around the tumour. Treatment planning systems are used to predict the outcome of the treatment in terms of dose distribution prior to the treatment. One of the most reliable dose calculation algorithms is Monte Carlo. The aim of this study is to evaluate the performance of automated external contouring tool on dose calculation using Monte Carlo algorithm. Materials and methods The external contour of thorax phantom was created by automated tools of Monaco treatment planning system, and then, the IAEA-TECDOC-1583 quality assurance tests were created. Then, the treatment plans were delivered to the phantom, and the dose was measured by the Farmer ionization chamber at specific points. The external contour was corrected according to the source surface distances (SSD) which are mentioned in TECDOC-1583, and the dose was re-calculated. Finally, a comparison was made between the results. Results Dosimetric tests of TECDOC-1583 showed the errors ranged from −2·8% to +2·5%. In case of editing external contour and omitting fluctuations, the errors were decreased. The comparisons indicated that the most significant variation occurred in test 4 and the least changes were related to the tests 1 and 3. Conclusions The results of the study showed that the fluctuations of the external contour affect the calculated volume of the phantom and thus the dose. In order to obtain correct results, automated external contouring tools should be used with the correct instructions and re-checked before treatment planning.